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Raymarine E12207, E12208, M81202, M81203 Installation Instructions Manual

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H
ydraulic Linear Drive
Installation instructions
E
12207 Type 2 (12 V)
E
12208 Type 2 (24 V)
M81202 Type 3 (12 V)
M81203 Type 3 (24 V)
HydraulicLinearDriveInstallationinstructions
Trademarksandregisteredtrademarks
Autohelm,hsb
2
,RayT echNavigator,RayTalk,SailPilot,SeaTalk,SeaT alk
NG
,SeaT alk
HS
andSportpilotareregisteredtrademarksof
RaymarineUKLimited.Seahawk,Smartpilot,PathnderandRaymarineareregisteredtrademarksofRaymarineHoldingsLimited.
Allotherproductnamesaretrademarksorregisteredtrademarksoftheirrespectiveowners.
FairUseStatement
Youmayprintnomorethanthreecopiesofthismanualforyourownuse.Youmaynotmakeanyfurthercopiesordistributeorusethe
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)
Type212V
E12208(replaces
M81201)
Type224V
M81202Type312V
M81203Type324V
Additionalhandbooks
Thefollowinghandbooksprovideadditionalinformationrelatingto
theoperationoftheHydraulicLinearDrive,andcompatiblecourse
computers.
DescriptionPartnumber
SPXSystemInstallationguide
87072
SPXSystemCommissioning
Instructions
81287
SeaTalk
ng
ReferenceManual
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.
Warning:Ensuresafenavigation
Thisproductisintendedonlyasanaidtonavigation
andmustneverbeusedinpreferencetosound
navigationaljudgment.Onlyofcialgovernment
chartsandnoticestomarinerscontainallthecurrent
informationneededforsafenavigation,andthe
captainisresponsiblefortheirprudentuse.Itisthe
user’sresponsibilitytouseofcialgovernmentcharts,
noticestomariners,cautionandpropernavigational
skillwhenoperatingthisoranyotherRaymarine
product.
Caution:Ensurecleanliness
Absolutecleanlinessisessentialwhenworkingwith
hydraulicsystems.Eventhesmallestdirtparticle
couldpreventthesteeringsystemcheckvalvesfrom
workingcorrectly.
Caution:Structuralstrength
DuringoperationtheHydraulicLinearDriveproduces
aconsiderableamountofforce.YouMUSTmountthe
Hydraulicramtoaverysolidstructure(forexample,
asubstantialframememberofyourvessel).Boththe
structureandthetillerarmorrudderquadrantMUST
becapableofwithstandingthepeaklevelsofthrust
statedintheT echnicalSpecicationinthisdocument.
Insomecasesitmaybenecessarytobuildaspecially
strengthenedframetomountthedriveunit.Consult
thesteeringgearmanufacturerifyouhaveanydoubt
aboutthestrengthofthetillerarmorrudderquadrant.
Caution:Avoiddamagetohydraulic
ram
Anydamagetothehydraulicramwilldamagethe
sealsandallowairintotheunit,reducingperformance
andpotentiallycausingoilleaks.
EMCconformance
Raymarineequipmentandaccessoriesconformtotheappropriate
ElectromagneticCompatibility(EMC)regulationsforuseinthe
recreationalmarineenvironment.
8
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.Youshouldstickthislabeltothewarranty
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
Installationincludesthefollowingactivities:
InstallationTask
1Planyourinstallation.
2
Obtainallrequiredequipmentandtools.
3Mountthesystemcomponents.
4Routeallcables.
5
Drillcableandmountingholes.
6Makeallconnectionstoequipment.
7
Secureallequipmentinplace.
8
Completethepost-installationcheck.
2.2Drivetypes
Thereare2drivetypes.Eachdrivetypehas2variants(onefor
12Vsystems,onefor24Vsystems).
Althoughthecorefunctionalityofeachdrivetypeisessentiallythe
same,theformfactorofsomeofthecomponentsdiffersasfollows:
Hydraulicram
Type2drive:
D11864-1
Type3drive:
D11865-1
Note:Thedrawingsincludedinthishandbookareforillustration
purposesonly.Theexactshapeofyoursystemcomponentsmay
differfromthoseshown.
12
HydraulicLinearDriveInstallationinstructions
2.3Reservoir
D11866-1
1
2
3
4
5
1.Transitscrew—mustberemovedfromthecapbeforeuse.
2.Screwcap—sealmustberemovedfromcapbeforeuse.
3.Filllevel—reservoirmustbelledbetweentheminimumand
maximumlevels.
4.Mountinghole—forsecuringthereservoirtoasuitablepart
ofyourvessel.
5.Tap—controlstheowofhydraulicuidtothepump.
2.4Productoverview
TheHydraulicLinearDriveisintendedtooperateavessel’ssteering
mechanismaspartofaRaymarineautopilotsystem.
TheHydraulicLinearDriveisdesignedforvesselswithexisting
mechanicalsteeringsystems,NOThydraulicsteeringsystems.It
ismountedbelowdecksandmovestherudderdirectlybypushing
thetillerarmorrudderquadrant.
TheHydraulicLinearDriveprovidesatotallyisolatedautopilot
steeringsystemconsistingof:
D11851-1
1
10
2
3
4
5
6
7
8
9
11
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.
Planning
13
7.Pushrod—extendsoutofthehydraulicramcasingtocontrol
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.
D11894-1
Forinformationoninstallingandconnectingtherudderreference
optionrefertotheinstructionsthataccompanythecoursecomputer.
2.5Typicalsystem
Thedrivecomponentsconnecttoacoursecomputeraspartofan
autopilotsystem.
ThefollowingdiagramillustratesatypicalSPX-30autopilotsystem:
D118 53 -1
SMARTPILOT
1
2
3
4
1.Autopilotcontroller.
2.SPXcoursecomputer.
3.Driveunit.
4.Fluxgatecompass.
14
HydraulicLinearDriveInstallationinstructions
2.6Partssupplied
D118 54 -1
03
2 3 4 5 6
1
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
15
2.7Partsrequired
Additionalpartsrequired,NOTsuppliedwiththeproduct.
Thefollowingadditionalpartsarerequiredfortheinstallationofthe
HydraulicLinearDrive:
•Suitableboltsandassociatednutsandwashersforsecuringthe
reservoirtoasuitablepartofyourvessel.Quantityrequired:2.
•Suitableboltsandassociatednutsandwashersforsecuringthe
pumptoasuitablepartofyourvessel.Quantityrequired:2.
•Suitablecableandelectricalconnectorsforconnectingand
extendingthemotorandclutchcables.
2.8Locationandmountingrequirements
Hydraulicram
Locationandmountingrequirements:
•MUSTbemountedonaverysolidstructure(forexample,a
substantialframememberofyourvessel).Thedriveproducesa
considerableamountofforce,soyouMUSTensurethatboththe
structureandyourtillerarmorrudderquadrantcancopewiththe
peaklevelsofthruststatedintheT echnicalSpeci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:
16
HydraulicLinearDriveInstallationinstructions
Type2:
D11899-1
Type3:
D11855-1
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
17
2.9Productdifferences
FactorstoconsiderwhenreplacinganexistingType2drive
(M81200,M81201)withanewType2drive(E12207,E12208).
Thereareanumberofimportantdifferencesbetweenthe2drives:
•TheexistingType2hydraulicram(M81200,M81201)hasa5
degreetoleranceofmovementintheverticalplane.ThenewType
2hydraulicram(E12207,E12208)hasa10degreetolerance.
•FortheexistingType2drive(M81200,M81201)thepipesthat
transportedthehydraulicuidtotheramunitwereconnectedto
thetopoftheunit.FortheNEWType2drive(E12207,E12208),
thepipesconnecttotherearoftheunit.Youmustallowatleast
17cm(6.7in)clearanceattherearoftheunitfortheextruding
pipes.Theminimumbendradiusforthepipesis7.6cm(3in).
•Thenewdrive(E12207,E12208)canbemountedhorizontally
orvertically.
•Thehydraulicuidreservoirsuppliedwiththenewdrive(E12207,
E12208)isadifferentsizeandshape.
2.10Dimensions
Type2drive
D11868-1
147.75 mm (5.82 in)
101.5 mm (4 in)
386.5 mm (15.22 in)
1
573.5 mm (22.58 in)
108.8 mm
(4.28 in)
116.0 mm (4.57 in)
1.Hydraulicramatmidstrokeposition.
18
HydraulicLinearDriveInstallationinstructions
Type3drive
D11856-1
101.6 mm (4 in)
152 mm (6 in)
80 mm
(3.15 in)
457 mm (18 in)
1
690 mm (27.15 in)
1.Hydraulicramatmidstrokeposition.
2.11Dimensions
Reservoirdimensions.
D11901-1
148.7 mm (5.85 in)
55.3 mm
(2.17 in)
9.5 mm
(0.37 in)
Planning
19
20
HydraulicLinearDriveInstallationinstructions
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