Raymarine Hydraulic Pump User manual

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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 Pump
Installation Guide
Drives covered:
M81120 Type 1 Hydraulic Pump 12 V
M81119 Type 1 Hydraulic Pump 24 V
M81121 Type 2 Hydraulic Pump 12 V
M81123 Type 2 Hydraulic Pump 24 V
M81122 Type 3 Hydraulic Pump 12 V
M81124 Type 3 Hydraulic Pump 24 V
Document number: 81178-3
March 2001

2 Hydraulic Pump - Installation Guide
Important information
Safety notices
WARNING: Product installation
Thisequipmentmustbeinstalledandoperatedinaccordance
withtheinstructionscontainedinthishandbook.Failuretodoso
couldresultinpoorproductperformance,personalinjuryand/
ordamage toyourboat.
Because correctperformance ofthe boat’s steering is critical for
safety,weSTRONGLYRECOMMENDthatanAuthorized
RaymarineServiceRepresentativefits thisproduct.
WARNING: Navigation aid
Althoughwehavedesignedthisproducttobe accurateand
reliable, many factorscanaffect itsperformance.As aresult,it
shouldonlybeused asanaidtonavigationandshouldnever
replacecommonsenseandnavigationaljudgement.Always
maintainapermanentwatchsoyoucanrespondtosituationsas
theydevelop.
EMC conformance
All Raymarine equipment and accessories aredesigned to thebest
industrystandards for use in the recreational marine environment.
The design and manufacture of Raymarine equipmentand
accessories conform tothe appropriateElectromagnetic
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 ofcontinuousproductimprovementmaychange
specifications without notice.Asa result,Raymarine cannot accept
liabilityfor any differences between the product andthe handbook.
©RaymarineLtd2001.

Hydraulic Pump - Installation Guide 3
Introduction
Product description
WelcometotheinstallationguidefortheRaymarinehydraulicpump
(alsoknownasthe Raymarinereversinghydraulic pump).
This product is intended to operatethe boat’s steeringmechanism as
partof aRaymarineautopilotsystem. Itis primarilydesignedforuse
on boats with an existing hydraulic steering system. Alternatively,
you can use this pump on a boat with mechanical steering in
conjunctionwith a secondarysteering ram.
The hydraulic pump containsa precision gearpump anda check
valve driven by a servo motor.
Figure 1: Main parts of a typical hydraulic pump
Contents
Thisguide contains:
1Product specifications page 4
2Installation instructions page 5
3Maintenance information page 17
Mounting foot
D5175-1
Reservoir port
Ram ports
Check valve
Gear pump
Motor

4 Hydraulic Pump - Installation Guide
Specifications
Pump specifications
Pump dimensions
Figure 2: Type 1 (12 V) and Type 2 pump dimensions
Table 1: Pump specifications
Performance
(at nominal voltage)
Type 1 (T1)
M81120 (12 V)
M81119 (24 V)
Type 2 (T2)
M81121 (12 V)
M81123 (24 V)
Type 3 (T3)
M81122 (12 V)
M81124 (24 V)
Ram compatibility single or double ended
Ram capacity
(min-max)
80-230 cc
(4.9-14 in3)
230-350 cc
(14-21 in3)
350-500 cc
(21-30.5 in3)
Maximum stall
pressure (at 12 V)
50 bar
(750 psi)
100 bar
(1450 psi)
80 bar
(1160 psi)
Peak flow rate
(no load)
1000 cc/min
(67 in3/min)
2000 cc/min
(122 in3/min)
2900 cc/min
(175 in3/min)
Other information (applies to Types 1, 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
175 mm (6.9 in)
90 mm (3.54 in)
105 mm (4.13 in)
D5174-1
All ports are 1/4 inch BSP (parallel threaded)
Type 1 (12 V) and Type 2 pumps
two holes to accept 6 mm (0.25 in) bolts

Hydraulic Pump - Installation Guide 5
Figure 3: Type 3 pump dimensions
Installation instructions
Parts required
To install this drive you will need:
•Partssupplied:
•hydraulicpump
•ifrequired:1/4inBSPto1/4in NPT adaptors (x3)
•Additional parts:
•suitable hydraulicpipes, hydraulic fluid,T-pieces, pipe
fittingsand thread-sealingcompound (seepage 8)
•suitable securing bolts andlock washers/lock nuts (see
page 8)
•suitable cable and electrical connectors for the drive motor
andclutch(see page 13)
Note:Makesureyouhaveobtainedtheseadditionalpartsbeforeyou
startinstallation.
117 mm (4.62 in)
103 mm (4.07 in)
D5173-1
235 mm (9.25 in)
Type 3 pump
All ports are 1/4 inch BSP (parallel threaded)
holes to accept 6 mm (0.25 in) bolts

6 Hydraulic Pump - Installation Guide
Installation steps
WARNING: Electrical safety
Make sure you have switched off thepower supply before you
start installingthis product.
Follow these steps toinstall yourhydraulic pump:
Ï
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1. EMC installation guidelines
All Raymarine equipment and accessories aredesigned to thebest
industrystandards for use in the recreational marine environment.
Theirdesign andmanufacture conformsto the appropriate
Electromagnetic Compatibility(EMC) standards, butcorrect
installation is required to ensure that performance is not
compromised.Although everyeffort hasbeen takento ensure that
they willperform underall conditions,it isimportant tounderstand
whatfactorscouldaffectthe operation oftheproduct.
TheguidelinesgivenheredescribetheconditionsforoptimumEMC
performance, butit is recognized that itmay not be possible to meet
all of these conditions in all situations. To ensure the best possible
conditionsforEMC performance withinthe constraintsimposed by
any location, always ensure the maximum separation possible
between different items of electrical equipment.
1Consult the EMC installation guidelines. page 6
2Mount the pump. page 8
3Connect to the hydraulic steering system. page 8
4Connect to the course computer. page 13
5Complete the post-installation checks. page 15

Hydraulic Pump - Installation Guide 7
For optimumEMC performance, it is recommended that wherever
possible:
•Raymarine equipment andcables connected to it are:
•Atleast 3ft(1 m)from anyequipment transmittingor cables
carryingradio signalse.g. VHFradios, cablesand antennas.
In the case ofSSB radios, the distance should be increased to
7ft(2m).
•More than7 ft (2m) fromthe path ofa radar beam.A radar
beam can normally be assumed to spread 20 degrees above
andbelow theradiating element.
•Theequipmentissuppliedfrom aseparatebatteryfromthat used
forengine start.Voltage dropsbelow10 V,and startermotor
transients,cancausetheequipmenttoreset.Thiswillnotdamage
theequipment, butmay causethe lossof someinformation and
maychangetheoperating mode.
•Raymarine specified cablesare used. Cuttingand rejoining these
cables can compromiseEMC performance and mustbe avoided
unless doing so is detailed in the installation manual.
•Ifasuppressionferriteisattachedtoacable,thisferriteshouldnot
beremoved. Iftheferriteneedstobe removedduring installation
it must be reassembled in the same position.
Suppression ferrites
Figure 4showstypicalcablesuppressionferritesused with
Raymarine equipment.Always use the ferritessupplied by
Raymarine.
Figure 4: Typical Suppression Ferrites
D3548-2

8 Hydraulic Pump - Installation Guide
Connections to other equipment
If your Raymarine equipment is to be connected to other equipment
usingacablenotsuppliedbyRaymarine,asuppressionferriteMUST
always beattachedto the cable nearto the Raymarineunit.
2. Pump mounting
Mount thehydraulic pump:
•ona substantialmembertoavoidvibrationthatcoulddamagethe
hydraulicpipes
•onasuitablehorizontalsurface, clearofsprayandpossiblewater
immersion
•levelor abovethehydraulic steeringramtopreventaircollecting
in the ram
•as close to the ram as possible
Note:Secure the pump using M6 (1/4inch)bolts,lock nutsand lock
washers.
3. Hydraulic connections
CAUTION:
Beforeyouconnecttheautopilotpumptoyourhydraulicsystem
westronglyrecommend thatyouconsultthesteeringgear
manufacturer.
General guidelines
CAUTION:
Absolute cleanlinessis essentialwhenworkingwithhydraulic
systems. Even the smallest particle of dirt could preventthe
steeringsystemcheckvalvesfromworkingproperly.
•All pipes used to fit the pump should match, orexceed, the
specification oftheexistingsteering system pipes. Contactthe
steeringsystemmanufacturer if youneed moreinformation.
•Use flexible pipe to connect the pump to the boat’s steering
system- thisavoids strain onthe pipes.
•Allports onthe autopilot pumpare1/4in BSP parallel threaded. If
youneed toconvertto 1/4in NPT, use the three BSP toNPT
adaptors(supplied).

Hydraulic Pump - Installation Guide 9
•Trytokeephydraulicfluidlosstoaminimumwheninstallingthe
pump. This will reduce the time and effort required to bleed the
systemof trappedair afterinstallation:
•non-pressurized systems: temporarily fit a non-venting plug
to the helm reservoir vent to minimize fluid loss
•pressurizedsystems:
WARNING:
Beforedisconnectinganypipesonpressurizedsystems,you
MUST release the pressure atthe reservoir by followingthe
manufacturer’s instructions.
•Follow the manufacturer’s instructionsifyou fitany T-pieces.
•All hydraulic pipes should slopeupwards towardsthe reservoir.
•A set of bleed valves near the steering ram,fitted at the highest
point, willallowanyair toescapeupwards.
CAUTION:
DonotusePTFEtapeonhydraulicpipeconnections.Ifnecessary
usea pipe-sealingcompoundtoensurealeakproof joint.
CAUTION:
Beforerunningthepumpforthefirsttime,makesurethesystem
contains sufficienthydraulicfluid.Youwilldamagethepumpif
youletitrunwhen‘dry’.
Check valves
Forsingle-steeringpositionboats:
•Consultthe steeringgear manufacturertodetermine whetherthe
helm pumpis fitted with reversing check valves:
•without check valves, the autopilot pump will drive the helm
pump(sometimesreferredtoas‘motoringthewheel’)instead
ofmoving thesteeringram
•If the boat has a singlehelm pump system withoutcheck valves,
you must incorporate adouble pilot check valve (part number
M81166) as shown in Figure 5.
•A double pilotcheck valve mayalsobe necessary on longtubing
runs- otherwisetubingexpansion maycause poorautopilot
performance. Install the check valveas shown in Figure 5.
Note:Iftheboathastwosteeringpositions,itwillalreadyhavecheck
valvesinstalledsothe twowheels canoperate independently.