Raymarine Hydraulic Linear Drive User 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.

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
Thisequipmentmustbeinstalledandoperatedinaccordance
withtheinstructionscontainedinthishandbook.Failuretodoso
couldresultinpoorproductperformance,personalinjuryand/
ordamagetoyourboat.
Because correctperformance of the boat’s steering is critical for
safety,weSTRONGLYRECOMMENDthatanAuthorized
RaymarineServiceRepresentativefits thisproduct.
WARNING: Navigation aid
Althoughwehavedesignedthisproducttobeaccurate and
reliable, many factorscan affectits performance.As aresult,it
shouldonlybeused asanaidtonavigationandshouldnever
replacecommonsenseandnavigationaljudgement.Always
maintainapermanentwatchsoyoucanrespondtosituationsas
theydevelop.
EMC conformance
All Raymarine equipment and accessories aredesigned tothe best
industrystandardsfor use in the recreational marine environment.
The design and manufacture of Raymarine equipmentand
accessories conformto theappropriate Electromagnetic
Compatibility(EMC)standards,butcorrectinstallationisrequiredto
ensure that performance isnot compromised.
Handbook information
To the best ofourknowledge,the information in this handbookwas
correct when it went to press. However, Raymarine cannot accept
liabilityforanyinaccuraciesoromissionsitmaycontain.Inaddition,
ourpolicyofcontinuousproductimprovementmaychange
specifications withoutnotice. Asaresult, Raymarinecannotaccept
liabilityfor anydifferences between theproduct andthe handbook.
©RaymarineLtd 2001.

Hydraulic Linear Drive - Installation Guide 3
Introduction
Welcometotheinstallationguideforthe Raymarinehydrauliclinear
drive system. This product is intended tooperate the boat’s steering
mechanism aspart of aRaymarine autopilot system.
The hydraulic linear drive system is designed for boats with existing
mechanical steering systems, nothydraulic steeringsystems. It
providesa totallyisolatedautopilotsteeringsystemconsistingof:
• Hydraulicram:aself-containedautopilotsteeringcylinderwitha
load limiting system and a built in clutch (to allow friction-free
steering when theautopilot is not inuse).
• Reversinghydraulic pump: powersthe hydraulic ram.
• Hydraulicfluidreservoir:supplieshydraulicfluidtothe system.
CAUTION:
Theramdrivestherudderdirectlyfromthetillerarm orrudder
quadrant.Before installingthisdriveunit,check thattheboat’s
steeringsystemcan be backdrivenfromtherudder.
Figure 1: Main components of the hydraulic linear drive system
Contents
1Product specifications page 4
2Installation instructions page 5
3Maintenance information page 15
Reservoir
Tie-wrap
Reservoir clip Reservoir pipe Pump
Ram
D5088-1
Motor cables
Clutch cable Rod end
Push rod
Mounting foot
Ram pipe
Pump pipes
Tap

4 Hydraulic Linear Drive - Installation Guide
Specifications
Ram specifications
Ram dimensions
Figure 2: Ram dimensions
Table 1: Ram specifications
Performance
(at nominal voltage)
Type 2 (T2)
M81200 (12 V)
M81201 (24 V)
Type 3 (T2)
M81202 (12 V)
M81203 (24 V)
Maximum boat
displacement
22,000 kg
(48,500 lb)
35,000 kg
(77,000 lb)
Peak thrust 585 kg
(1,290 lb)
1,000 kg
(2,200 lb)
Maximum stroke 254 mm
(10 in)
300 mm
(12 in)
Hardover to hardover time
(+/- 35º, no load)
10 sec 12 sec
Maximum rudder torque 1,270 Nm
(11,300 lb.in)
2,565Nm
(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
D5093-1
101.6 mm (4 in)
152 mm (6 in)
80 mm
(3.15 in)
457 mm (18 in)
A (mid stroke)
Drive A (mid stroke)
Type 2 540 mm (21.25 in)
Type 3 690 mm (27.15 in)
4 fixing holes for
8 mm (0.3125 in) bolts

Hydraulic Linear Drive - Installation Guide 5
Installation instructions
Parts required
To install this drive you will need:
•Partssupplied:
•pre-filledandpre-bled systemconsistingof:hydraulicram;
hydraulic pump; hydraulic pipes; fluid reservoir (supplied
fitted with transit cap; standard cap also supplied)
•hydraulicfluid(tofillreservoir)
•tiller pin assembly (see Figure 7) consisting of: tiller pin,
R-clip,topwasher,lock washer,nut(UNCnylock)
•Additional parts:
•suitable securing bolts andlock washers/lock nuts for the
hydraulicramand pump(seepage 9)
•suitable cable and electrical connectors for the drive motor
andclutch (see page 12)
Note:Makesureyouhaveobtainedtheseadditionalpartsbeforeyou
startinstallation.
Installation steps
WARNING: Electrical safety
Makesure youhaveswitchedoffthe powersupplybefore you
startinstallingthisproduct.
Follow these steps to install your hydraulic lineardrive system:
Ï
Ï
Ï
1Consult the EMC installation guidelines. page 6
2Mount the drive system components. page 7
3Connect to the course computer. page 12
4Complete the post-installation check. page 14

6 Hydraulic Linear Drive - Installation Guide
1. EMC installation guidelines
All Raymarine equipment and accessories aredesigned tothe best
industrystandardsfor use in the recreational marine environment.
Theirdesignandmanufacture conformstothe appropriate
Electromagnetic Compatibility (EMC) standards,but correct
installation is requiredto ensure that performance is not
compromised.Although everyefforthas beentakento ensure that
they willperform under all conditions, it isimportant to understand
whatfactors could affectthe operationoftheproduct.
TheguidelinesgivenheredescribetheconditionsforoptimumEMC
performance, butit is recognized that it may notbe possible to meet
all of these conditions in all situations. To ensure the best possible
conditionsforEMC performancewithin the constraints imposedby
any location, alwaysensure the maximumseparationpossible
between different items of electrical equipment.
For optimumEMC performance, it is recommended that wherever
possible:
•Raymarine equipment and cables connected toit are:
•At least3 ft(1 m)fromany equipmenttransmittingor cables
carryingradiosignalse.g.VHF radios, cablesand antennas.
In the case of SSB radios, the distance should be increased to
7ft(2m).
•More than7 ft(2 m)fromthe path ofa radarbeam. Aradar
beamcan normallybeassumedto spread 20degrees above
andbelow theradiatingelement.
•The equipment is supplied from a separate battery fromthat used
for engine start. Voltage drops below10 V, and starter motor
transients,cancausetheequipmenttoreset.Thiswillnotdamage
theequipment,butmay cause theloss of some informationand
maychange theoperatingmode.
•Raymarine specified cables are used. Cutting and rejoining these
cables can compromise EMC performanceand must be avoided
unless doing sois detailed in theinstallation manual.
•Ifasuppressionferriteisattachedtoacable,thisferriteshouldnot
beremoved.Iftheferrite needs to be removed duringinstallation
it mustbereassembled in thesame position.

Hydraulic Linear Drive - Installation Guide 7
Suppression ferrites
The followingillustration showstypicalcablesuppressionferrites
usedwithRaymarineequipment.Alwaysusetheferritessuppliedby
Raymarine.
Figure 3: Typical Suppression Ferrites
Connections to other equipment
If your Raymarine equipment is to be connected to otherequipment
usingacablenotsuppliedbyRaymarine,asuppressionferriteMUST
always be attached to the cable near to the Raymarine unit.
2. Mounting the drive components
Mountingthedrivecomponentsinvolvesfourmainsteps:
•ensuringcorrecthydraulicram alignment
•securing the hydraulic ram to the boat
•connecting the hydraulic ram to the steering system
•installing the other parts of the drive system
Ram alignment
When mountingthe hydraulic ram, check that itis aligned correctly:
•The ram must be at right angles to themounting surface(see
Figure 4).
•Therammustbeatrightanglestothetillerarmwhentherudderis
amidships (see Figure 4).
•The push rod must beaccurately aligned with the tillerarm plane
ofrotation.Theballend fitting only allows up to 5 degrees
misalignment betweenthe push rodandtillerarm planeof
rotation (see Figure 5).
D3548-2

8 Hydraulic Linear Drive - Installation Guide
Figure 4: Hydraulic ram alignment
Figure 5: Alignment between push rod and tiller arm plane of rotation
CAUTION:
Accurateangularalignmentisextremelyimportant.You must
notexceed this+/-5 degreelimitunderanycircumstances.
Securing the hydraulic ram
Mounting location
Before yousecure the hydraulic ram toyourboat,you must first
check the suitability of the mounting location.
CAUTION:
Consulttheboatmanufacturer ifyouhaveanydoubtaboutthe
strengthorsuitabilityofthemountinglocation.
D5091-1
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)
A(mid stroke)
90º
90ºB(tiller arm
radius)
aft
View from
astern
View from
above
D5092-1
5ºMax.
5ºMax.
View from astern

Hydraulic Linear Drive - Installation Guide 9
•Structuralstrength:
•This drive produces a considerable amount of force, soyou
mustmount it on a solidstructure(i.e. a substantialframe
member) in the boat.In somecases it may be necessary to
buildaspeciallystrengthenedframetomount the driveunit.
•Topreventexcessnoise andvibration,do notattachthisdrive
to any structuresthat support cabins.
•Driveorientation:
•You must mount thehydraulicram horizontally withits
mounting foot on a horizontalsurface (see Figure 6).The
swiveljointdoesnothavesufficientmovementtopositionthe
mountingfootvertically.
•General position:
•Refer to the EMC installation guidelines (page 6)
•Make sure thedrive willbe accessible forfuture servicing.
•Environment:
•This drive is notwaterproof, so you shouldmount it in a dry
location,clearofany bilge water.
Figure 6: Drive orientation
Securing bolts
Attach the mounting foot with four stainless steel M8 (5/16inch) bolts
andlocknuts/lockwashers.
Note:Always mount the hydraulicram assecurely as possible to
make sureit performs reliably and remains correctly aligned.
D5089-1
View from above
View from above
aft
aft

10 Hydraulic Linear Drive - Installation Guide
Connecting to the steering system
CAUTION:
Consult the steering gear manufacturerif youhave anydoubt
aboutthe strengthofthe existingtillerarm or rudder quadrant.
This drive producesa considerable amount of force,soyou must
ensure that your tiller arm or rudderquadrantcan cope with the peak
thrust specified in the Table 1,Ram specifications
Use one ofthese methods to attach the push rod to therudder stock:
1. Independenttillerarm:werecommendthatyouattachthepush
rodto the rudderstockviaan independenttillerarm(Edsonand
Whitlock offer a standard fitting).
2. Steeringlinkagetillerarmorrudder quadrant: in certain
cases,youmaybeabletoattachthepushrodtothesametillerarm
orrudder quadrantusedbythemainsteeringlinkage.Consultthe
steeringmanufacturerbefore youmodifytherudderquadrant.
Attaching the rod end
Use the supplied tiller pin assembly to attach the rod end to the tiller
arm, at the tiller arm radius shownin 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 thesupplied lock washerand fully tighten the locknut
Note:Ifnecessary,youwillneed todrillaholeinthetillerarmatthe
radiusshowninFigure 4.
Figure 7: Attaching the push rod to the tiller arm
Lock
washer
Tiller arm
Flange
Drive Hole diameter 'X'
Type 2 13 mm (0.52 in)
Type 3 20 mm (0.78 in)
D5090-1
Tiller pin
Washer
Rod end
R-clip
X
Lock nut

Hydraulic Linear Drive - Installation Guide 11
2. Attach the rodendto thetillerpin:
•place the rod endonto thetiller pin
•secure with the supplied washer and R-clip (see Figure 7)
Steering check
Whenyouhavemountedtheram,turntheboat’ssteeringwheelfrom
hardover to hardover and check that:
•Angular movement ofthe ballend fitting is less than5 degrees
(see Figure 5). Ifyouexceed this 5degree limit, thedrive will
catchonthetillerarm/rudderquadrantandtheballjointwillbind.
•Nopartof thedriveunitfouls the boat’s structure when thepush
rodmovesin and out.
•The total rudder movement is limited to +/- 35 degrees by the
steering system endstops ratherthan the lineardrive’s end limits
(see Figure 8).
Figure 8: Total rudder movement
CAUTION:
Make sure rudder movement is limited by the steering system
end stops beforethe push rod reaches its end stop.Failureto do
this could damage the driveand will invalidate thewarranty.
Installing the other parts of the system
Note:To make installationeasier,we supply thehydrauliclinear
drive system pre-plumbed,pre-filled with hydraulic fluid and
pre-bled,withjustthe reservoirempty. Asaresultyou shouldnot
needtobleed the systemduringinstallation.If you doneedto
disconnectthepipesfor anyreason, contact Raymarine Technical
Services Call Center for advice onbleeding thesystem.
35º35º
Steering system
end stop
Steering system
end stop
D5079-1

12 Hydraulic Linear Drive - Installation Guide
Hydraulic pump
Mount thehydraulic pump:
•ona substantialmembertoavoidvibrationthatcoulddamagethe
hydraulicpipes
•ona horizontalsurface,clearof watersprayand possible
immersion.
•levelorabovethehydraulicramto prevent air from collecting
in the ram
Note:Securethepumpusingsuitablebolts,locknuts&lockwashers.
Reservoir
Mount the reservoir vertically and atleast 150mm(6in)abovethe
hydraulicpump(toensure a goodsupplyoffluidtothe system):
1. Attachtheclip,thenusethetie-wraptosecurethereservoirtothe
clip.
2. Remove the temporary(non-breathable) transit cap fitted to the
reservoir.
3. Fillthe reservoirwith the supplied hydraulic fluid, sothe level is
between the minimum and maximumlines.
CAUTION:
Absolute cleanlinessis essentialwhen workingwithhydraulic
systems. Even the smallest particle of dirt could prevent the
steeringsystemcheckvalvesfrom workingproperly.
4. Fit the supplied standard (breathable) cap to the reservoir.
5. Openthe reservoir tap.
3. Connecting to the course computer
WARNING: Electrical safety
Makesurethepowersupplyisswitchedoffbeforeyoumakeany
electrical connections.
The hydraulic linear drive system haselectrical connections for:
•the motor in the pump: two cables: red (+) and black (-)
•the clutch in the hydraulic ram: a two-core cable withbrown (+)
andblue (-)cores

Hydraulic Linear Drive - Installation Guide 13
Connectthe pumpand ramto the course computer:
1. Measure thedistance ofcable runfrom thepumpand ramto the
coursecomputer:
•useTable 2toidentify the appropriate motorcable sizes
•use at least 1.5mm2(16AWG) coppercableforthe clutch
2. Join these cablesto the ones on the pumpand ramusing
appropriate electrical connectors orjunction boxesat the correct
powerrating.
Note:To meet currentEMClegislation, youmust NOTuntwistthe
pumpcables,andyoumustNOTremovethe suppressionferrite.
3. Routethecablesbacktothecoursecomputer,takingintoaccount
the EMC installation guidelines (page 6).
4. Connect:
•the cables from the pumpto the MOTOR terminals on the
coursecomputer(seeFigure 9): at this stage you canconnect
either motorcable to eitherterminal. You willcheckthese
connections after installing the rest of the autopilot system.
•thecablesfromthehydraulicramtotheCLUTCH terminalson
the course computer (see Figure 9): brown (+) and blue (-)
Table 2: Recommended cable sizes
Cable length
(pump to course computer)
Cable gauge
(AWG)
Copper area
(mm2)
Type 2 drive 12 V
up to 5 m (16 ft)
up to 7 m (23 ft)
up to 16 m (52 ft)
10
8
6
6
10
16
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)
12
10
8
6
4
6
10
16
Type 3 drive 12 V
up to 5 m (16 ft)
up to 7 m (23 ft)
up to 16 m (52 ft)
8
6
4
10
16
25
Type 3 drive 24 V
up to 5 m (16 ft)
up to 7 m (23 ft)
up to 16 m (52 ft)
10
8
6
6
10
16

14 Hydraulic Linear Drive - Installation Guide
Figure 9: Cable connections at course computer
4. Post-installation check
WARNING:
Keepclear ofmovingsteeringsystemsatalltimes. Protect
moving partsfromaccess duringnormal use.
Checkthe followingpointsafterinstallingthedrive:
1. Isthemountingfootsecuredtoa substantialstructureontheboat?
2. Isthe hydraulic ram correctly aligned,i.e:
•Is the mountingfoot correctly oriented?
•Is the drive mounted at right angles to thetiller arm, in a mid-
stroke position, when the rudder is amidships?
•Is the push rod accurately aligned with the tiller arm plane of
rotation(deviationlessthan 5degrees)?
3. Isthe hydraulicram rod end:
•securely attachedto the tillerarm or quadrant?
•attached at the recommended tiller armradius fortheboat?
4. Are the motor and clutch cables correctlyrouted and securely
connectedto thecourse computer?
5. Are all hydraulic pipes securely connected, with no leaks?
6. Haveyou filled thereservoir, fitted the standardcap andopened
thereservoir tap?
7. Haveyou completeda hand-steering check (see page 11)?
Note:When you have installed the entire autopilot system, you will
needtocompleteanautopilotsteeringcheck.Refertothecontrolunit
handbook formoredetails.
+–+–12
+– AB–+
–
–
D5080-1
lk CLUTCH MOTORPOWER
Type 100/300 course computer
MOTORPOWER
OFF
SWITCH SOLENOID CLUTCH
Type 150/400 course computer

Hydraulic Linear Drive - Installation Guide 15
Maintenance
On a regular basis:
•check all connection andmountings are secure
•checkhydraulic ram alignment
•checkpipesand cablesforany signsofwear or damage
•checkhydraulicpipesand jointsfor leaks
EMC servicing and safety guidelines
•Raymarine equipment should be serviced onlybyauthorized
Raymarine service technicians. Theywill ensure that service
procedures andreplacement parts used will not affect
performance. There are no user serviceable parts in any
Raymarine product.
•Someproductsgeneratehighvoltages,soneverhandlethecables
or connectors when poweris being supplied tothe equipment.
•When poweredup, 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 minimize
these effects and enable you to getthe bestpossible performance
from your Raymarine equipment, guidelines are given in the
installationinstructions,toenableyouto ensure minimum
interaction betweendifferentitemsof equipment,i.e. ensure
optimum Electromagnetic Compatibility (EMC).
•Alwaysreport anyEMC-relatedproblemto yournearest
Raymarine dealer. We use such information to improveour
quality standards.
•In someinstallations,itmay notbe possibleto prevent the
equipment frombeing affected by external influences. In general
this will not damagethe equipment butit can lead to spurious
resetting action, or momentarily may result in faulty operation.
Product support
Raymarine products are supported by aworldwide network of
distributors and Authorized Service Representatives. Ifyou
encounteranydifficultieswiththisproduct,pleasecontact either
your national distributor, or your service representative, orthe
RaymarineTechnicalServicesCallCenter.Refertothebackcover
or the WorldwideDistributor List for contact details.

16 Hydraulic Linear Drive - Installation Guide
Raymarine Ltd
Anchorage Park
Portsmouth, Hampshire
England PO3 5TD
Telephone [phone]
Fax [phone]
www.raymarine.com
Raymarine Inc
22 Cotton Road, Suite 280
Nashua
NH 03063-4219, USA
Telephone [phone]
Fax [phone]
www.raymarine.com
Raymarine Technical Services Call Center
UK: [phone] or
[phone] ext. 1083
USA: [phone] or
1-800-539-5539 ext. 2333