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.
Hydraulic Linear
Drive
Installation Guide
Drives covered:
M81200 Type 2 Hydraulic Linear Drive 12 V
M81201 Type 2 Hydraulic Linear Drive 24 V
M81202 Type 3 Hydraulic Linear Drive 12 V
M81203 Type 3 Hydraulic Linear Drive 24 V
Document number: 81177-3
March 2001
2 Hydraulic Linear 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 injury an d/
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 differen ces between the product and the handbook.
© Raymarine Ltd 2001.
Hydraulic Linear Drive - Installation Guide 3
Introduction
W elcome to the installation guide for the Raymarine hydraulic linear
drive system. This product is intended to operate the boat’ s steering
mechanism as part of a Raymarine autopilot system.
The hydraulic linear drive system is designed for boats with existing
mechanical steering systems, not hydrauli c steering systems. It
provides a totally isol ated autopilot steering system consi sting of:
• Hydraulic ram: a self-contained autopilot steering cylinder with a
load limiting system and a built in clutch (to allow friction-free
steering when the autopilot is not in use).
• Reversing hydraulic pump: po wers the hydraulic ram.
• Hydraulic fluid reservoir: sup plies hydraulic fluid to the system.
CAUTION:
The ram drives the rudder directly from the tiller arm or rudder
quadrant. Before installing this drive unit, check that the boat’s
steering system can be backdriven from the rudder .
Figure 1: Main components of the hydraulic linear drive system
Contents
Reservoir
Reservoir clip
Tie-wrap
Tap
Mounting foot
Clutch cable
Reservoir pipe
Ram pipe
Pump pipes
Ram
Pump
Motor cables
Push rod
Rod end
D5088-1
1
2
3
Product specifications page 4
Installation instructions page 5
Maintenance information page 15
4 Hydraulic Linear Drive - Installation Guide
Specifications
Ram specifications
Table 1: Ram specifications
Performance
(at nominal voltage)
Maximum boat
displacement
Type 2 (T2)
M81200 (12 V)
M81201 (24 V)
22,000 kg
(48,500 lb)
Peak thrust 585 kg
(1,290 lb)
Maximum stroke 254 mm
(10 in)
Hardover to hardover time
10 sec 12 sec
Type 3 (T2)
M81202 (12 V)
M81203 (24 V)
35,000 kg
(77,000 lb)
1,000 kg
(2,200 lb)
300 mm
(12 in)
(+/- 35º, no load)
Maximum rudder torque 1,270 Nm
(11,300 lb.in)
2,565 Nm
(23,100 lb.in)
Other information (applies to Types 2 and 3)
protected for use in engine compartments
CE approvals - conforms to:
89/336/EC (EMC), EN60945:1997
94/25/EC (RCD), EN28846:1993
Ram dimensions
80 mm
(3.15 in)
152 mm (6 in)
4 fixing holes for
8 mm (0.3125 in) bolts
Figure 2: Ram dimensions
101.6 mm (4 in)
A (mid stroke)
457 mm (18 in)
Drive A (mid stroke)
Type 2 540 mm (21.25 in)
Type 3 690 mm (27.15 in)
D5093-1
Hydraulic Linear Drive - Installation Guide 5
Installation instructions
Parts required
T o install this drive you will need:
• Parts supplied:
• pre-filled and pre-bled sy stem consisting of: hydraulic ram;
hydraulic pump; hydraulic pipes; fluid res ervoir (supplied
fitted with transit cap; standard cap also supplied)
• hydraulic fluid (to fill reserv oir)
• tiller pin assembly (see Figure 7) consisting of: tiller pin,
R-clip, top washer , lock washer , nut (UNC nylock)
• Additional parts:
• suitable securing bolts and lock washers/lock nuts for the
hydraulic ram and pump (see page 9)
• suitable cable and electrical connectors for the drive motor
and clutch (see page 12)
Note: Make sure you have obtai ned these additional parts before you
start installa tion.
Installation steps
WARNING: Electrical safety
Make sur e you have swit ched off the powe r supply befor e you
start installing this produc t.
Follow these steps to install you r hydraulic linear drive system:
Consult the EMC installation guidelines. page 6
1
Mount the drive system components. page 7
2
Ï
3
4
Ï
Connect to the course computer. page 12
Ï
Complete the post-installation check. page 14
6 Hydraulic Linear Drive - Installation Guide
1. EMC installation guidelines
All Raymarine equipment and accessories are designed to the best
industry standards for use in the recreational marine environment .
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 important to understand
what factors could affect the operation of the product.
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 poss ible
conditions for EMC performance within the constrai nts imposed by
any location, always ensure the maximum separation possibl e
between different items of electrical equipment.
For op ti mum EMC perform ance, it is recommended that wherever
possible:
• Raymarine equipment and cables connected to it are:
• At least 3 ft (1 m) from any equipment tr ansmitting or cables
carrying radio signals e.g. VHF radios, cables and ante nnas.
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 t he installation manual.
• If a suppression ferrite is attached to a cable, this ferrite should not
be removed. If the ferrite needs t o be removed during installation
it must be reassembled in the same position.
Hydraulic Linear Drive - Installation Guide 7
Suppression ferrites
The following illustration sh ows typical cable suppression ferrites
used with Raymarine equipment. Always use the ferrites supplied by
Raymarine.
D3548-2
Figure 3: Typical Suppression Ferrites
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.
2. Mounting the drive components
Mounting the drive components involves f our main steps:
• ensuring correct hydraulic ram alignment
• securing the hydraulic ram to the boat
• connecting the hydraulic ram to the steering s ystem
• installing the other parts of the drive system
Ram alignment
When mounting the hydraulic ram, check that it is aligned correctly:
• The ram must be at right angles to the mounting surface (see
Figur e 4).
• The ram must be at right angles to the tiller arm when the rudder is
• The push rod must be accurately aligned with the tiller arm plane
amidships (see Figur e 4).
of rotation. The ball end fitting onl y allows up to 5 degrees
misalignment between the push rod and tiller arm plane of
rotation (see Figure 5).
8 Hydraulic Linear Drive - Installation Guide
A (mid stroke)
º
View from
astern
View from
above
90
Drive A (mid stroke) B (tiller arm radius)
Type 2 540 mm (21.25 in) 180 mm (7.1 in)
Type 3 690 mm (27.15 in) 267 mm (10.5 in)
aft
90º
B (tiller arm
radius)
D5091-1
Figure 4: Hydraulic ram alignment
5º Max.
5º Max.
View from astern
D5092-1
Figure 5: Alignment between push rod and tiller arm plane of rotation
CAUTION:
Accurate angular alignment is extremely important. Y ou must
not exceed this +/- 5 degree limit under any circumstances.
Securing the hydraulic ram
Mounting location
Before you secure the hydraulic ram to your boat, you must first
check the suitability of the mounting location.
CAUTION:
Consult the boat manufactur er if you have any doubt about th e
strength or s uitability of the mounting location.
Hydraulic Linear Drive - Installation Guide 9
• S tructural strength:
• This drive produces a considerable amount of force, so you
must mount it on a solid structure (i.e. a substa ntial frame
member) in the boat. In some cases it may be necessary to
build a specially strengthened frame to mount the drive unit.
• T o prevent excess noise and vibration, do not attach this drive
to any structures that support cabins.
• Drive orientation:
• Y ou must mount the hydraulic ram horizontally with its
mounting foot on a horizontal surface (see Figure 6). The
swivel joint does not have sufficient movement to position the
mounting foot vertically .
• General position:
• Refer to the EMC installation guidelines (page 6)
• Make sure the drive will be accessible for future servicing.
• Environment:
• This drive is not waterproo f, so you should mount it in a dry
location, clear of any bilge water.
View from above
aft
View from above
aft
Figure 6: Drive orientation
D5089-1
Securing bolts
Attach the mounting foot with four stainless steel M8 (
and lock nuts/lock was hers.
Note: Always mount the hydraul ic ram as securely as possible t o
make sure it performs reliably and re mains correctly aligned.
5
/
inch) bolts
16
10 Hydraulic Linear Drive - Installation Guide
Connecting to the steering system
CAUTION:
Consult the steering gear manufacturer if you have any doubt
about the strength of the existing tiller arm or rudder quadrant.
This drive produces a considerable amount of force, so you must
ensure that your tiller arm or rudder quadrant can cope with the peak
thrust specified in the T able 1, Ram specifications
Use one of these methods to attach the push rod to the rudder stock:
1. Independent tiller arm: we recommend that you attach the push
rod to the rudder stock via an independent till er arm (Edson and
Whitlock offer a standard fitting).
2. S teering linkage tiller arm or rudder quadrant: in certain
cases, you may be able to attach the push rod to the same tiller arm
or rudder quadrant used by the main steering linkage. Consult the
steering manufacturer before you modify the rudder quadrant.
Attaching the rod end
Use the supplied tiller pin assembly to attach the rod end to the tiller
arm, at the tiller arm radius shown in Figure 4.
1. Attach the tiller pin to the tiller arm:
• insert the tiller pin through the tiller arm hole, so the flange
remains above the arm (see Figure 7)
• make sure that the tiller pin is a tight fit in the tiller arm
• use the supplied lock washer and ful ly tighten the lock nut
Note: If necessary, you will need to drill a hol e in the tiller arm at the
radius shown in Figure 4.
R-clip
Washer
Rod end
Flange
Lock
washer
Tiller arm
Lock nut
Tiller pin
Drive Hole diameter 'X'
Type 2 13 mm (0.52 in)
Type 3 20 mm (0.78 in)
Figure 7: Attaching the push rod to the tiller arm
X
D5090-1
Hydraulic Linear Drive - Installation Guide 11
2. Attach the rod end to the tiller pin:
• place the rod end onto the tiller pin
• secure with the supplied washer and R-clip (see Figur e 7)
Steering check
When you have mounted the ram, turn the boat’s steering wheel from
hardover to hardover and check that:
• Angular movement of the ball end fi tting is less than 5 degrees
(see Figure 5). If you exceed this 5 degree limit, the drive will
catch on the tiller arm/rudder quadrant and the ball joint will bind.
• No part of the drive unit fouls t he boat’s s tructure when the push
rod moves in and out.
• The total rudder movement is limited to +/- 35 degrees b y the
steering system end stops rather than the linear drive’s end li mits
(see Figure 8).
Steering system
end stop
Steering system
end stop
35º35º
D5079-1
Figure 8: Total rudder movement
CAUTION:
Make sure rudder movement is limited by the steering system
end stops before the push rod reaches its end stop. Failure to do
this could damage the drive and will invalidate the warranty.
Installing the other parts of the system
Note: To make installation easier, we sup ply the hydraulic linear
drive system pre-plumbed, pre-fil led with hydraulic fluid and
pre-bled, with just the reservo ir empty. As a result you should not
need to bleed the system during instal lation. If you do need to
disconnect the pipes for any reason, contact Raymarine Technical
Services Call Center for advice on bleeding the system.
12 Hydraulic Linear Drive - Installation Guide
Hydraulic pump
Mount the hydraulic pump:
• on a substantial m ember to avoid vibration that could damage the
hydraulic pipes
• on a horizontal surface, clear of water spray and possi ble
immersion.
• level or above the hydraulic ram to prevent air from collecting
in the ram
Note: Secure the pump using suitable bolts, lock nuts & lock washers.
Reservoir
Mount the reservoir vertically and at least 150 mm (6 in) above the
hydraulic pump (to ensure a good suppl y of fluid to the system):
1. Attach the clip, then use the tie-wrap to secure the reservoir to the
clip.
2. Remove the temporary (non-breathable) transit cap fitted to the
reservoir.
3. Fill the reservoir with the supplied hy draulic fluid, so the level is
between the minimum and maximum lines.
CAUTION:
Absolute cleanliness is essential when working with hydraulic
systems. Even the smallest particle of dirt could prevent the
steering system check valves fr om working properly .
4. Fit the supplied standard (breathable) cap to the reservoir .
5. Open the reservoir tap.
3. Connecting to the course computer
WARNING: Electrical safety
Make sure the power supply is switched off befor e you make any
electrical connections.
The hydraulic linear drive system has electrical connections for:
• the motor in the pump: two cables: red (+) and black (-)
• the clutch in the hydraulic ram: a two-core cable with brown (+)
and blue (-) cores
Hydraulic Linear Drive - Installation Guide 13
Table 2: Recommended cable sizes
Cable length
(pump to course computer)
Type 2 drive 12 V
up to 5 m (16 ft)
up to 7 m (23 ft)
up to 16 m (52 ft)
Type 2 drive 24 V
up to 3 m (10 ft)
up to 5 m (16 ft)
up to 10 m (32 ft)
up to 16 m (52 ft)
Type 3 drive 12 V
up to 5 m (16 ft)
up to 7 m (23 ft)
up to 16 m (52 ft)
Type 3 drive 24 V
up to 5 m (16 ft)
up to 7 m (23 ft)
up to 16 m (52 ft)
Cable gauge
(AWG)
10
8
6
12
10
8
6
8
6
4
10
8
6
Copper area
2
)
(mm
6
10
16
4
6
10
16
10
16
25
6
10
16
Connect the pump and ram to the course computer:
1. Measure the distance of cable run from the pump and ram to the
course computer:
• use Table 2 to identify the appropriate motor cable sizes
• use at least 1.5 mm
2
(16 A WG) copper cable for the clutch
2. Join these cables to the ones on the pump and ram using
appropriate electrical connectors or junction boxes at the correct
power rating.
Note: To meet current EMC legislati on, you must NOT untwist the
pump cables, and you must NOT remove the suppression ferrite.
3. Route the cables back to the course computer, taking into account
the EMC installation guidelines (page 6).
4. Connect:
• the cables from the pump to the
MOTOR terminals on the
course computer (see Figure 9): at this stage you can connect
either motor cable to either terminal. Y ou will check these
connections after installing the rest of the autopilot system.
• the cables from the hydraulic ram to the
CLUTCH terminals on
the course computer (see Figure 9): brown (+) and blue (-)
14 Hydraulic Linear Drive - Installation Guide
+–
A
OFF
SWITCH
B
–
MOTORPOWER
SOLENOID CLUTCH
+
–
–
+–+–
lk CLUTCH MOTORPOWER
1
2
Type 150/400 course computer
Figure 9: Cable 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 in stalling the drive:
1. Is the mounting foot secured to a subs tantial structure on the boat?
2. Is the hydraulic ram correctly aligned, i.e:
• Is the mounting foot correctly oriented?
• Is the drive mounted at right angles to the tiller arm, in a mid-
stroke position, when the rudder is amidships?
• Is the push rod accurately aligned with the tiller arm plane of
rotation (deviation less than 5 degrees)?
3. Is the hydraulic ram rod end:
Type 100/300 course computer
D5080-1
• securely attached to the tiller arm or quadrant?
• attached at the recommended tiller arm radius for the boat?
4. Are the motor and clutch cables correctly routed and securely
connected to the course computer?
5. Are all hydraulic pipes securely connected, with no leaks?
6. Have you filled the reservoir , fitted the standard cap and opened
the reservoir tap?
7. Have you completed a hand-steering check (see page 11)?
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.
Hydraulic Linear Drive - Installation Guide 15
Maintenance
On a regular basis:
• check all connection and mountings are secure
• check hydraulic ram alignment
• check pipes and cables for any signs of wear or damage
• check hydraulic pipes and joints for leak s
EMC servicing and safety guidelines
• Raymarine equipment should be ser viced only by authorized
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, s o never handle the cables
or connectors when power is being suppli ed 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 mini mize
these effects and enable you to get the best possible performance
from your Raymarine equipment, guidelines are given in the
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, i t 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 l ead to spurious
resetting action, or momentarily may result in faulty operation.
Product support
Raymarine products are supported by a worldwi de network of
distributors and Authorized Service Representati ves. If you
encounter any difficul ties with this product, please contact either
your national distributor , or your service representative, or the
Raymarine T echnical Services Call Center. Refer to the back cover
or the W orldwide Distributor List for contact details.
16 Hydraulic Linear Drive - Installation Guide
Raymarine Ltd
Anchorage Park
Portsmouth, Hampshire
England PO3 5TD
Telephone +44 (0)23 9269 3611
Fax +44 (0)23 9269 4642
www.raymarine.com
Raymarine Technical Services Call Center
UK: +44 (0)23 9271 4713 or
+44 (0)23 9269 3611 ext. 1083
Raymarine Inc
22 Cotton Road, Suite 280
Nashua
NH 03063-4219, USA
Telephone +1 603 881 5200
Fax +1 603 864 4756
www.raymarine.com
USA: +1 603 881 5200 or
1-800-539-5539 ext. 2333
Loading...