Raymarine E12207 Installation Instructions Manual

Brand: Raymarine

Model: E12207

Type: Installation Instructions Manual

This manual is also suitable for

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)

HydraulicLinearDriveInstallationinstructions

Trademarksandregisteredtrademarks

Autohelm,hsb

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

,SeaT alk

andSportpilotareregisteredtrademarksof

RaymarineUKLimited.Seahawk,Smartpilot,PathnderandRaymarineareregisteredtrademarksofRaymarineHoldingsLimited.

Allotherproductnamesaretrademarksorregisteredtrademarksoftheirrespectiveowners.

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Youmayprintnomorethanthreecopiesofthismanualforyourownuse.Youmaynotmakeanyfurthercopiesordistributeorusethe

manualinanyotherwayincludingwithoutlimitationexploitingthemanualcommerciallyorgivingorsellingcopiestothirdparties.

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

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

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

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.

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

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.

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

2.1Installationchecklist

Installationincludesthefollowingactivities:

InstallationTask

1Planyourinstallation.

Obtainallrequiredequipmentandtools.

3Mountthesystemcomponents.

4Routeallcables.

Drillcableandmountingholes.

6Makeallconnectionstoequipment.

Secureallequipmentinplace.

Completethepost-installationcheck.

2.2Drivetypes

Thereare2drivetypes.Eachdrivetypehas2variants(onefor

12Vsystems,onefor24Vsystems).

Althoughthecorefunctionalityofeachdrivetypeisessentiallythe

same,theformfactorofsomeofthecomponentsdiffersasfollows:

Hydraulicram

Type2drive:

D11864-1

Type3drive:

D11865-1

Note:Thedrawingsincludedinthishandbookareforillustration

purposesonly.Theexactshapeofyoursystemcomponentsmay

differfromthoseshown.

HydraulicLinearDriveInstallationinstructions

2.3Reservoir

D11866-1

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.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

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.Autopilotcontroller.

2.SPXcoursecomputer.

3.Driveunit.

4.Fluxgatecompass.

HydraulicLinearDriveInstallationinstructions

2.6Partssupplied

D118 54 -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

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:

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

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)

573.5 mm (22.58 in)

108.8 mm

(4.28 in)

116.0 mm (4.57 in)

1.Hydraulicramatmidstrokeposition.

HydraulicLinearDriveInstallationinstructions

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)

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

HydraulicLinearDriveInstallationinstructions

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