Raymarine E12171 User manual

Hydraulic Pump
Installation Guide
Drives covered:
E12171 Constant Running Pump (Variable Flow) 12V
E12172 Constant Running Pump (Variable Flow) 24V
Document number: 87039-3
Date: 05-2018

3
Important information
Safety notices
WARNING
Intended use
A properly installed and operated hydraulic pump as part of an autopilot
system is designed to be used only as a backup to a vessel’s existing
primary steering system. The autopilot system is NOT intended or
warranted to be used as a replacement for the primary steering system.
WARNING
Product installation
This equipment must be installed in accordance with the instructions
contained in this handbook. Failure to do so could result in poor product
performance, personal injury and/or damage to your boat.
Because correct performance of the boat’s steering is critical for safety, we
STRONGLY RECOMMEND that an Authorized Raymarine Service
Representative fits this product.
WARNING
Navigation aid
When this product is used within a navigation system, it is only an aid to
navigation. It’s accuracy can be affected by many factors, including
equipment failure or defects, environmental conditions and improper use
or handling. It is the user’s responsibility to exercise common prudence
and navigational judgements. This product should not be relied upon as a
substitute for such prudence and judgement. Always maintain a permanent
watch so that you can respond to situations as they develop.

4
EMC installation guidelines
Raymarine equipment and accessories conform to the appropriate
Electromagnetic Compatibility (EMC) regulations, to minimize electromagnetic
interference between equipment and minimize the effect such interference
could have on the performance of your system.
Correct installation is required to ensure that EMC performance is not
compromised.
For optimum EMC performance we recommend that wherever possible:
• Raymarine equipment and cables connected to it are:
• At least 1 m (3ft) away from any equipment transmitting or cables carry-
ing radio signals e.g. VHF radios, cables and antennas. In the case of
SSB radios, the distance should be increased to 7 ft (2 m).
• More than 2 m (7 ft) from the path of a radar beam. A radar beam can nor-
mally be assumed to spread 20 degrees above and below the radiating
element.
• The product is supplied from a separate battery from that used for engine
start. This is important to prevent erratic behavior and data loss which can
occur if the engine start does not have a separate battery.
• Raymarine specified cables are used.
• Cables are not cut or extended, unless doing so is detailed in the installation
manual.
• The EMC filter box must not be removed from the motor cable.
Note: Where constraints on the installation prevent any of the above recommendations,
always ensure the maximum possible separation between different items of electrical
equipment, to provide the best conditions for EMC performance throughout the installa-
tion.
WARNING
Ensure cleanliness
Absolute cleanliness is essential when working with hydraulic systems.
Even the smallest dirt particle could prevent the steering system check
valves from working correctly. Ensure that no dirt enters the system during
the installation, and that all hoses and fittings are cleaned before making
any connections.

5
Figure 1
Connections to other equipment
If your Raymarine equipment is to be connected to other equipment using a
cable not supplied by Raymarine, a suppression ferrite MUST always be
attached to the cable near to the Raymarine unit.
Water ingress
Water ingress disclaimer
This equipment is intended for a“below-decks” installation only. It is IP55 rated.
It is not waterproof.
Waste Electrical and Electronic Equipment
Directive
The Waste Electrical and Electronic Equipment (WEEE) Directive
requires the recycling of waste electrical and electronic equipment.
Whilst the WEEE Directive does not apply to some of Raymarine’s
products, we support its policy and ask you to be aware of how to
dispose of this product.
The crossed out wheelie bin symbol, illustrated above, and found on our products
signifies that this product should not be disposed of in general waste or landfill.
Please conact your local dealer, national distributor or Raymarine Technical
Services for information on product disposal.
Warranty
To register your Raymarine product ownership, please visit www.raymarine.com
and register online. It is important that you register your product to receive full
warranty benefits. Your unit package includes a bar code label indicating the serial
number of the unit. You will need this serial number when registering your product
online. You should retain the label for future reference.
D3548-2

6
IMO and SOLAS
The equipment described within this document is intended for use on leisure
marine boats and workboats not covered by International Maritime
Organization (IMO) and Safety of Life at Sea (SOLAS) Carriage Regulations.
Technical accuracy
To the best of our knowledge, the information in this handbook was correct
when it went to press. However, Raymarine cannot accept liability for any
inaccuracies or omissions it may contain. In addition, our policy of continuous
product improvement may change specifications without notice. As a result,
Raymarine cannot accept liability for any differences between the product and
the handbook.

7
Introduction
Product description
The Raymarine hydraulic pump (also known as the Raymarine constant
runninng hydraulic pump) is intended to operate a vessel’s steering mechanism
as part of a Raymarine autopilot system. It is primarily designed for use on
vessels with an existing hydraulic steering system. Alternatively, you can use
this pump on a vessel with mechanical steering in conjunction with a secondary
steering ram.
Raymarine pumps are driven by 12 or 24 V dc permanent magnet motors. The
pumps include pilot-operated check valves that prevent the pump being back
driven by the manual steering system or rudder load. The motors can be
removed from the pump without allowing air into the hydraulic system or fluid to
escape. The pumps also include compatibility with balanced or unbalanced
cylinders and can be used with pressurised reservoir systems.
Figure 2
Contents
This guide contains:
1Product specifications page 8
2Installation instructions page 9
3Maintenance information page 23

8
Specifications
Pump specifications
Table 1-1: Pump specifications
Performance
(at nominal voltage) E12171 (12 V) E12172 (24 V)
Ram compatability Single or double ended
Ram capacity
(min-max)
1000-1500cc
(61.0 -91.5 in3)
1000-1500cc
(61.0 -91.5 in3)
Maximum intermittent
pressure
55 bar (800 psi)
Peak flow rate
(no load)
4000cc/min
(244.0 in3/min)
4500 cc/min
(274.6in3/min)
Typical current at 12 V,
55 bar
55 A N/A
Typical current at 24 V,
55 bar
N/A 28 A
Fuse - Class D breaker 60 A 40 A
Oil
As per steering system
recommendation.
Range ISO VG10 to VG40
Other information
protected for use in engine com-
partments
CE approvals - conforms to:
2004/108/EC (EMC),
EN60945:2002
94/25/EC (RCD), EN28846:1993
& EN ISO 10592:1995.

9
Pump dimensions
Figure 3
Installation instructions
Parts required
To install this drive you will need:
• Parts supplied:
• hydraulic pump
•1/4in BSP bonded rubber / metal seals (x2)
• 3/8 in BSP bonded rubber / metal seals (x1)
• if required: 1/4in BSP to 1/4in NPT adaptors (x2)
• if required: 3/8 in BSP to 3/8 in NPT adaptor (x1)
• Additional parts:
• suitable hydraulic pipes, hydraulic fluid, T-pieces, and pipe fittings (see
page 12)
• suitable securing bolts and lock nuts (see page 11)
• cable and electrical connectors for the drive motor (see page 18)

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Installation steps
Follow these steps to install your hydraulic pump:




WARNING
Electrical safety
Make sure you have switched off the power supply before you start
installing this product.
1Consult the EMC installation guidelines. page 4
2Mount the pump. page 11
3Connect to the hydraulic steering system. page 12
4Connect to the SPX course computer or Evolution ACU (Actu-
ator Control Unit). page 18
5Complete the post-installation checks. page 20

11
2. Pump mounting
Location requirements
• pump is designed for below-deck installations only.
• fit pump to a substantial structure to avoid vibration that could damage
the pipes.
• mount away from sources of heat and excessive vibration and fumes.
• do NOT mount in confined areas containing flammable materials.
• install pump above areas liable to flooding.
• on a suitable surface, clear of spray and possible water immersion.
• level or above the hydraulic steering ram to prevent air collecting in the
ram.
• as close to the ram as possible.
Orientation
The pump can be mounted horizontally, foot down or vertically, tank down. The
pump has 1 reservoir port (“R port”). In both bbcases allow the R hose to
continuously rise to the helm pump or external reservoir. The following diagram
illustrates the preferred routing of the reservoir hose, based on the mounting
orientations:
Figure 4:
Note: Secure the pump using the M10 bobbins and lock nuts.
If mounting vertically replace the bobbins with M10 bolts of a suitable length (not
supplied).

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3. Hydraulic connections
Connections overview
Figure 5
WARNING
Pressurized systems
Before disconnecting any pipes on pressurized systems, you MUST release
the pressure at the reservoir by following the manufacturer’s instructions.
CAUTION
Pump connection
Before you connect the autopilot pump to your hydraulic system we
strongly recommend that you consult the steering gear manufacturer.
CAUTION
Hydraulic systems
Absolute cleanliness is essential when working with hydraulic systems.
Even the smallest particle of dirt could prevent the steering system check
valves from working properly.

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General guidelines
• The ports on the autopilot pump are 1/4 in BSPP and 3/8 in BSPP parallel
threaded. If you need to convert to 1/4 in NPT, use the three BSPP to NPT
adaptors (supplied). Use only bonded rubber / metal washers to seal the fit-
tings. Do NOT use tapered adapters, sealing compound, or PTFE tape.
• The ram ports are the service line connections to the ram. The hydraulic
hoses and connections must be of a suitable pressure rating. Refer to the
Technical Specification in this document.
• The reservoir port is the reservoir or balance line and MUST be connected,
through a continuous rise to the helm pump lowest connection or other exter-
nal reservoir. To avoid potential damage or steering failure, do NOT plug this
reservoir port. The optional reservoir port on the top of the unit is an optional
port to allow for the most appropriate fitting of pipes, depending on the
mounting orientation of the pump. The optional port is accessed by removing
the blanking plug.
• All pipes used to fit the pump should match, or exceed, the specification of
the existing steering system pipes. Contact the steering system manufac-
turer if you need more information.
• Use flexible pipe to connect the pump to the boat’s steering system - this
avoids strain on the pipes.
• Try to keep hydraulic fluid loss to a minimum when installing the pump. This
will reduce the time and effort required to bleed the system of trapped air
after installation:
• non-pressurized systems: temporarily fit a non-venting plug to the helm
reservoir vent to minimize fluid loss
• pressurized systems:
• Follow the manufacturer’s instructions if you fit any T-pieces.
• The reservoir hose must be of a suitable pressure rating. Refer to the
Technical Specification in this document.
• All hydraulic pipes should slope upwards towards the reservoir.
• A set of bleed valves near the steering ram, fitted at the highest point, will
allow any air to escape upwards.
CAUTION
PTFE tape
Do not use PTFE tape or a pipe sealing compound on hydraulic pipe
connections to ensure a leak-proof joint.

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Check valves
For single-steering position boats:
• Consult the steering gear manufacturer to determine whether the helm
pump is fitted with reversing check valves:
• without check valves, the autopilot pump will drive the helm pump (some-
times referred to as ‘motoring the wheel’) instead of moving the steering
ram
• If the boat has a single helm pump system without check valves, you
must incorporate a double pilot check valve (part number M81166).
• A double pilot check valve may also be necessary on long tubing runs -
otherwise tubing expansion may cause poor autopilot performance.
Note: If the boat has two steering positions, it will already have check valves installed so
the two wheels can operate independently.
Hydraulic steering systems
There are three basic types of hydraulic steering systems:
• two line systems
• two line pressurized systems
• three line systems
On the following pages typical connection points are described for the autopilot
pump on each of these systems. For all of the systems you will need to connect
a third hydraulic pipe (as shown) between the autopilot pump and the helm
pump or system reservoir.
CAUTION
Hydraulic fluid
• Before running the pump for the first time, make sure the system contains
sufficient hydraulic fluid. You will damage the pump if you let it run when
‘dry’.
• Do NOT use “brake fluid”. Use only mineral-based good quality hydraulic
fluid compatible with nitrile rubber hydraulic seals.
• For suitable hydraulic fluid, refer to the helm pump manufacturer’s recom-
mendations for compatibility. Also refer to the technical data provided in
the technical specification section of this document.

15
Two line systems
Figure 6 shows a typical two line steering system. Hydraulic fluid flows into the
ram in either direction, depending on the direction the helm pump rotates.
Connect the autopilot pump to the steering system as shown in Figure 6.
Figure 6

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Two line pressurized systems
Two line pressurized systems have an external pressurized reservoir. This
reduces the possibility of introducing air into the system and reduces any
steering ‘sponginess’ caused by pipe expansion.
Connect the autopilot pump to the steering system as shown in Figure 7.
Note: Refer to the manufacturer’s instructions for de-pressurizing and re-pressurizing
the system.
Figure 7

17
Figure 8
Three line systems
In a three line system, the hydraulic fluid flows in only one direction:
• out of the helm pump to the ram
• returning from the other side of the ram to the reservoir via a common
return line
The system will include a check valve block to direct all returned fluid from the
ram back to the reservoir.
Connect the autopilot pump to the steering system as shown in Figure 8.

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4. Connecting to the course computer or ACU
Note: To meet current EMC legislation, you must NOT untwist the pump cables.
The CR pump has electrical connections for:
• motor supply: two single core cables
• solenoid control valve supply: two plug in connectors (supplied)
• clutch connection: two cable
Connecting to course computer / ACU
WARNING
Electrical safety
Make sure you have switched off the power supply before you start
installing this product.

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Make the following connections:
1. CR pump motor supply:
• using appropriate cables connect the CR pump motor to the boat’s
power supply via an appropriate circuit breaker and fuse (see table
above).
2. Solenoid control valves - using suitable cable (at least 16 AWG or 1.5mm²for
runs up to 16m/52 ft.):
• for the “A” side: connect the positive core to the MOTOR A terminal and
the negative core to one of the SOLENOID (-) terminals at the course
computer.
•for the “B” side: connect the positive core to the MOTOR B terminal and
the negative core to one of the SOLENOID (-) terminals at the course
computer.
3. Using a pair of cables, connect the motor relay control terminals on the pump
to the course computer CLUTCH terminals.
WARNING: CLUTCH VOLTAGE
To avoid damaging your CR pump, you MUST set the CLUTCH VOLTAGE
fuse on your course computer to 12V. This applies even on 24V motor
systems.
Note: if installing the pump on a boat with mechanical steering, you also need to
connect a bypass valve to the CLUTCH terminals (see page 20).
Table 1-2: Recommended cable sizes
Cable length
(pump to
course
computer or
ACU)
Cable gauge
(AWG)
Copper area
(mm²)
Fuse rating
12V CR pumps
up to 3m (10ft.)
up to 7m (23 ft.)
up to 16m (52 ft.)
10
8
6
6
10
16
60 A
12V CR pumps
up to 3m (10ft.)
up to 5m (16 ft.)
up to 10m (32 ft.)
up to 16m (52 ft.)
12
10
8
6
4
6
10
16
40A

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Mechanical steering systems
If you are fitting the pump to a boat with mechanical steering you will need to
connect it to a secondary steering ram, along with a solenoid-operated bypass
valve. This bypass valve allows you to switch between autopilot course control
and manual steering.
To fit to a mechanical steering system:
• Use suitable hydraulic pipes to connect the pump to the secondary steering
ram and a suitable reservoir.
• Install the solenoid-operated bypass valve (part number: M81167) across
these pipes (as shown in Figure 10).
• Connect the bypass valve to the CLUTCH terminals on the course computer
or ACU using at least 1.5 mm2(16 AWG) copper cable.
Note: Follow the manufacturer’s instructions for mounting the hydraulic ram and reservoir.
Figure 10