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
Ï
Ï
Ï
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.

10 Hydraulic Pump - Installation Guide
Hydraulic steering systems
There are three basictypes of hydraulic steering systems:
•twolinesystems
•two linepressurizedsystems
•threelinesystems
Onthefollowingpages wedescribetypicalconnectionpointsforthe
autopilotpumpon each ofthese systems.Forallofthe systemsyou
will needto connect a third hydraulic pipe (as shown) between the
autopilot pump and the helm pump or system reservoir.
Two line systems
Figure 5showsa typical two linesteeringsystem.Hydraulic fluid
flows into the ram in either direction, depending onthe direction the
helm pump rotates. Connectthe autopilot pump to the steering
systemas showninFigure 5.
Figure 5: Autopilot pump location for two line systems
D5163-1
Helm
pump
Autopilot
pump
Steering ram
Ram pipes
Reservoir pipe
Check valve (if required)

Hydraulic Pump - Installation Guide 11
Two line pressurized systems
Two line pressurized systems havean external pressurized reservoir.
Thisreduces the possibility of introducingair into the system and
reducesany steering ‘sponginess’causedbypipeexpansion.
Connect the autopilot pump to the steering system as shown in
Figure 6.
Note:Refer to the manufacturer’s instructions for de-pressurizing
andre-pressurizingthesystem.
Figure 6: Autopilot pump location for two line pressurized systems
D5162-1
Helm
pump
Autopilot
pump
Steering ram
Ram pipes
Reservoir pipe
Pressurized reservoir

12 Hydraulic Pump - Installation Guide
Three line systems
Inathreelinesystem,thehydraulic fluidflows inonlyonedirection:
•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 as shownin
Figure 7.
Figure 7: Autopilot pump location for three line systems
D5161-1
Helm
pump
Autopilot
pump
Steering ram
Ram pipes
Reservoir
pipe
Check valve

Hydraulic Pump - Installation Guide 13
4. Connecting to the course computer
WARNING: Electrical safety
Makesurethepowersupplyisswitchedoffbeforeyoumakeany
electricalconnections.
Thehydraulicpumphaselectricalconnectionsforitsmotor:aredand
ablackcable.
Note:Tomeet currentEMC legislation,you must NOTuntwistthe
pumpcables,and youmustNOT removethe suppressionferrite.
Followthesestepstoconnectthepumpmotortothecoursecomputer:
1. Measure the distanceof cable runfrom the pump to the course
computer,thenuse Table 2 to identify the appropriate cable sizes.
2. Join these cables to the ones on the pump using appropriate
electricalconnectorsorjunctionboxesatthecorrectpowerrating.
3. Routethecablesbacktothecoursecomputer,takingintoaccount
the EMC installation guidelines (page 6).
4. ConnectthecablesfromthepumptotheMOTOR terminalsonthe
coursecomputer (see Figure 8): at this stage you can connect
eithermotorcable to eitherterminal.Youwillcheck these
connections after installing therest of the autopilotsystem.
Note:Ifinstalling the pump on aboatwith mechanicalsteering,you
needtoconnectabypassvalvetothe CLUTCH terminals
(seepage 14).
Figure 8: Course computer connections
D5171-1
lk CLUTCH MOTORPOWER
+–+–12
Type 100/300 course computer
MOTORPOWER
+– AB
OFF
SWITCH SOLENOID
–
CLUTCH
+–
Type 150/400 course computer
–

14 Hydraulic Pump - Installation Guide
Mechanical steering systems
Ifyouarefittingthepumptoaboatwithmechanicalsteeringyouwill
need to connect it to asecondary steering ram, alongwith a solenoid-
operated bypass valve. This bypassvalve allows you to switch
between autopilot course control and manual steering.
To fit to a mechanical steering system:
•Usesuitablehydraulicpipestoconnectthepumptothesecondary
steeringram and asuitable reservoir.
•Install the solenoid-operated bypass valve (part number:
M81167)across thesepipes (asshown inFigure 9).
•Connect the bypass valve to the CLUTCH terminals on the course
computer using at least 1.5 mm2(16AWG)coppercable.
Table 2: Recommended cable sizes
Cable length
(pump to course computer)
Cable gauge
(AWG)
Copper area
(mm2)
Type 1 drive (12 V and 24 V)
up to 3 m (10 ft)
up to 5 m (16 ft)
up to 7 m (23 ft)
up to 10 m (32 ft)
up to 16 m (52 ft)
14
12
10
8
6
2.5
4
6
10
16
Type 2 drive 12 V
up to 5 m (16 ft)
up to 7 m (23 ft)
up to 16 m (52 ft)
10
8
6
6
10
16
Type 2 drive 24 V
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
Type 3 drive 12 V
up to 5 m (16 ft)
up to 7 m (23 ft)
up to 16 m (52 ft)
8
6
4
10
16
25
Type 3 drive 24 V
up to 5 m (16 ft)
up to 7 m (23 ft)
up to 16 m (52 ft)
10
8
6
6
10
16

Hydraulic Pump - Installation Guide 15
Note:Followthe manufacturer’sinstructionsformountingthe
hydraulicramandreservoir.
Figure 9: Connecting to a secondary steering ram
5. Post-installation check
WARNING:
Keepclearof movingsteering systems atalltimes.Protect
movingpartsfromaccessduringnormaluse.
Check the following points after installing the pump:
1. Isthe pumpinstalledas closetothe steering ramas possible?
2. Is the pumpsecured toa substantial structure onthe boat?
3. Haveyouconnectedareservoirpipebetweenthehelmpumpand
autopilotpump?
4. Haveyoufittedcheck valveswhere appropriate?
5. Arethe hydraulicpipesmade of asuitableflexiblematerial (i.e.
rubberor nylon)with a suitable pressurerating?
6. Are power cables correctly routed and securely connected to the
coursecomputer?
Youhavenowfinishedinstallingthepump.Afterinstallingtherestof
the autopilot youmust bleed all air from the system (see below).
Note:When you have installed the entire autopilot system, you will
alsoneedtocompleteanautopilotsteeringcheck.Refertothecontrol
unit handbook for moredetails.
D5172-2
Bypass valve
Secondary steering ram
Manual steering system
Autopilot pump
connect to CLUTCH
on course computer
connect to MOTOR
on course computer

16 Hydraulic Pump - Installation Guide
Bleeding the system
Bleeding the hydraulic system correctly is one ofthe mostimportant
stepswhen installingthe autopilothydraulic pump. If there isany air
inthesystemthesteeringwillfeelspongy,particularlywhenyouturn
the wheel to hardover.
CAUTION:
Anyairinthe hydraulicsystemwillgreatly reducethe
performance of the autopilot andtheoverall steering system.
Inaddition tothe manufacturer’s instructions for bleeding the
steeringsystem,follow thesesteps tobleed the autopilotpump when
you haveinstalled andset upthe rest of the autopilot system:
1. With the system in auto mode,pressthe-10 button ten times:
•the autopilot pump will try to drive the rudder to port
•counter this rudder movementby turning the helm to
starboard to keep the rudderstationary
•youwillbeabletofeelanyairinthehelmpump:anyairinthis
side of the pump will rise to the helm pumpandexhaust into
thereservoir
•continue until all of the air is out ofthis sideof the pump
2. Clear anyair on the other side of the pump:
•press the +10 buttonten times
•the autopilot will try to drive the rudder to starboard
•counter the rudder movement by turning the helm to port
•continue until all of the air is out ofthis sideof the pump
3. Repeatinbothdirections untilboth sidesof thehelp pumpare
totally free of air.
Note:Monitor the reservoir atall timesand top upwith the
manufacturer’srecommendedhydraulicfluid asrequired.
CAUTION:
Afterinstallationandbleeding,leavethesystemfor 24hours
thencheckforany airinthesystemor leaks atthejointsand
aroundthepump.

Hydraulic Pump - Installation Guide 17
Maintenance
Onaregular basis:
•check that all connections and mountings are secure
•checkpipesandcables forany signsofwearordamage
•checkpipesandjoints forany leaks
EMC servicing and safety guidelines
•Raymarine equipment should be serviced onlyby authorized
Raymarine service technicians. Theywill ensure that service
procedures andreplacement parts used will not affect
performance. There are no user serviceable parts in any
Raymarine product.
•Some products generate high voltages: neverhandle the cables/
connectors when power is being supplied to theequipment.
•When poweredup, all electrical equipment produces
electromagnetic fields. These can cause adjacent pieces of
electrical equipment to interact with one another, with a
consequent adverse effect on operation. In order to minimize
these effects and enable you to getthe best possible performance
from your Raymarine equipment, guidelines are given in the
installationinstructions,to enableyou toensure minimum
interaction betweendifferentitemsof equipment,i.e.ensure
optimum Electromagnetic Compatibility (EMC).
•AlwaysreportEMC-relatedproblemstoyournearestRaymarine
dealer.Weusesuchinformationtoimproveourqualitystandards.
•In someinstallations, itmay not bepossibleto prevent the
equipment frombeing affected by external influences. In general
this will notdamage the equipmentbut it can leadto spurious
resetting action, or momentarily may result in faulty operation.
Product support
Raymarine products are supported by aworldwide networkof
distributors and Authorized Service Representatives. Ifyou
encounteranydifficulties withthisproduct, pleasecontact either
your national distributor, oryour servicerepresentative, orthe
RaymarineTechnicalServicesCallCenter.Refertothebackcover
or the WorldwideDistributorList for contactdetails.

18 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