Raymarine IO, E12019 Drive Installation Manual

Distributed by

Any reference to Raytheon or

RTN in this manual should be

interpreted as Raymarine.

The names Raytheon and RTN

are owned by the

Raytheon Company.

I/O Drive

Installation Guide

Drives covered:

M81138 I/O (Stern) Drive 12 V
E12019 KAD 32 I/O (Stern) Drive 12 V

Document number: 81176-3
March 2001

2 I/O Drive - Installation Guide

Important information

Safety notices

WARNING: Product installation

This equipment must be installed and operated in accordance
with the instructions contained in this handbook. Failure to do so
could result in poor pr oduct performance, personal in jury and/
or damage to your boat.

Because correct performance of the boat’s steering is critical for
safet y, we STRONGLY RECOM MEND that an Autho rized
Raymarine Service Representative fits this product.

WARNING: Navigation aid

Although we have designed this p roduct to be accurate and
reliable, many factors can affect its performance. As a result, it
should only be used as an aid to navigation and should nev er
replace commo nsense and navigational jud gement. Always
maintain a permanent watch so you can res pond to situations as
they develop.

EMC conformance

All Raymarine equipment and accessories are designed to the best
industry standards for use in the recreational marine environment .
The design and manufacture of Raymarine equipment and
accessories conform to the appropriate Electromagnetic
Compatibility (EMC) standards, but correct installation is required to
ensure that performance is not compromised.

Handbook information

T o the best of our knowledge, the information i n this handbook was
correct when it went to press. However, Raymarine cannot accept
liability for any inaccuracies or omissions it may contain. In addition,
our policy of continuous product improvement may change
specifications without notice. As a result, Raymarine cannot accept
liability for any dif ferences between the product and the handbook.

© Raymarine Ltd 2001.

I/O Drive - Installation Guide 3

Introduction

Product description

W elcome to the installation gu ide for the Raymarine inboard/
outboard drive (also known as an I/O or st ern drive). This product is
intended to operate the boat’ s steering mechanism as part of a
Raymarine autopilot system.

It is designed to drive cable operated, power assisted steering
systems. It operates the power steering valve in the same way as the
steering cable. When you disengage the autopilo t, a clutch
disengages the I/O drive so you can steer the boat manually .

CAUTION:

Any attempt to install an I /O drive to a non-compatible engi ne
type may void the warranty on both the drive and the engine.

Figure 1: Main parts of the I/O drive

Contents

This guide contains:

Main motor, gear
and clutch assembly

Product specifications page 4

1

Installation instructions page 5

2

Maintenance information page 21

3

Socket
for cable

Girdle tube Rod end

Push rod

D5211-1

4 I/O Drive - Installation Guide

Specifications

Drive specifications

Table 1: Drive specifications

Performance

(at nominal voltage)

Drive method Electromechanical

Maximum thrust 150 kg (330 lb)

Maximum stroke 214 mm (8.3 in)

Hardover to hardover time 8.8 sec

Other information

Drive dimensions

I/O drive

M81138 (12 V)
E12019 (KAD 32: 12 V)

protected for use in engine compartments

CE approvals - conforms to:
89/336/EC (EMC), EN60945:1997
94/25/EC (RCD), EN28846:1993

102.5 mm
(4.0 in)

63.4 mm
(2.5 in)

220 mm (8.66 in)

460 mm (18.1 in) mid-stroke

Figure 2: I/O drive dimensions

240 mm (9.45 in)

D5185-1

I/O Drive - Installation Guide 5

Installation instructions

Parts required

T o install the I/O drive the following parts are supplied:

• standard I/O drive unit

• power cable

• appropriate installation kit (see page 7)

Installation steps

WARNING: Electrical safety

Make sur e you have swit ched off the powe r supply befor e you
start installing this pro duct.

Follow these steps to install your I/O drive unit:

Consult the EMC installation guidelines. page 5

1

Mount the drive. page 7

2

Connect the power cable. page 19

3

Complete the post-installation checks. page 20

4

Ï

Ï

Ï

1. EMC installation guidelines

All Raymarine equipment and accessories are designed to the best
industry standards for use in the recreational marine environmen t.

Their design and manufacture conforms to the appropriate
Electromagnetic Compatibility (EMC) standards, but correct
installation is required to ensure that performance is not
compromised. Although every ef fort has been taken to ensure that
they will perform under all conditions, it is import ant to understand
what factors could affect the operation of the produ ct.

6 I/O Drive - Installation Guide

The guidelines given here describe the conditio ns for optimum EMC
performance, but it is recognized that it may not be possibl e to meet
all of these conditions in all situations. T o ensure the best possible
conditions for EMC performance within the constraint s imposed by
any location, always ensure the maximum separation possibl e
between different items of electrical equipment.

For optimum EMC performance, it is recommended that wherever
possible:

• Raymarine equipment and cables connected to it are:

• At least 3 ft (1 m) from any equipment transmi tting or cables

carrying radio signals e.g. VHF radios, cables and antennas.
In the case of SSB radios, the distance should be increased to
7ft (2m).

• More than 7 ft (2 m) from the path of a radar beam. A radar

beam can normally be assumed to spread 20 degrees above
and below the radiating element.

• The equipment is supplied from a separate battery from that used
for engine start. Voltage drops below 10 V, and starter motor
transients, can cause the equipment to reset. This will not damage
the equipment, but may cause the loss of some i nformation and
may change the operating mode.

• Raymarine specified cables are used. Cutting and rejoining these
cables can compromise EMC performance and must be avoided
unless doing so is detailed in the ins tallation manual.

• If a suppression ferrite is attached to a cable, this ferri te should not
be removed. If the ferrite needs to be removed during installation
it must be reassembled in the same position.

Suppression ferrites

Figur e 3 shows typical cable suppressi on ferrites used with
Raymarine equipment. Always use the ferrites supp lied by
Raymarine.

Connections to other equipment

If your Raymarine equipment is to be connected to other equipment
using a cable not supplied by Raymarine, a suppression ferrite MUST
always be attached to the cable near to the Raymarine unit.

I/O Drive - Installation Guide 7

D3548-2

Figure 3: Typical Suppression Ferrites

2. Mounting the drive

CAUTION:

I/O drives are affected by substantial vibration during use. When
installing this I/O drive, make sur e that you fully tighten all bolts
and use lock washers. Using a suitable thread-locking comp ound
on the threads will help keep the bolts securely ti ghtened.

Raymarine provide installation ki ts (see Figure 4) so you can fit the
drive unit to stern drive systems made by:

• Volvo: see page 8 for installation instructions

• Mercruiser 93, OMC and Y amaha: see page 10 for insta llation

instructions

• Mercruiser 95: see page 12 for installation instructions

• Volvo KAD 32 : require s the KAD 3 2 I/O drive (part nu mber:

E12019) see page 15 for installation instructions

Securing bolt

Shakeproof
washer

Split pin

R-clip

Figure 4: Installation kit parts (Volvo, Mercruiser 93, OMC and Yamaha)

Adaptor pin
bracket

Girdle support
bracket

Spring-loaded
location pin

D3365-2

8 I/O Drive - Installation Guide

Installation for Volvo (after type 872215)

1. Fit the girdle support bracket (s upplied in the installation kit) as
shown in Figure 5:

• remove the locating pin that attaches the cable rod to the tiller

end block

• replace it with the girdle support bracket

• secure the assembly with the supplied split pin

• rotate the girdle support bracket so that the spring-loaded pin

faces forward

2. Fit the adaptor pin bracket to the cable end sheath (see Figure 6):

• the adaptor pin bracket must sit against, but not on, the

shoulder on the cable end sheath

• the securing bolts must be on the stern (aft) side of the cable

end sheath

• make sure the bracket is vertical

• tighten the two securing bolts

Figure 5: Fitting the girdle support bracket (Volvo)

Girdle support
bracket

Tiller end block

Split pin

D3366-2

I/O Drive - Installation Guide 9

Adaptor pin bracket

Cable end sheath

Aft

Cable end sheath shoulder

D3367-2

Figure 6: Fitting the adaptor pin bracket (Volvo)

3. Fit the I/O drive into the girdle support bracket (see Figure 7):

• position the I/O drive unit so the fi xed support pin (on the
bracket) fits into the location hole in the I/O drive girdle tube.

• twist and lower the I/O drive unit into the bracket until the
spring-loaded pin fits into the other locatio n hole

CAUTION:

The fixed and spring-load ed location pins must be fully engaged
in the I/O drive girdle tube. If they are not the autopilot will fail.

I/O drive girdle tube

'R' clip

Figure 7: Fitting the I/O drive unit (Volvo)

4. Position the drive uni t pushrod end over the top of the adapto r pin

D3368-2

and secure with the R-clip.

10 I/O Drive - Installation Guide

5. Complete a hardover to hardover check:

• Slowly turn the steering syst em from hardover to hardover .

• Make sure that the drive unit and adaptor pin bracket do not

come into contact with any part of the engine, b oat or steering
system.This includes any engine hoses that may have a
passing contact with the I/O drive unit.

Note: If necessary, you can rotate the main body of the drive unit
relative to the girdle tube (see Figure 18).

Installation for Mercruiser 93/OMC/Yamaha

1. Fit the girdle support brack et as shown in Figure 8:

• remove the locating pin that attaches the cable rod to the tiller
end block

• replace it with the girdle support bracket

• secure the assembly with the supplied split pin

• rotate the girdle support bracket so that the spring-loaded pin

faces forward

Cable end
sheath

Girdle support
bracket

Tiller end
block

Split
pin

Figure 8: Fitting girdle support bracket (Mercruiser 93/OMC/Yamaha)

2. With the hel m turned hard to port:

• assemble the adaptor pin bracket onto the steering cable end
sheath, 165 mm (6.5 in) from the girdle s upport bracket (as
shown in Figure 9)

D3369-2

I/O Drive - Installation Guide 11

• make sure that the bracket is vertical and that the securing
bolts are on the bow (forward) side of the cable end sheath

• tighten the two securing bolts on the adapto r pin bracket

165 mm (6.5 in)

Cable
end sheath

Adaptor pin
bracket

Forward

D3370-2

Figure 9: Fitting the adaptor pin bracket (Mercruiser 93/OMC/Yamaha)

3. Fit the I/O drive into the girdle support bracket (see Figure 10):

• position the I/O drive unit so the fi xed support pin (on the
bracket) fits into the location hole in the I/O drive girdle tube.

• twist and lower the I/O drive unit into the bracket until the
spring-loaded pin fits into the other locatio n hole

I/O drive girdle tube

Figure 10:Fitting the I/O drive unit (Mercruiser 93/OMC/Yamaha)

CAUTION:

The fixed and spring-load ed location pins must be fully engaged
in the I/O drive girdle tube. If they are not the autopilot will fail.

D3371-2

12 I/O Drive - Installation Guide

4. Position the drive unit pushrod end over the top of the adaptor pin
and secure with the R-clip.

5. Complete a hardover to hardover check:

• Slowly turn the steering syst em from hardover to hardover .

• Make sure that the drive unit and adaptor pin bracket do not

come into contact with any part of the engine, b oat or steering
system.This includes any engine hoses that may have a
passing contact with the I/O drive unit.

Note: If necessary, you can rotate the main body of the drive unit
relative to the girdle tube (see Figure 18).

Installation for Mercruiser 95

CAUTION:

Before you insta ll any of the autopilot components, make sure
there is sufficient space between the complete drive unit and the
engine manifold.

Use Raymarine installation kit D309 to install the I/O drive unit to
Mercruiser engines manufactured from 1994 onwards.

Install the I/O drive by following these st eps:

1. Remove the existing pins securing:

• the tiller and twin engine connecting bars:

• the power steering ram to the tiller arm and twin engine

connecting bar .

• the steering cable to the power steering ram.

Note: These pins are retained by split pins t hat may be hard to
remove. You will probably need someone’s h elp to hold the legs of the
split-pins together so you can remove them.

2. Fit the pivot assembly to the steering system as shown in
Figur e 11:

• use the new retaining pins (supplied with the installation kit)

• secure these with the split pins (supplied)

I/O Drive - Installation Guide 13

Retaining pins

Pivot assembly

Tiller arm

Twin engine
connecting bar

Power
steering ram

D5180-1

Figure 11:Fitting the pivot assembly (Mercruiser 95)

3. Fit the main support bracket to the spool valve cable connection
on the s teering system ( see Figure 12):

• position the main support bracket behi nd the spool valve

cable connection

• fit the clamp around the spool valve cable connection

• put the spring washers on the f our securing bolts

• tighten the bolts to secure the main support bracket

Main support bracket

Clamp

Figure 12:Fitting the main support bracket (Mercruiser 95)

Spool valve cable connection

Bolts and
spring washers

D5181-1

14 I/O Drive - Installation Guide

4. Place the I/O drive’s pu shrod end on the pivot assembly pin – the
flat part of the pushrod should rest on top of the pivot assembly .

5. Fit the R-clip to the pivot assembly pin to secure the I/O drive
pushrod in place.

D5182-1

Figure 13:Fitting the I/O drive unit (Mercruiser 95)

6. Lower the I/O drive into the main support bracket (see Figure 13),
making sure that:

• the fixed and spring-loaded pins locate in the corresp onding

holes in the I/O drive’s girdle tube

• the I/O drive’s pushrod is parall el with the power steering ram

CAUTION:

The fixed and spring-loaded location pins must be fully engaged
in the I/O drive girdle tube. If they are not the autopilot will fail.

7. Complete a hardover to hardover check:

• Slowly turn the steering syst em from hardover to hardover .

• Make sure that the drive unit and adaptor pin bracket do not

come into contact with any part of the engine, b oat or steering
system.This includes any engine hoses that may have a
passing contact with the I/O drive unit.

Note: If necessary, you can rotate the main body of the drive unit
relative to the girdle tube (see below).

I/O Drive - Installation Guide 15

Installation for Volvo KAD 32

Note: You must u se the KAD 32 I/O drive unit (part number E12 019)
for this system.

Volvo KAD 32 installation kit

When installing the I/O drive unit on a Volvo KAD 32, the first s tep is
to fit an extension bracket to raise the engine filter assembly and
provid e suffi cient space for the d rive unit ( see Figur e 14):

1. Remove the KAD 32 bracket bolts

2. Lift the filter/bracket assembly clear of the engine.

3. Remove the filter assembly bolts.

Securing
bolt (x2)

Shakeproof
washer (x2)

Girdle support
bracket

Volvo adaptor pin

Split pin (x2)

Extension bracket

Extension bracket bolt,
washer and nut (x2)

D5212-1

4. Fit the extension bracket (supplied) to the KAD 32 bracket using
the extension bracket bolts (s upplied)

5. Use the filter assembly bolts to attach the filter assembly to the
extension bracket.

6. Make sure the flexible hose is secure.

7. Use the KAD 32 bolts to refit the complete filter/bracket
assembly .

16 I/O Drive - Installation Guide

Filter assembly bolts

Filter
assembly

Flexible hose

KAD 32 bracket bolt

Figure 14:Fitting the extension bracket

When you have fitted the extension bracket:

Extension
bracket bolts

Extension bracket

KAD 32 bracket

KAD 32 bracket bolt

D5216-1

1. Remove the locating pin that attaches the steering cable rod to the
tiller end block.

2. Replace it with the V olvo adaptor pin, using one of the split pins to
hold it in place (see Figure 15).

I/O Drive - Installation Guide 17

Volvo adaptor pin

Split pin

Tiller end

block

Figure 15:Fitting the Volvo adaptor pin

3. Fit the girdle support bracket onto the spool val ve rod:

• the adaptor pin bracket must sit against, but no t on, the

shoulder on the spool valve rod

• the spring-loaded location pin and the securing b olts must be

on the stern (aft) side of the cable end sheath

• make sure the bracket is vertical, then tighten the two bolts

Shoulder

Spring-loaded location pin

Girdle support
bracket

Spool valve rod

Aft

D5213-1

Figure 16:Fitting the girdle support bracket

4. Position the I/O drive unit to align its location holes with the fixed

D5214-1

and spring-loaded pins in the girdle s upport bracket (Figure 17).

18 I/O Drive - Installation Guide

I/O drive girdle tube

Girdle
support bracket

Pushrod end

D5215-1

Figure 17:Fitting the I/O drive unit (KAD 32)

CAUTION:

The fixed and spring-loaded location pins must be fully engaged
in the I/O drive girdle tube. If they are not the autopilot will fail.

5. Fit the pushrod onto the adaptor pin and secure it with the split pin.

6. Complete a hardover to hardover check:

• Slowly turn the steering syst em from hardover to hardover .

• Make sure that the drive unit and adaptor pin bracket do not

come into contact with any part of the engine, b oat or steering
system.This includes any engine hoses that may have a
passing contact with the I/O drive unit.

Note: If necessary, you can rotate the main body of the drive unit
relative to the girdle tube (see Figure 18).

Mounting in a restricted area

If an obstruction prevents you from installing the I/O drive unit as
supplied, rotate the main body of the drive relative to t he girdle tube
as follows:

1. Remove the two fixing screws on the front cover .

2. Carefully slide the cover forwards, making sure you do not pull
any of the four cables from the plugs inside the cover .

3. Loosen the lock nut.

I/O Drive - Installation Guide 19

4. Rotate the main body as required.

Fixing screw

Lock nut

Figure 18:Rotating the main body of the I/O drive unit

5. Tighten the lock nut, making sure it is less than one turn from the
start of the thread.

6. Replace the cover, taking care not to trap or pinch the cables.

7. Complete a hardover check:

• Use the steering wheel to move from hardover to hardover .

• Make sure that the drive unit and adaptor pin bracket do not

come into contact with any part of the engine, boat or steering
system.This includes any engine hoses that may have a
passing contact with the I/O drive unit.

3. Electrical connections

WARNING: Electrical safety

Make sur e the powe r supply is sw itched off be fore you make any
electrical connections.

Front cover

D5183-1

When you have fitted the I/O drive to the st eering system, connect it
to the course computer as follows:

1. Plug in the power cable (supplied) into the so cket on the drive

2. Route the cable to the course computer, taking into account the

3. Connect the motor cables (thicker blue and brown cables) and the

unit. Lock the connector in place by turning the locking ring
clockwise.

EMC installation guidelines (see page 5).

clutch cables (thinner red and black cables) to the connections on
the course computer as shown in Figure 19.

20 I/O Drive - Installation Guide

4. Secure the cable close to the I/O drive unit, making sure there is
enough free length to allow the drive unit to move.

5. Complete another hardover check: use the steering wheel to move
the rudder from hardover to hardover , and check that the cable
does not catch on any part of the boat or its fittings.

Type 100/300 course computerType 150/400 course computer

+–

A

OFF

SWITCH

blue

B

MOTORPOWER

SOLENOID–CLUTCH

brown

–

black

+

–

red

+–+–

lk CLUTCH MOTORPOWER

black

red

blue

1

2

brown

Figure 19:Connections at course computer

4. Post-installation check

WARNING:

Keep clear of moving steering systems at all times. Protect
moving parts from access during normal use.

Check the following points after inst alling the drive:

1. Is the drive unit securely attached to the steering system (with all
brackets, bolts, split pins, etc. secure)?

2. Is the drive unit correctly aligned?

3. Are the motor and clutch cables correctly routed and securely
connected to the course computer?

4. Complete a hand-steering check: Are you sure there is no contact
between the drive unit and any part of the engi ne, steering system
or boat’s structure when the push rod moves in and out?

D5184-2

Note: When you have installed the entire autop ilot system, you will
need to complete an autopilot steering check. Refer to the control unit
handbook for more details.

I/O Drive - Installation Guide 21

Maintenance

On a regular basis:

• check all connections and mountings are secure

• check drive alignment

• check cables for signs of wear or damage

EMC servicing and safety guidelines

• Raymarine equipment should be serviced only by aut horized
Raymarine service technicians. They will ensure that service
procedures and replacement parts used will not affect
performance. There are no user serviceable parts in any
Raymarine product.

• Some products generate high voltages, so nev er handle the
cables/connectors when power is being supplied to the
equipment.

• When powered up, all electrical equipment produces
electromagnetic fields. These can cause adjacent pieces of
electrical equipment to interact with one another , with a
consequent adverse effect on operation. In order to mi nimize
these effects and enable you to get the be st possible performance
from your Raymarine equipment, guidelines are given in t he
installation instructions, t o enable you to ensure minimum
interaction between different items of equipment, i.e. ensure
optimum Electromagnetic Compatibility (EMC).

• Always report any EMC-related problem to your n earest
Raymarine dealer. We use such information to improve our
quality standards.

• In some installations, it may not be possible to prevent the
equipment from being affected by external influences. In g eneral
this will not damage the equipment but it can lead to spuri ous
resetting action, or momentarily may result in faulty operation.

22 I/O Drive - Installation Guide

Product support

Raymarine products are supported by a worldw ide network of
distributors and Authoriz ed Service Representatives. If you
encounter any difficulti es with this product, please contact either
your national distributor , or your service representative, or t he
Raymarine T echnical Services Call Center. Refer to the back cover
or the W orldwide Distributor List for contact details.

Raymarine Ltd

Anchorage Park
Portsmouth, Hampshire
England PO3 5TD
Telephone [phone]
Fax [phone]
www.raymarine.com

Raymarine Technical Services Call Center

UK: [phone] or
[phone] ext. 1083

Raymarine Inc

22 Cotton Road, Suite 280
Nashua
NH 03063-4219, USA
Telephone [phone]
Fax [phone]
www.raymarine.com

USA: [phone] or
1-800-539-5539 ext. 2333