Raymarine M81203 Installation Instructions Manual

Brand: Raymarine

Model: M81203

Type: Installation Instructions Manual

This manual is also suitable for

Raymarine M81203 is a powerful hydraulic linear drive designed for boats up to 50 ft (15 m) in length. It provides precise and reliable steering control, even in challenging conditions. The M81203 is ideal for use with Raymarine autopilot systems, and can also be used as a standalone steering system.

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

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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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Model: M81203

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