Raymarine Constant Running Hydraulic Pump User manual

Constant Running
Hydraulic Pump
Installation Guide
Drives covered:
M81125 Type CR1 (3 L) Constant Running Pump 12 V
M81127 Type CR1 (3 L) Constant Running Pump 24 V
M81126 Type CR2 (4.5 L) Constant Running Pump 12 V
M81128 Type CR2 (4.5 L) Constant Running Pump 24 V
Document number: 81179-3
March 2001

2 Constant Running Hydraulic Pump - Installation Guide
Important information
Safety notices
WARNING: Product installation
Thisequipmentmustbe installedand operatedin accordance
withtheinstructionscontainedinthishandbook.Failuretodoso
couldresultin poorproductperformance,personalinjuryand/
ordamageto yourboat.
Because correctperformance ofthe boat’s steering is critical for
safety,weSTRONGLYRECOMMENDthatanAuthorized
RaymarineServiceRepresentativefits this product.
WARNING: Navigation aid
Althoughwehavedesignedthis producttobe accurateand
reliable, many factorscan affectitsperformance.As aresult,it
shouldonlybe usedasanaidto navigationandshouldnever
replacecommonsenseandnavigationaljudgement.Always
maintainapermanentwatchsoyou canrespondtosituationsas
theydevelop.
EMC conformance
All Raymarine equipment and accessories aredesigned tothe 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 improvementmay change
specifications without notice.As aresult, Raymarine cannotaccept
liabilityfor any differences between the product and thehandbook.
©Raymarine Ltd2001.

Constant Running Hydraulic Pump - Installation Guide 3
Introduction
Product description
WelcometotheinstallationguidefortheRaymarineconstantrunning
(CR) hydraulic pump.This product is intended to operate the boat’s
steeringmechanism as partof aRaymarineautopilot system.
The pump providesan ideal drive system forlarge boats andheavy
duty steering applications. Itis primarily designed foruse on boats
withanexistinghydraulicsteeringsystem.Alternatively,youcanuse
this pump on a boat with mechanical steering in conjunction with a
secondarysteering ramand bypassvalve.
The pump contains a built-in reservoir that holds hydraulic fluid and
an integral solenoid valve that controls the flowof hydraulic fluid to
the steering ram. Theautopilot system steers the boat byusing the
solenoid controlvalves tocontrol the flowof hydraulic fluidto the
steeringram.
Figure 1: Main parts of the CR pump
Contents
Thisguidecontains:
1Product specifications page 4
2Installation instructions page 5
3Maintenance information page 17
Mounting foot
Reservoir port
Ram ports
Reservoir
Motor
Motor cables
D5176-1
Solenoid
control valve x2
Power connector x2
(for solenoid control valve)

4 Constant Running Hydraulic Pump - Installation Guide
Specifications
Pump specifications
Pump dimensions
Figure 2: Pump dimensions
Table 1: Pump specifications
Performance
(at nominal voltage)
Type CR1
M81125 (12 V)
M81127 (24 V)
Type CR2
M81126 (12 V)
M81128 (24 V)
Ram capacity 350-500 cc
(21-30 in3)
500-1200 cc
(30-73 in3)
Ram single or double ended
Maximum stall
pressure (at 12 V)
50 bar
(750 psi)
50 bar
(750 psi)
Peak flow rate
(no load)
3000 cc/min
(180 in3/min)
4500 cc/min
(270 in3/min)
Other information (applies to Types CR1 and CR2)
protected for use in engine compartments
CE approvals - conforms to:
89/336/EC (EMC), EN60945:1997
94/25/EC (RCD), EN28846:1993
356 mm (14 in) 262 mm (10.3 in)
224 mm (8.8 in)
D5178-1

Constant Running Hydraulic Pump - Installation Guide 5
Installation instructions
Parts required
To install this drive you will need:
•Partssupplied:
•CR hydraulic pump
•ifrequired:BSP toNPTadaptors(x3)
•Additional parts:
•suitable hydraulicpipes, hydraulicfluid, T-pieces,pipe
fittingsand thread-sealingcompound(see page 8)
•suitable securing bolts, lock washers/locknuts (see page 7)
•suitable cable and electrical connectors for the drive motor
andsolenoidcontrolvalves(seepage 13)
•CR interface (to connect toType 100/300 course computer)
•bypassvalve (if connecting to a secondarysteering ram)
Note:Obtainthese additionalparts before you startinstallation.
Installation steps
WARNING: Electrical safety
Makesure youhaveswitchedoffthepowersupplybeforeyou
startinstallingthisproduct.
Follow these steps to install your CR pump:
Ï
Ï
Ï
Ï
1Consult the EMC installation guidelines. page 6
2Mount the pump. page 7
3Connect to the hydraulic steering system. page 8
4Connect to the course computer. page 13
5Complete the post-installation checks. page 16

6 Constant Running Hydraulic Pump - Installation Guide
1. EMC installation guidelines
All Raymarine equipment and accessories aredesigned tothe best
industrystandards for use in the recreational marine environment.
Theirdesign andmanufactureconformstotheappropriate
Electromagnetic Compatibility(EMC) standards,but correct
installation is required to ensure that performance is not
compromised.Althoughevery effort has been taken to ensure that
they willperform under all conditions, it isimportant to understand
whatfactorscould affecttheoperationoftheproduct.
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 theconstraintsimposedby
any location, always ensure the maximumseparation possible
between different items of electrical equipment.
For optimumEMC performance, itisrecommended that wherever
possible:
•Raymarine equipment and cables connected toit are:
•At least3 ft (1m) fromany equipmenttransmittingor 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 radar beam. Aradar
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 dropsbelow 10 V, and starter motor
transients,cancausetheequipmenttoreset.Thiswillnotdamage
theequipment,but maycause the lossofsome informationand
maychange the operatingmode.
•Raymarine specified cables are used. Cutting and rejoining these
cables can compromise EMC performance andmust be avoided
unless doing sois detailed in the installation manual.
•Ifasuppressionferriteisattachedtoacable,thisferriteshouldnot
beremoved. Iftheferriteneedsto beremoved duringinstallation
it mustbe reassembled in the same position.

Constant Running Hydraulic Pump - Installation Guide 7
Suppression ferrites
Thisfigureshows typicalcable suppressionferrites usedwith
Raymarine equipment. Alwaysuse the ferritessuppliedby
Raymarine.
Connections to other equipment
If your Raymarine equipment is to be connected to other equipment
usingacablenotsuppliedbyRaymarine,asuppressionferriteMUST
always be attached to the cable near tothe Raymarine unit.
2. Pump mounting
CAUTION:
Duringinstallation,takecarenottoknocktheCR pump’s
mounting feet onany solid structures asthe impact may damage
thealuminiumcastings.
Mount the CR pump:
•ona substantialmember toavoidvibrationthatcoulddamagethe
hydraulicpipes
•on a suitable horizontal surface clear of sprayand possible water
immersion
•levelorabovethehydraulic steeringramto preventaircollecting
in the ram
•as close tothe steering ram as possible
•using suitable bolts with lock nuts/lock washers
Note:As thepumpcan transmitnoise to theboat’sstructure, we
recommendplacingrubbermountsbetweenthepumpandtheboat’s
structure to reduce noise transfer.
CAUTION:
Locatethepumpinaventilatedandsoundproofenclosure.
D3548-2

8 Constant Running Hydraulic Pump - Installation Guide
3. Hydraulic connections
CAUTION:
Beforeyouconnecttheautopilotpumptoyourhydraulicsystem
westronglyrecommendthatyouconsultthesteeringgear
manufacturer.
General guidelines
CAUTION:
Absolute cleanlinessis essentialwhenworkingwithhydraulic
systems. Even the smallest particle of dirt could preventthe
steeringsystemcheckvalvesfromworkingproperly.
•All pipes used to fit the pump shouldmatch, or exceed, the
specification oftheexisting steering systempipes.Contact the
steeringsystemmanufacturerif youneed moreinformation.
•Use flexible pipe to connect the pump to the boat’s steering
system- thisavoids strain onthe pipes.
•Trytokeephydraulicfluidlosstoaminimumwheninstallingthe
pump. This will reduce the time and effort required to bleed the
systemof trappedair afterinstallation:
•non-pressurized systems: temporarily fit anon-venting plug
to the helm reservoir vent to minimizefluid loss
•pressurized systems:
WARNING:
Beforedisconnectinganypipesonpressurized systems, you
MUSTreleasethepressureat thereservoirbyfollowingthe
manufacturer’sinstructions.
•The ram ports onthe CR pump aretappedto 1/4in BSP and the
reservoirportis tappedto 3/8 inBSP.ThreeNPTadaptors are
includedfor conversionto NPTwhere required.
•Followthe manufacturer’s instructions if you fit any T-pieces.
•Make sure allhydraulic pipes slopeupwardstowards the
reservoir.
•A set ofbleed valves near thesteering ram, fitted at thehighest
point,willallowany airto escapeupwards.

Constant Running Hydraulic Pump - Installation Guide 9
CAUTION:
DonotusePTFEtapeonhydraulicpipeconnections.Ifnecessary
usea pipe-sealingcompoundtoensure aleakproof joint.
CAUTION:
Beforerunningthepumpforthefirsttime,makesurethesystem
contains sufficienthydraulicfluid.Youwilldamagethepumpif
youletitrunwhen‘dry’.
Check valves
Forsingle-steeringpositionboats:
•Consultthe steering gearmanufacturertodeterminewhetherthe
helm pumpis fitted with reversing check valves:
•without check valves, the autopilot pump will drive the helm
pump(sometimesreferredtoas‘motoringthewheel’)instead
ofmovingthe steeringram
•If the boat has a singlehelm pump system withoutcheckvalves,
you must incorporate adouble pilot checkvalve (part number:
M81166) as shown in Figure 3.
•A double pilot check valve may alsobe necessary on long pipe
runs- otherwisepipeexpansion maycause poorautopilot
performance. Install the check valveas shownin Figure 3.
Note:Iftheboathastwosteeringpositions,itwillalreadyhavecheck
valvesinstalledso thetwo wheelscan operate independently.
Hydraulic steering systems
There arethree basictypes ofhydraulic steeringsystems:
•two line system
•three line system
•twolinepressurized system
On the following pages we describe each type of system and typical
connectionpointsfortheautopilotpump.Forallofthesesystemsyou
will need toconnect a thirdhydraulic pipeas shownbetween the
autopilotpump and the helm pump or dedicated system reservoir.

10 Constant Running Hydraulic Pump - Installation Guide
Two line systems
Figure 3showsa typical twoline steeringsystem.Hydraulic fluid
flows into the ram in either direction, depending on the direction the
helm pump rotates.
Connect the autopilot pump to thesteering system asshown in
Figure 3.
Figure 3: Autopilot pump location for two line systems
D5168-1
Helm
pump
CR pump
Steering ram
Ram pipes
Reservoir pipe
Check valve (if required)

Constant Running Hydraulic Pump - Installation Guide 11
Twolinepressurized systems
Two line pressurized systems havean external pressurized reservoir.
Thisreduces the possibility of introducingair into the system and
reducesany steering‘sponginess’causedbypipe expansion.
Connect the autopilot pump to the steering system as shown in
Figure 4.
Note:Refer to the manufacturer’sinstructionsforde-pressurizing
andre-pressurizingthe system.
Figure 4: Autopilot pump location for two line pressurized systems
D5167-1
Helm
pump
Steering ram
Ram pipes
Reservoir pipe
CR pump

12 Constant Running Hydraulic Pump - Installation Guide
Threelinesystems
Inathree linesystem,thehydraulic fluidflows in onlyonedirection:
•out of the helmpump to the ram
•returning from the other side ofthe ram to the reservoir via a
commonreturn line
The system will include acheck valve blockto direct all returned
fluid from the ram back to the reservoir.
Connect the autopilot pump to thesteering system asshown in
Figure 5.
Figure 5: Autopilot pump location for three line systems
D5166-1
Helm
pump
CR pump
Steering ram
Ram pipes
Reservoir
pipe
Check valve

Constant Running Hydraulic Pump - Installation Guide 13
4. Connecting to the course computer
WARNING: Electrical safety
Makesurethepowersupplyisswitchedoffbeforeyoumakeany
electricalconnections.
The CR pumphas electrical connections for:
•motorsupply: two single-corecables
•solenoid controlvalve supply:two plug-inconnectors (supplied)
Note:When routingcables, refer to the EMC installation guidelines.
Connecting to Type 150/400 course computer
Makethe followingconnections:
1. CR pump motor supply:
•usingappropriate cables(seeTable 2) connect the CR pump
motor to the boat’s powersupply,via an appropriatecircuit
breakerand fuse (asspecifiedinFigure 6)
2. Solenoidcontrolvalves–usingsuitablecable(atleast16AWGor
1.5 mm2forruns upto16 m/52ft):
•forthefirstvalve:connectonecoretotheMOTOR A terminal
and the other core to one of the SOLENOID terminals at the
coursecomputer (see Figure 6)
•for the second valve: connect one coreto the MOTOR B
terminal and the other core to the other SOLENOID terminal
Note:
If installing the pump on aboat with mechanical steering, you
need toconnect a bypass valve to the
CLUTCH terminals (see page 15).
Table 2: Recommended cable sizes
Pump motor cable length
(distribution panel to pump)
Cable gauge
(AWG)
Copper area
(mm2)
12 V CR pumps
up to 3 m (10 ft)
up to 7 m (23 ft)
up to 16 m (52 ft)
10
8
6
6
10
16
24 V CR pumps
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

14 Constant Running Hydraulic Pump - Installation Guide
Figure 6: CR pump connections to a Type 150/400 course computer
Connecting to Type 100/300 course computer
Wheninstallingthe CRpump witha Type 100/300course computer
werecommend usinga Raymarineconstantrunning(CR) interface
(part number: M81129).
Connecting the CR interface
Runcablesfrom the mainpowersupply to:
•themotor onthe CRpump
•the CR interface and then onto thecourse computer power
connections
Install a suitable circuit breaker in the power supply to the complete
system (as specified in thecore pack installation guide).
Note:It is important touse the correct cable size for the length of
cable run betweenthe pumpand thepower supply (see Table 2).
TheCRinterfaceunit hasconnectionsforthe solenoidvalves (onthe
CR pump)and abypass valve(if fittingtoa mechanical steering
system):
•connect the solenoid valves to the CR interface as shown in
Figure 7, using atleast 16 AWG (1.5 mm2)cable.
+–
AB
––
–
MOTORPOWER
OFF
SWITCH SOLENOID CLUTCH
+
To bypass valve
(if required)
Solenoid 'A' cable
Motor supply
CR1 (12V) - 50A
CR1 (24V) - 30A
CR2 (12V) - 70A
CR2 (24V) - 40A
D5189-2
Course computer
connections
Solenoid 'B' cable
CR pump
To boat's battery
Fuse
Circuit
breaker

Constant Running Hydraulic Pump - Installation Guide 15
Figure 7: CR pump connections to a Type 100/300 course computer
Mechanical steering
Ifyouarefittingthepumptoaboatwithmechanicalsteeringyouwill
need to connect itto a secondary steering ram, along with a solenoid-
operated bypassvalve (part no. M81167).The bypass valve allows
youto switch betweenautopilotcourse controlandmanual steering.
To fit to a mechanical steeringsystem:
1. Usesuitablehydraulicpipestoconnectthepumptothesecondary
steering ramand a suitable reservoir.
2. Install the solenoid-operated bypass valve across these pipes (as
showninFigure 8).
3. Connectthebypassvalve to:
•theCLUTCH terminalsonthecoursecomputer(Type150/400
coursecomputer),or
•the BYPASS terminals onthe CRinterface(Type 100/300
coursecomputer
Note:Follow themanufacturer’sinstructionsformountingthe
hydraulicram.
Supply Circuit breaker
Type CR
interface unit
To bypass
valve (if
required) 12 V - 25 A
24 V - 10 A
Solenoid 'A' cable
Motor supply
CR1 (12 V) – 50 A
CR1 (24 V) – 30 A
CR2 (12 V) – 70 A
CR2 (24 V) – 40 A
D5164-2
Course computer
Solenoid 'B' cable
MOTOR
POWER
CLUTCH
Course computer
connections:
Fuse
+ – + – + – + –
BYPASS
VALVE
BATTERY A B
SOLENOIDS
+– +–
M1 M2 SUPPLY
CLUTCH
1
23
4
5
1
2
3
4
5

16 Constant Running Hydraulic Pump - Installation Guide
Figure 8: Connecting the bypass valve
5. Post-installation check
WARNING:
Keepclearof moving steering systemsatall times.Protect
moving partsfromaccessduringnormaluse.
Checkthe followingpoints afterinstallingthepump:
1. Is the pump installed as close to the steering ram as possible?
2. Is the pump secured to a substantial structure on the boat?
3. Haveyou connecteda thirdhydraulicpipe betweenthe helm
pump andautopilot pump?
4. Haveyou fittedcheck valveswhereappropriate?
5. Are the hydraulic pipes madeof a suitable flexible material(i.e.
rubber or nylon)with a suitable pressure rating?
6. Haveyousealedallhydraulicconnectionsandcheckedforleakages?
7. Are power cables correctly routed and securely connected to the
coursecomputer?
Youhavenowfinishedinstallingthepump.Afterinstallingtherestof
the autopilot youmust bleedall airfrom the system(see below).
Note:When you have installedthe entire autopilotsystem, youwill
alsoneedtocompleteanautopilotsteeringcheck.Refertothecontrol
unithandbookfor moredetails.
Bleeding the system
Bleeding the hydraulic system correctly is one ofthe most important
stepswhen installingthe autopilot hydraulic pump. If there isany air
Secondary steering ram Bypass valve
Hydraulic pipes to
CR pump
Manual steering system Connect to:
CLUTCH terminal on 150/400 course computer
BYPASS on CR connector (100/300 course computer)
D5177-1

Constant Running Hydraulic Pump - Installation Guide 17
inthesystemthesteeringwillfeelspongy,particularlywhenyouturn
the wheel to hardover.
CAUTION:
Any airin the hydraulic system will greatlyreduce the
performance of the autopilot and the overall steering system.
In addition to the manufacturer’s instructionsforbleeding the
steeringsystem, followthese stepsto bleedthe autopilot pumpwhen
you haveinstalledand setup the rest ofthe autopilot system:
1. With the system in auto mode, press the -10 buttonten times:
•theautopilotpumpwilltryto drive theruddertoport
•counter this rudder movementby turning the helmto
starboardto keep the rudderstationary
•youwillbeabletofeelanyairinthehelmpump:anyairinthis
side of the pumpwill risetothe helmpump andexhaust into
thereservoir
•continue until all ofthe air is out of thisside of the pump
2. Clear anyair onthe otherside ofthe pump:
•pressthe+10 buttonten times
•the autopilot will try to drive the rudder to starboard
•counterthe ruddermovementby turningthe helmto port
•continue until all ofthe air is out of thisside of the pump
3. Repeat in both directions until bothsides ofthe help pump are
totally freeof air.
Note:Monitor the reservoir atall timesand top upwiththe
manufacturer’srecommended hydraulicfluidas required.
CAUTION:
Afterinstallationandbleeding,leavethe systemfor 24hours
then check forany air inthe system or leaksat the jointsand
aroundthe pump.
Maintenance
On a regular basis:
•checkall connections and mountingsare secure
•checkpipes andcables forany signsofwearor damage
•check hydraulic pipesand connections forleaks

18 Constant Running Hydraulic Pump - 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
EMC servicing and safety guidelines
•Raymarineequipmentshouldbe serviced onlybyauthorized
Raymarine service technicians. They will ensure that service
procedures/ replacement parts usedwill not affect performance.
There are no user serviceable parts in any Raymarine product.
•Someproductsgeneratehighvoltages,soneverhandlethecables
or connectors when power is being supplied to the equipment.
•When powered up,all electrical equipment produces
electromagnetic fields. These cancauseadjacentpiecesof
electrical equipment to interact with one another, with a
consequent adverse effect on operation. In order to minimize
these effects and enable you to get the best possible performance
fromyour Raymarineequipment, guidelinesare givenin the
installationinstructions,to enableyou toensureminimum
interaction between different items ofequipment, i.e. ensure
optimum Electromagnetic Compatibility(EMC).
•Alwaysreport anyEMC-related problem toyour nearest Raymarine
dealer. We use such information to improve our quality standards.
•In someinstallations,it maynot be possible to prevent the
equipmentfrombeingaffectedby externalinfluences.In general
this will not damage the equipment but it can lead to spurious
resetting action, ormomentarily may result in faultyoperation.
Product support
Raymarine products are supported bya worldwide network of
distributorsand AuthorizedService Representatives.If you
encounter anydifficulties with this product, please contacteither
yournationaldistributor,service representative,or theRaymarine
Technical Services Call Center.