Raymarine M81138 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.
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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
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2 I/O Drive - Installation Guide
Important information
Safety notices
WARNING: Product installation
Thisequipmentmustbeinstalledandoperated in accordance
withtheinstructionscontainedinthishandbook.Failuretodoso
couldresultin poorproductperformance,personalinjuryand/
ordamageto yourboat.
Because correctperformance ofthe boat’ssteering is critical for
safety,weSTRONGLYRECOMMENDthatanAuthorized
RaymarineServiceRepresentativefits thisproduct.
WARNING: Navigation aid
Althoughwehavedesignedthisproducttobeaccurateand
reliable, many factorscanaffectitsperformance.As aresult,it
shouldonlybeusedasanaidtonavigationandshouldnever
replacecommonsenseandnavigationaljudgement.Always
maintainapermanentwatchsoyoucanrespondtosituationsas
theydevelop.
EMC conformance
All Raymarine equipment and accessoriesare designed to thebest
industry standards for use in the recreational marine environment.
The design and manufacture of Raymarine equipmentand
accessories conformto the appropriate Electromagnetic
Compatibility(EMC)standards,butcorrectinstallationisrequiredto
ensure that performance isnot compromised.
Handbook information
To the best ofour knowledge, the information in this handbook was
correct when it went to press. However, Raymarine cannot accept
liabilityforanyinaccuraciesoromissionsitmaycontain.Inaddition,
ourpolicy ofcontinuousproductimprovementmay change
specifications without notice.As aresult,Raymarine cannotaccept
liabilityfor any differences between the product andthe handbook.
©Raymarine Ltd2001.
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I/O Drive - Installation Guide 3
Introduction
Product description
Welcometo the installationguide forthe Raymarine inboard/
outboarddrive (also known as an I/O or stern drive). 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 valvein the same way asthe
steeringcable.When youdisengage theautopilot, aclutch
disengagestheI/O driveso youcan steerthe boatmanually.
CAUTION:
AnyattempttoinstallanI/Odrivetoanon-compatibleengine
typemayvoidthewarrantyon both thedrive andtheengine.
Figure 1: Main parts of the I/O drive
Contents
Thisguidecontains:
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
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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
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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
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1. EMC installation guidelines
All Raymarine equipment andaccessories are designed to the best
industrystandards for use in the recreational marine environment.
Their design and manufacture 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 important tounderstand
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
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6 I/O Drive - Installation Guide
Theguidelinesgivenhere describetheconditionsforoptimumEMC
performance, butit is recognized that it may not be possible to meet
all of these conditions in all situations. To ensure the best possible
conditionsforEMC performancewithin theconstraintsimposed by
any location, always ensure the maximumseparation possible
between different items of electrical equipment.
For optimumEMC performance, itis recommended that wherever
possible:
•Raymarine equipment and cables connectedto it are:
•At least3 ft (1m) fromany equipmenttransmitting or cables
carryingradio signalse.g.VHFradios,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 radarbeam. A radar
beam can normally be assumed to spread 20degrees above
andbelow the radiating element.
•The equipment is supplied from a separate battery fromthat used
for engine start. Voltage drops below10 V, and startermotor
transients,cancausetheequipmenttoreset.Thiswillnotdamage
theequipment,but maycausethe lossofsome informationand
maychange the operatingmode.
•Raymarine specified cables are used. Cutting and rejoining these
cables can compromise EMC performanceand must be avoided
unless doing sois detailed in the installation manual.
•Ifasuppressionferriteisattachedtoacable,thisferriteshouldnot
beremoved. Iftheferrite needstoberemovedduringinstallation
it mustbe reassembled in the same position.
Suppression ferrites
Figure 3showstypicalcable suppressionferrites usedwith
Raymarineequipment.Alwaysusethe ferritessuppliedby
Raymarine.
Connections to other equipment
If your Raymarine equipment is to be connected to other equipment
usingacablenotsuppliedbyRaymarine,asuppressionferriteMUST
always beattachedto the cable nearto theRaymarineunit.
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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
onthethreadswillhelp keeptheboltssecurelytightened.
Raymarine provide installationkits(see Figure 4)so youcanfit the
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 15 for 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
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8 I/O Drive - Installation Guide
Installation for Volvo (after type 872215)
1. Fit the girdle support bracket (suppliedin the installationkit) as
showninFigure 5:
•removethe locating pin that attaches the cable rod to the tiller
endblock
•replace it with the girdle support bracket
•secure theassemblywith the suppliedsplitpin
•rotate the girdle support bracket so that thespring-loaded pin
faces forward
2. Fit the adaptor pin bracket to the cable end sheath (see Figure 6):
•the adaptor pin bracket must sit against,but noton, the
shoulderon the cableend sheath
•the securing bolts must be onthe stern(aft) sideofthecable
endsheath
•make sure the bracket is vertical
•tightenthe twosecuringbolts
Figure 5: Fitting the girdle support bracket (Volvo)
Girdle support
bracket
Tiller end block
Split pin
D3366-2
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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/Odrive unit so thefixed support pin (on the
bracket)fits intothe locationhole in theI/O drivegirdle tube.
•twist and lower the I/O drive unit into thebracket until the
spring-loaded pin fits into the other locationhole
CAUTION:
Thefixedandspring-loadedlocationpinsmustbe fullyengaged
inthe I/Odrivegirdletube.Iftheyare nottheautopilotwillfail.
Figure 7: Fitting the I/O drive unit (Volvo)
4. Positionthedriveunitpushrodendoverthetopoftheadaptorpin
andsecure with the R-clip.
Adaptor pin bracket
Cable end sheath
Aft
Cable end sheath shoulder
D3367-2
I/O drive girdle tube
D3368-2
'R' clip
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10 I/O Drive - Installation Guide
5. Complete a hardoverto hardover check:
•Slowlyturnthe steeringsystemfromhardover tohardover.
•Make surethat the drive unit and adaptor pinbracket donot
comeintocontactwithanypartoftheengine,boatorsteering
system.Thisincludesany enginehoses thatmayhave a
passing contact with the I/O drive unit.
Note:If necessary, you can rotatethe main body of thedrive unit
relative to the girdle tube (see Figure 18).
Installation for Mercruiser 93/OMC/Yamaha
1. Fit the girdle support bracket asshownin Figure 8:
•removethe locating pin that attaches the cable rod to the tiller
endblock
•replace it with the girdle support bracket
•secure theassemblywith the suppliedsplitpin
•rotate the girdle support bracket so that thespring-loaded pin
faces forward
Figure 8: Fitting girdle support bracket (Mercruiser 93/OMC/Yamaha)
2. With the helm turned hard to port:
•assemble theadaptor pinbracket onto thesteeringcable end
sheath,165 mm(6.5 in) from the girdlesupport bracket(as
shownin Figure 9)
Cable end
sheath
Girdle support
bracket Tiller end
block
Split
pin
D3369-2
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I/O Drive - Installation Guide 11
•make surethat the bracket isvertical andthat the securing
bolts are onthe bow (forward) side ofthe cable end sheath
•tightenthe twosecuring bolts onthe adaptorpin bracket
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/Odrive unit so thefixed support pin (on the
bracket)fits intothe locationhole in theI/O drivegirdle tube.
•twist and lower the I/O drive unit into thebracket until the
spring-loaded pin fits into the other locationhole
Figure 10:Fitting the I/O drive unit (Mercruiser 93/OMC/Yamaha)
CAUTION:
Thefixedandspring-loadedlocationpinsmustbe fullyengaged
inthe I/Odrivegirdletube.Iftheyare nottheautopilotwillfail.
165 mm (6.5 in)
Cable
end sheath
Forward
Adaptor pin
bracket
D3370-2
I/O drive girdle tube
D3371-2
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12 I/O Drive - Installation Guide
4. Positionthedriveunitpushrodendoverthetopoftheadaptorpin
and secure with the R-clip.
5. Complete a hardoverto hardover check:
•Slowlyturnthe steeringsystemfromhardover tohardover.
•Make surethat the drive unit and adaptor pinbracket donot
comeintocontactwithanypartoftheengine,boatorsteering
system.Thisincludesany enginehoses thatmayhave a
passing contact with the I/O drive unit.
Note:If necessary, you can rotatethe main body of thedrive unit
relative to the girdle tube (see Figure 18).
Installation for Mercruiser 95
CAUTION:
Before youinstallanyoftheautopilotcomponents,makesure
thereis sufficient spacebetween thecomplete drive unit and the
enginemanifold.
Use Raymarine installation kit D309 to install the I/O drive unit to
Mercruiserengines manufacturedfrom 1994onwards.
Installthe I/O drive by following these steps:
1. Remove theexistingpinssecuring:
•thetiller andtwin engine connectingbars:
•the power steering ram to the tiller arm and twin engine
connectingbar.
•thesteeringcable tothe powersteeringram.
Note:These pinsare retainedby splitpinsthatmay be hardto
remove.Youwillprobablyneedsomeone’shelptoholdthelegsofthe
split-pins togetherso you canremove them.
2. Fit the pivot assembly to the steering system as shown in
Figure 11:
•use thenew retainingpins(supplied with theinstallationkit)
•secure these with the split pins (supplied)
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I/O Drive - Installation Guide 13
Figure 11:Fitting the pivot assembly (Mercruiser 95)
3. Fit the main supportbracket to the spoolvalve cable connection
onthesteeringsystem(seeFigure 12):
•positionthe mainsupportbracket behindthe spool valve
cableconnection
•fitthe clamp around the spool valve cable connection
•put thespringwashers on the four securingbolts
•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
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14 I/O Drive - Installation Guide
4. Place theI/Odrive’s pushrodend on thepivotassemblypin–the
flat part ofthe pushrod shouldrest ontop 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),
makingsure that:
•thefixed andspring-loadedpinslocatein thecorresponding
holes in the I/O drive’sgirdletube
•theI/Odrive’spushrodisparallelwiththepowersteeringram
CAUTION:
Thefixedandspring-loadedlocationpinsmustbefullyengaged
intheI/Odrive girdle tube. If they arenottheautopilot willfail.
7. Complete a hardoverto hardover check:
•Slowlyturnthe steeringsystemfromhardover tohardover.
•Make surethat the drive unit and adaptor pinbracket donot
comeintocontactwithanypartoftheengine,boatorsteering
system.Thisincludesany enginehoses thatmayhave a
passing contact with the I/O drive unit.
Note:If necessary, you can rotatethe main body of thedrive unit
relative to the girdle tube (see below).
D5182-1
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I/O Drive - Installation Guide 15
Installation for Volvo KAD 32
Note:YoumustusetheKAD32I/Odriveunit(partnumberE12019)
forthissystem.
WheninstallingtheI/OdriveunitonaVolvoKAD32,thefirststepis
tofit an extension brackettoraise the enginefilterassembly and
provide sufficient space forthe drive unit(see Figure 14):
1. Remove the KAD 32 bracket bolts
2. Lift the filter/bracket assembly clearof the engine.
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 32boltstorefit the 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
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16 I/O Drive - Installation Guide
Figure 14:Fitting the extension bracket
Whenyou havefitted theextensionbracket:
1. Removethelocatingpin thatattachesthesteeringcablerodtothe
tillerend block.
2. ReplaceitwiththeVolvoadaptorpin,usingoneofthesplitpinsto
holdit in place (seeFigure 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
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I/O Drive - Installation Guide 17
Figure 15:Fitting the Volvo adaptor pin
3. Fit thegirdle support bracket onto the spool valve rod:
•the adaptor pin bracket must sit against,butnoton,the
shoulderon thespoolvalve rod
•thespring-loadedlocationpinand thesecuring boltsmustbe
onthestern (aft)side ofthe cable end 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
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18 I/O Drive - Installation Guide
Figure 17:Fitting the I/O drive unit (KAD 32)
CAUTION:
Thefixedandspring-loadedlocationpinsmustbefullyengaged
intheI/Odrive girdle tube. If they arenottheautopilot willfail.
5. Fitthepushrodontotheadaptorpinandsecureitwiththesplitpin.
6. Complete a hardoverto hardover check:
•Slowlyturnthe steeringsystemfromhardover tohardover.
•Make surethat the drive unit and adaptor pinbracket donot
comeintocontactwithanypartoftheengine,boatorsteering
system.Thisincludesany enginehoses thatmayhave a
passing contact with the I/O drive unit.
Note:If necessary, you can rotatethe main body of thedrive unit
relative to the girdle tube (see Figure 18).
Mounting in a restricted area
If an obstruction prevents youfrom installing the I/O drive unit as
supplied, rotate the main body ofthe drive relative to the girdle tube
as follows:
1. Remove the twofixing screws onthe front cover.
2. Carefullyslidethe coverforwards, makingsure youdonot pull
anyof the fourcablesfromthe plugsinsidethecover.
3. Loosenthe locknut.
D5215-1
I/O drive girdle tube
Girdle
support bracket
Pushrod end
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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 ofthe thread.
6. Replace the cover, taking care not to trap or pinch the cables.
7. Completea hardovercheck:
•Use the steering wheel to move from hardover to hardover.
•Make sure that thedrive unit andadaptor pin bracket do not
comeintocontactwithanypartoftheengine,boatorsteering
system.This includesanyengine hosesthatmay havea
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 cableto the coursecomputer, taking into accountthe
EMC installation guidelines (see page 5).
3. Connectthemotorcables(thickerblueandbrowncables)andthe
clutchcables (thinnerred andblackcables)totheconnectionson
thecoursecomputeras showninFigure 19.
Front cover
Lock nut
Fixing screw
D5183-1
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