Raymarine IO Drive User manual

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RTN in this manual should be
interpreted as Raymarine.
The names Raytheon and RTN
are owned by the
Raytheon Company.

I/O Drive
Installation Guide
Drives covered:
M81138 I/O (Stern) Drive 12 V
E12019 KAD 32 I/O (Stern) Drive 12 V
Document number: 81176-3
March 2001

2 I/O Drive - Installation Guide
Important information
Safety notices
WARNING: Product installation
Thisequipmentmustbeinstalledandoperatedinaccordance
withtheinstructionscontainedinthishandbook.Failuretodoso
couldresultin poorproductperformance, personalinjuryand/
ordamagetoyourboat.
Because correctperformance of the boat’s steering is critical for
safety,weSTRONGLYRECOMMENDthatanAuthorized
RaymarineServiceRepresentativefitsthisproduct.
WARNING: Navigation aid
Althoughwehavedesignedthisproducttobe accurateand
reliable, many factorscan affectits performance.As aresult,it
shouldonlybeused asanaidtonavigationandshouldnever
replacecommonsenseandnavigationaljudgement.Always
maintaina permanentwatchsoyoucanrespondtosituationsas
theydevelop.
EMC conformance
All Raymarine equipment and accessories aredesigned to the best
industrystandards for use in the recreational marine environment.
The design and manufacture of Raymarine equipmentand
accessories conform tothe appropriate Electromagnetic
Compatibility(EMC)standards,butcorrectinstallationisrequiredto
ensure that performance isnot compromised.
Handbook information
To the best of our knowledge, the information in this handbook was
correct when it went to press. However, Raymarine cannot accept
liabilityforanyinaccuraciesoromissionsitmaycontain.Inaddition,
ourpolicy ofcontinuousproduct improvement may change
specifications withoutnotice. Asa result, Raymarine cannotaccept
liabilityfor any differences between the product and thehandbook.
©RaymarineLtd2001.

I/O Drive - Installation Guide 3
Introduction
Product description
Welcometothe installationguide for the Raymarine inboard/
outboarddrive (also knownas an I/O or sterndrive). This productis
intended to operate the boat’s steering mechanism as partof a
Raymarine autopilot system.
It is designed to drive cable operated, power assistedsteering
systems. It operates the power steering valve inthe same way as the
steeringcable. When youdisengage the autopilot, a clutch
disengagesthe I/Odriveso you cansteertheboatmanually.
CAUTION:
Anyattempt toinstallan I/Odriveto anon-compatibleengine
typemayvoidthe warrantyon both the drive and theengine.
Figure 1: Main parts of the I/O drive
Contents
Thisguide contains:
1Product specifications page 4
2Installation instructions page 5
3Maintenance information page 21
D5211-1
Girdle tube Rod end
Socket
for cable Push rod
Main motor, gear
and clutch assembly

4 I/O Drive - Installation Guide
Specifications
Drive specifications
Drive dimensions
Figure 2: I/O drive dimensions
Table 1: Drive specifications
Performance
(at nominal voltage)
I/O drive
M81138 (12 V)
E12019 (KAD 32: 12 V)
Drive method Electromechanical
Maximum thrust 150 kg (330 lb)
Maximum stroke 214 mm (8.3 in)
Hardover to hardover time 8.8 sec
Other information
protected for use in engine compartments
CE approvals - conforms to:
89/336/EC (EMC), EN60945:1997
94/25/EC (RCD), EN28846:1993
220 mm (8.66 in) 240 mm (9.45 in)
460 mm (18.1 in) mid-stroke
102.5 mm
(4.0 in)
63.4 mm
(2.5 in)
D5185-1

I/O Drive - Installation Guide 5
Installation instructions
Parts required
To install the I/O drive the following parts are supplied:
•standardI/O drive unit
•power cable
•appropriate installation kit (see page 7)
Installation steps
WARNING: Electrical safety
Makesure youhaveswitchedoffthepowersupplybefore you
startinstallingthisproduct.
Follow these steps to install your I/O drive unit:
Ï
Ï
Ï
1. EMC installation guidelines
All Raymarine equipment andaccessories are designedto the best
industrystandards for use in the recreational marine environment.
Their design andmanufacture conforms to the appropriate
Electromagnetic Compatibility (EMC) standards, but correct
installation is required to ensure that performance is not
compromised. Although every effort has been taken to ensure that
they willperform under all conditions, it is importantto understand
what factors couldaffect the operation of the product.
1Consult the EMC installation guidelines. page 5
2Mount the drive. page 7
3Connect the power cable. page 19
4Complete the post-installation checks. page 20

6 I/O Drive - Installation Guide
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, always ensure the maximum separation possible
between different items of electrical equipment.
For optimumEMC performance, it isrecommended that wherever
possible:
•Raymarine equipment and cables connected toit are:
•At least3 ft (1 m) from any equipment transmitting orcables
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)from the path ofa radar beam. Aradar
beam can normally be assumed to spread 20degrees above
andbelow theradiating element.
•The equipment is supplied from a separate battery fromthat used
for engine start. Voltage dropsbelow 10 V, and starter motor
transients,cancausetheequipmenttoreset. Thiswillnotdamage
theequipment,butmay cause theloss ofsome informationand
maychange the operatingmode.
•Raymarine specified cables are used. Cutting and rejoining these
cables can compromise EMC performance andmust be avoided
unless doing so is detailed in the installation manual.
•Ifasuppressionferriteisattachedtoacable,thisferriteshouldnot
beremoved.Iftheferrite needs to be removed duringinstallation
it mustbe reassembled in the sameposition.
Suppression ferrites
Figure 3showstypical cable suppressionferritesusedwith
Raymarineequipment.Alwaysuse the ferrites supplied by
Raymarine.
Connections to other equipment
If your Raymarine equipment is to be connected to otherequipment
usingacablenotsuppliedbyRaymarine,asuppressionferriteMUST
always be attached tothe cable near to the Raymarine unit.

I/O Drive - Installation Guide 7
Figure 3: Typical Suppression Ferrites
2. Mounting the drive
CAUTION:
I/Odrivesareaffectedbysubstantialvibrationduringuse.When
installingthisI/Odrive,makesurethatyoufullytightenallbolts
anduselockwashers.Usingasuitablethread-lockingcompound
onthethreadswillhelpkeeptheboltssecurelytightened.
Raymarine provideinstallation kits (seeFigure 4)so you canfitthe
drive unit to stern drive systems made by:
•Volvo: see page 8for installation instructions
•Mercruiser 93, OMC and Yamaha: see page 10 forinstallation
instructions
•Mercruiser 95: see page 12forinstallationinstructions
•VolvoKAD32:requirestheKAD32I/Odrive(part number:
E12019)see page 15for installation instructions
Figure 4: Installation kit parts (Volvo, Mercruiser 93, OMC and Yamaha)
D3548-2
D3365-2
Securing bolt
R-clip
Adaptor pin
bracket
Split pin
Spring-loaded
location pin
Shakeproof
washer
Girdle support
bracket

8 I/O Drive - Installation Guide
Installation for Volvo (after type 872215)
1. Fit thegirdle support bracket (suppliedin the installation kit)as
showninFigure 5:
•removethe locating pin that attaches the cable rod tothe tiller
endblock
•replace it with the girdle support bracket
•secure the assembly withthe suppliedsplit pin
•rotate the girdle supportbracket so that the spring-loadedpin
faces forward
2. Fit the adaptor pin bracket to the cable end sheath (see Figure 6):
•the adaptor pin bracket must sit against,butnot on, the
shoulderon the cable endsheath
•the securing bolts must be on thestern (aft) side ofthe cable
endsheath
•make sure the bracket is vertical
•tightenthetwosecuringbolts
Figure 5: Fitting the girdle support bracket (Volvo)
Girdle support
bracket
Tiller end block
Split pin
D3366-2

I/O Drive - Installation Guide 9
Figure 6: Fitting the adaptor pin bracket (Volvo)
3. Fit the I/O drive into the girdle support bracket (see Figure 7):
•positionthe I/O drive unit so the fixed support pin(on the
bracket)fits into the location hole in theI/O drive girdle tube.
•twist and lower the I/O drive unit into thebracket until the
spring-loadedpin fits intothe other location hole
CAUTION:
Thefixedandspring-loadedlocationpinsmustbefullyengaged
intheI/Odrivegirdletube.Ifthey arenottheautopilotwillfail.
Figure 7: Fitting the I/O drive unit (Volvo)
4. Positionthedriveunitpushrodendoverthetopoftheadaptorpin
andsecure withthe R-clip.
Adaptor pin bracket
Cable end sheath
Aft
Cable end sheath shoulder
D3367-2
I/O drive girdle tube
D3368-2
'R' clip

10 I/O Drive - Installation Guide
5. Complete a hardover to hardover check:
•Slowlyturn the steeringsystem from hardover tohardover.
•Make surethat the drive unit andadaptor pin bracket donot
comeintocontactwithanypartoftheengine,boatorsteering
system.Thisincludes any enginehosesthatmay have a
passing contact with the I/O drive unit.
Note:If necessary, you can rotate the main body of the drive unit
relative to the girdle tube (see Figure 18).
Installation for Mercruiser 93/OMC/Yamaha
1. Fit the girdle support bracket asshown inFigure 8:
•removethe locating pin that attaches the cable rod tothe tiller
endblock
•replace it with the girdle support bracket
•secure the assembly withthe suppliedsplit pin
•rotate the girdle supportbracket so that the spring-loadedpin
faces forward
Figure 8: Fitting girdle support bracket (Mercruiser 93/OMC/Yamaha)
2. With the helm turned hard to port:
•assemble the adaptor pin bracketonto thesteering cable end
sheath,165 mm (6.5in) from the girdlesupport bracket(as
showninFigure 9)
Cable end
sheath
Girdle support
bracket Tiller end
block
Split
pin
D3369-2

I/O Drive - Installation Guide 11
•make surethat the bracketisvertical and that thesecuring
bolts are onthe bow (forward) side of thecable end sheath
•tightenthe two securingbolts onthe adaptor pinbracket
Figure 9: Fitting the adaptor pin bracket (Mercruiser 93/OMC/Yamaha)
3. Fit the I/O drive into the girdle support bracket (see Figure 10):
•positionthe I/O drive unit so the fixed support pin(on the
bracket)fits into the location hole in theI/O drive girdle tube.
•twist and lower the I/O drive unit into thebracket until the
spring-loadedpin fits intothe other location hole
Figure 10:Fitting the I/O drive unit (Mercruiser 93/OMC/Yamaha)
CAUTION:
Thefixedandspring-loadedlocationpinsmustbefullyengaged
intheI/Odrivegirdletube.Ifthey arenottheautopilotwillfail.
165 mm (6.5 in)
Cable
end sheath
Forward
Adaptor pin
bracket
D3370-2
I/O drive girdle tube
D3371-2

12 I/O Drive - Installation Guide
4. Positionthe driveunitpushrodendoverthetopof theadaptorpin
and secure with the R-clip.
5. Complete a hardover to hardover check:
•Slowlyturn the steeringsystem from hardover tohardover.
•Make surethat the drive unit andadaptor pin bracket donot
comeintocontactwithanypartoftheengine,boatorsteering
system.Thisincludes any enginehosesthatmay have a
passing contact with the I/O drive unit.
Note:If necessary, you can rotate the main body of the drive unit
relative to the girdle tube (see Figure 18).
Installation for Mercruiser 95
CAUTION:
Beforeyouinstallanyofthe autopilotcomponents,makesure
thereis sufficientspace between the completedrive unit and the
engine manifold.
Use Raymarine installation kit D309 to install the I/O drive unit to
Mercruiserenginesmanufacturedfrom 1994 onwards.
InstalltheI/O drive by followingthese steps:
1. Remove theexisting pinssecuring:
•thetiller and twinengine connectingbars:
•the power steering ram to the tiller arm and twin engine
connectingbar.
•thesteeringcable to the power steering ram.
Note:These pins are retained bysplitpinsthatmay be hardto
remove.Youwillprobablyneedsomeone’shelptoholdthelegsofthe
split-pinstogetherso you canremove them.
2. Fit the pivot assembly to the steering system as shown in
Figure 11:
•use thenew retaining pins (supplied withthe installation kit)
•secure these with the split pins (supplied)

I/O Drive - Installation Guide 13
Figure 11:Fitting the pivot assembly (Mercruiser 95)
3. Fit the main supportbracket to the spool valve cable connection
onthesteeringsystem(seeFigure 12):
•positionthe main support bracketbehind the spool valve
cableconnection
•fitthe clamparound the spoolvalve cable connection
•put thespring washerson the foursecuring bolts
•tighten the bolts to secure the main support bracket
Figure 12:Fitting the main support bracket (Mercruiser 95)
Tiller arm
Retaining pins
Pivot assembly
Twin engine
connecting bar
Power
steering ram
D5180-1
Main support bracket
Spool valve cable connection
Clamp
Bolts and
spring washers
D5181-1

14 I/O Drive - Installation Guide
4. Place the I/O drive’s pushrodend on the pivot assemblypin–the
flat part ofthe pushrod should reston top of the pivotassembly.
5. Fit the R-clip to the pivot assemblypin to secure the I/O drive
pushrodin place.
Figure 13:Fitting the I/O drive unit (Mercruiser 95)
6. LowertheI/Odriveintothemainsupportbracket(seeFigure 13),
makingsurethat:
•thefixedand spring-loadedpinslocate inthecorresponding
holes in the I/O drive’sgirdle tube
•theI/O drive’spushrodisparallelwiththepowersteeringram
CAUTION:
Thefixedandspring-loadedlocationpinsmustbefullyengaged
intheI/O drivegirdletube.Ifthey arenot theautopilot willfail.
7. Complete a hardover to hardover check:
•Slowlyturn the steeringsystem from hardover tohardover.
•Make surethat the drive unit andadaptor pin bracket donot
comeintocontactwithanypartoftheengine,boatorsteering
system.Thisincludes any enginehosesthatmay have a
passing contact with the I/O drive unit.
Note:If necessary, you can rotate the main body of the drive unit
relative to the girdle tube (see below).
D5182-1

I/O Drive - Installation Guide 15
Installation for Volvo KAD 32
Note:YoumustusetheKAD32I/Odriveunit(partnumberE12019)
forthissystem.
WheninstallingtheI/OdriveunitonaVolvoKAD32,thefirststepis
tofit an extensionbracket toraisethe engine filterassembly and
providesufficientspace forthe drive unit (see Figure 14):
1. Remove the KAD 32 bracket bolts
2. Lift the filter/bracket assembly clearof theengine.
3. Remove the filter assembly bolts.
4. Fit theextension bracket (supplied)to the KAD 32bracket using
the extension bracket bolts (supplied)
5. Use the filter assembly bolts to attach the filter assembly to the
extensionbracket.
6. Make sure the flexible hose is secure.
7. Usethe KAD 32 boltsto refitthe completefilter/bracket
assembly.
Split pin (x2)
Securing
bolt (x2)
Shakeproof
washer (x2)
Volvo adaptor pin
Girdle support
bracket
D5212-1
Extension bracket
Extension bracket bolt,
washer and nut (x2)
Volvo KAD 32 installation kit

16 I/O Drive - Installation Guide
Figure 14:Fitting the extension bracket
Whenyou have fitted theextensionbracket:
1. Removethelocatingpinthatattachesthesteeringcablerodtothe
tillerend block.
2. ReplaceitwiththeVolvoadaptorpin,usingoneofthesplitpinsto
holdit inplace (see Figure 15).
D5216-1
Extension bracket
Extension
bracket bolts
Flexible hose
Filter
assembly
KAD 32 bracket
Filter assembly bolts
KAD 32 bracket bolt
KAD 32 bracket bolt

I/O Drive - Installation Guide 17
Figure 15:Fitting the Volvo adaptor pin
3. Fit thegirdle supportbracket onto the spoolvalve rod:
•the adaptor pin bracket must sit against,butnoton,the
shoulderon thespoolvalverod
•thespring-loadedlocationpinand the securing boltsmustbe
onthe stern(aft) side of the cableend sheath
•make sure the bracket is vertical, then tighten the two bolts
Figure 16:Fitting the girdle support bracket
4. PositiontheI/Odriveunittoalignitslocationholeswiththefixed
and spring-loaded pins in the girdle support bracket (Figure 17).
Tiller end
block
Split pin
Volvo adaptor pin
D5213-1
D5214-1
Girdle support
bracket Aft
Spool valve rod
Shoulder Spring-loaded location pin

18 I/O Drive - Installation Guide
Figure 17:Fitting the I/O drive unit (KAD 32)
CAUTION:
Thefixedandspring-loadedlocationpinsmustbefullyengaged
intheI/O drivegirdletube.Ifthey arenot theautopilot willfail.
5. Fitthepushrodontotheadaptorpinandsecureitwiththesplitpin.
6. Complete a hardover to hardover check:
•Slowlyturn the steeringsystem from hardover tohardover.
•Make surethat the drive unit andadaptor pin bracket donot
comeintocontactwithanypartoftheengine,boatorsteering
system.Thisincludes any enginehosesthatmay have a
passing contact with the I/O drive unit.
Note:If necessary, you can rotate the main body of the drive unit
relative to the girdle tube (see Figure 18).
Mounting in a restricted area
If an obstruction prevents you frominstalling the I/O drive unit as
supplied, rotate the main body ofthe drive relative to the girdle tube
as follows:
1. Remove the two fixing screws onthe front cover.
2. Carefullyslide the coverforwards, makingsure you do notpull
anyofthe fourcables from theplugsinside thecover.
3. Loosenthelock nut.
D5215-1
I/O drive girdle tube
Girdle
support bracket
Pushrod end

I/O Drive - Installation Guide 19
4. Rotate the main body as required.
Figure 18:Rotating the main body of the I/O drive unit
5. Tighten the lock nut, making sure it is less than one turn from the
start of the thread.
6. Replace the cover, taking care not to trap or pinch the cables.
7. Completeahardovercheck:
•Use the steering wheel to move from hardover to hardover.
•Make sure that thedrive unit and adaptor pinbracket do not
comeinto contactwith anypartofthe engine,boator steering
system.Thisincludesany engine hosesthatmay have a
passing contact with the I/O drive unit.
3. Electrical connections
WARNING: Electrical safety
Makesurethepowersupplyisswitchedoffbeforeyoumakeany
electricalconnections.
When you have fitted the I/O drive to the steering system, connect it
to the coursecomputer as follows:
1. Plug in the power cable (supplied) into the socket on the drive
unit. Lock the connector in place by turning the locking ring
clockwise.
2. Route the cabletothe course computer, takinginto account the
EMC installation guidelines (see page 5).
3. Connectthemotorcables(thickerblueandbrowncables)andthe
clutchcables (thinnerredandblack cables)to theconnectionson
thecoursecomputeras shownin Figure 19.
Front cover
Lock nut
Fixing screw
D5183-1