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Chapter 5: Maintenance and troubleshooting

Chapter contents

5.1 Maintenance checks on page 36

5.2 Bleeding the system on page 36

5.3 Troubleshooting on page 37

5.4 Raymarine technical support on page 38

Maintenance and troubleshooting

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Содержание E12207

Страница 1: ...Hydraulic Linear Drive Installation instructions E12207 Type 2 12 V E12208 Type 2 24 V M81202 Type 3 12 V M81203 Type 3 24 V ...

Страница 2: ......

Страница 3: ...ited All other product names are trademarks or registered trademarks of their respective owners Fair Use Statement You may print no more than three copies of this manual for your own use You may not make any further copies or distribute or use the manual in any other way including without limitation exploiting the manual commercially or giving or selling copies to third parties Copyright 2010 Raym...

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Страница 5: ...ing requirements 16 2 9 Product differences 18 2 10 Dimensions 18 2 11 Dimensions 19 Chapter 3 Mounting 21 3 1 Mounting checklist 22 3 2 Hydraulic ram alignment 22 3 3 Hydraulic ram mounting 24 3 4 Steering system connection 24 3 5 Hydraulic pump mounting 26 3 6 Reservoir mounting 27 3 7 Filling the reservoir 27 Chapter 4 Cables and connections 29 4 1 General cabling guidance 30 4 2 Clutch connect...

Страница 6: ...6 Hydraulic Linear Drive Installation instructions ...

Страница 7: ...ved installer A certified installation qualifies for enhanced product warranty benefits Contact your Raymarine dealer for further details and refer to the separate warranty document packed with your product Warning Product installation and operation This product must be installed and operated in accordance with the instructions provided Failure to do so could result in personal injury damage to yo...

Страница 8: ...aution and proper navigational skill when operating this or any other Raymarine product Caution 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 Caution Structural strength During operation the Hydraulic Linear Drive produces a considerable amount of force Y...

Страница 9: ...nsure 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 3 ft from any equipment transmitting or cables carrying 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...

Страница 10: ...unit package includes a bar code label indicating the serial number of the unit You should stick this label to the warranty registration card Installation prerequisites Before installing this product you must adhere to the installation prerequisites The hydraulic ram drives the rudder directly from the tiller arm or rudder quadrant Before installing this drive unit check that the vessel s steering...

Страница 11: ...12 2 3 Reservoir on page 13 2 4 Product overview on page 13 2 5 Typical system on page 14 2 6 Parts supplied on page 15 2 7 Parts required on page 16 2 8 Location and mounting requirements on page 16 2 9 Product differences on page 18 2 10 Dimensions on page 18 2 11 Dimensions on page 19 Planning 11 ...

Страница 12: ...t installation check 2 2 Drive types There are 2 drive types Each drive type has 2 variants one for 12 V systems one for 24 V systems Although the core functionality of each drive type is essentially the same the form factor of some of the components differs as follows Hydraulic ram Type 2 drive D11864 1 Type 3 drive D11865 1 Note The drawings included in this handbook are for illustration purpose...

Страница 13: ... for vessels with existing mechanical steering systems NOT hydraulic steering systems It is mounted below decks and moves the rudder directly by pushing the tiller arm or rudder quadrant The Hydraulic Linear Drive provides a totally isolated autopilot steering system consisting of D11851 1 1 10 2 3 4 5 6 7 8 9 11 1 Hydraulic fluid reservoir supplies hydraulic fluid to the system 2 Reservoir pipe t...

Страница 14: ...ounting the hydraulic ram to a suitable part of your vessel Rudder reference option The course computer is supplied with a rudder reference sensor which provides enhanced performance for autopilot systems D 11894 1 For information on installing and connecting the rudder reference option refer to the instructions that accompany the course computer 2 5 Typical system The drive components connect to ...

Страница 15: ...n assembly consisting of Tiller pin R clip Lock nut Washer quantity 2 3 Hydraulic ram mounting screw pack consisting of Bolts quantity 4 Washers quantity 4 Lock nuts quantity 4 4 Pump mounting screw pack consisting of Bolts quantity 2 Washers quantity 2 Lock nuts quantity 2 5 Installation instructions 6 Hydraulic fluid transit container Planning 15 ...

Страница 16: ...ng gear manufacturer if you have any doubt about the strength of the tiller arm or rudder quadrant The Type 2 drive may be mounted horizontally or vertically The Type 3 drive MUST be mounted horizontally with its mounting foot on a horizontal surface The swivel joint does NOT have sufficient movement to position the foot vertically The hydraulic ram must NOT foul any part of the vessel s structure...

Страница 17: ...o a bulkhead MUST be mounted at least 150 mm 6 in ABOVE the hydraulic pump and hydraulic ram to ensure a good supply of fluid to the system MUST be accessible for hydraulic fluid top ups and refills Raymarine recommends the use of M8 bolts and suitable nuts and washers to secure the reservoir to the vessel Pipes The pipes transport fluid and pressure around the Hydraulic Linear Drive system The sy...

Страница 18: ...m unit were connected to the top of the unit For the NEW Type 2 drive E12207 E12208 the pipes connect to the rear of the unit You must allow at least 17 cm 6 7 in clearance at the rear of the unit for the extruding pipes The minimum bend radius for the pipes is 7 6 cm 3 in The new drive E12207 E12208 can be mounted horizontally or vertically The hydraulic fluid reservoir supplied with the new driv...

Страница 19: ...6 1 101 6 mm 4 in 152 mm 6 in 80 mm 3 15 in 457 mm 18 in 1 690 mm 27 15 in 1 Hydraulic ram at mid stroke position 2 11 Dimensions Reservoir dimensions D11901 1 148 7 mm 5 85 in 55 3 mm 2 17 in 9 5 mm 0 37 in Planning 19 ...

Страница 20: ...20 Hydraulic Linear Drive Installation instructions ...

Страница 21: ...list on page 22 3 2 Hydraulic ram alignment on page 22 3 3 Hydraulic ram mounting on page 24 3 4 Steering system connection on page 24 3 5 Hydraulic pump mounting on page 26 3 6 Reservoir mounting on page 27 3 7 Filling the reservoir on page 27 Mounting 21 ...

Страница 22: ...ment When mounting the hydraulic ram ensure it is correctly aligned Hydraulic ram The hydraulic ram must be at right angles to the mounting surface The hydraulic ram must be in the mid stroke position and at right angles to the tiller arm when the rudder is at midships The following diagram illustrates correct alignment of the hydraulic ram The hydraulic ram in the top half of the diagram shows th...

Страница 23: ...ller arm plane of rotation Type 2 drive 10 degrees Type 3 drive 5 degrees The following diagrams illustrate the degree limit for each type of drive The diagrams show a view from astern Type 2 D 11900 1 10º 10º Type 3 D 11858 1 5º 5º Note Accurate angular alignment of the hydraulic ram is extremely important You must NOT exceed the specified degree alignment limits under any circumstances Mounting ...

Страница 24: ...em ensure that your vessel s tiller arm or rudder quadrant can cope with the peak thrust stated in the Technical Specification Use one of the following methods to attach the push rod to the rudder stock Independent tiller arm this is the recommended method Steering linkage tiller arm or rudder quadrant in some cases you may be able to attach the push rod to the same tiller arm or rudder quadrant u...

Страница 25: ... in Type 3 20 mm 0 78 in Note It may be necessary to drill a hole in the tiller arm The hole must be of the diameter specified above Steering check Once the hydraulic ram is mounted you must perform a steering check to ensure the ram has been mounted correctly Turn your vessel s steering wheel from hardover to hardover and check the following Angular movement of the ball end fitting is less than 1...

Страница 26: ...validate the warranty 3 5 Hydraulic pump mounting The hydraulic pump must be mounted in a suitable location to ensure reliable performance Before mounting the hydraulic pump refer to the guidance provided in the 2 8 Location and mounting requirements section Drill 2 mounting holes Secure the pump to the appropriate part of your vessel using suitable stainless steel bolts washers and lock nuts Full...

Страница 27: ...ydraulic fluid reservoir is supplied empty and must be filled to the correct level with the supplied hydraulic fluid Do NOT attempt to move or operate the hydraulic push rod before completing the following steps 1 The reservoir is fitted with a special cap featuring a breather hole which is sealed for transit purposes Remove the transit screw and seal from the cap to open the breather Retain the s...

Страница 28: ...28 Hydraulic Linear Drive Installation instructions ...

Страница 29: ...es and connections Chapter contents 4 1 General cabling guidance on page 30 4 2 Clutch connection on page 31 4 3 Course computer connection on page 32 4 4 Post installation check on page 34 Cables and connections 29 ...

Страница 30: ...ving or hot objects Secure cables in place using tie wraps or lacing twine Coil any extra cable and tie it out of the way Where a cable passes through an exposed bulkhead or deckhead use a suitable watertight feed through Do NOT run cables near to engines or fluorescent lights Always route data cables as far away as possible from other equipment and cables high current carrying ac and dc power lin...

Страница 31: ...belled 1 in the diagram above is the clutch To connect the clutch and ground cables you must remove the clutch housing using a suitable screwdriver The clutch housing contains the 3 terminals for the clutch and ground connections D 11898 1 2 3 1 Item Description Suitable cable 1 Ground connection Minimum 4 mm2 12 AWG copper cable 2 Pin 1 POSITIVE Minimum 1 5 mm2 16 AWG copper cable 3 Pin 2 NEGATIV...

Страница 32: ...the NEGATIVE terminal of the hydraulic ram s clutch to the course computer s NEGATIVE clutch terminal 4 Power input Connect to POSITIVE terminal of power supply for example via distribution panel 5 Power input Connect to NEGATIVE terminal of power supply for example via distribution panel 6 Pump motor Motor Connect the POSITIVE terminal of the pump to the course computer s MOTOR A terminal 7 Pump ...

Страница 33: ... correct cable gauge required Drive type Cable length Cable gauge AWG Cable gauge mm2 Type 2 12 V Up to 5 m 16 ft 10 6 Up to 7 m 23 ft 8 10 Up to 16 m 52 ft 6 16 Type 2 24 V Up to 3 m 10 ft 12 4 Up to 5 m 16 ft 10 6 Up to 10 m 32 ft 8 10 Up to 16 m 52 ft 6 16 Type 3 12 V Up to 5 m 16 ft 8 10 Up to 7 m 23 ft 6 16 Up to 16 m 52 ft 4 25 Type 3 24 V Up to 5 m 16 ft 10 6 Up to 7 m 23 ft 8 10 Up to 16 m...

Страница 34: ...r and clutch cables are correctly routed and securely connected to the course computer 5 Ensure that all hydraulic pipes are securely connected with no leaks 6 Ensure that the reservoir is filled with hydraulic fluid to the correct level 7 Ensure that the transit screw and seal have been removed from the reservoir cap Ensure that the cap is fitted securely to the reservoir 8 Ensure that the reserv...

Страница 35: ...ance and troubleshooting Chapter contents 5 1 Maintenance checks on page 36 5 2 Bleeding the system on page 36 5 3 Troubleshooting on page 37 5 4 Raymarine technical support on page 38 Maintenance and troubleshooting 35 ...

Страница 36: ... any storage containers are clean and free of contamination 1 Ensure the reservoir tap is in the ON position 2 Push the hydraulic rod in so that it is fully retracted 3 Fill the reservoir and slacken the pipes connected to the hydraulic ram unit Do NOT disconnect the pipes 4 Re tighten the pipes once the oil emerges from the fittings 5 Run the pump in order to direct flow to the hydraulic cylinder...

Страница 37: ...ulic ram unit External oil loss may indicate this The system may need bleeding Motor runs but erratic or no hydraulic rod movement Drive coupling Contact your dealer and ask them to check the motor drive coupling The dealer should ensure that the coupling is in place and aligned with the motor drive tang Motor may be damaged or faulty Check the motor for damage Excessive air in the hydraulic ram u...

Страница 38: ...Frequently Asked Questions servicing information e mail access to the Raymarine Technical Support Department and details of worldwide Raymarine agents Telephone support In the USA call 1 603 881 5200 extension 2444 In the UK Europe the Middle East or Far East call 44 0 23 9271 4713 Product information If you need to request service please have the following information to hand Product name Product...

Страница 39: ... stroke 254 mm 10 in 300 mm 12 in Hardover to hardover time 35 degrees no load 10 seconds 12 seconds Maximum rudder torque 1270 Nm 11300 lb in 2565 Nm 23100 lb in Conformance applies to Type 2 and Type 3 EN60945 2002 EMC 2004 108 EC EMC Directive EN28846 1993 Ignition Protection 94 25 EC RCD Hydraulic fluid Mineral based hydraulic oil minimum ISO VG10 maximum ISO VG40 Technical specification 39 ...

Страница 40: ...40 Hydraulic Linear Drive Installation instructions ...

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Страница 42: ...www raymarine com ...

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