User manual RAYMARINE REVERSING HYDRAULIC PUMP INSTALLATION GUIDE (TYPE 1,2,3)

[. . . ] © Raymarine Ltd 2001. Hydraulic Pump - Installation Guide 3 Introduction Product description Welcome to the installation guide for the Raymarine hydraulic pump (also known as the Raymarine reversing hydraulic pump). This product is intended to operate the boat's steering mechanism as part of a Raymarine autopilot system. It is primarily designed for use on boats with an existing hydraulic steering system. Alternatively, you can use this pump on a boat with mechanical steering in conjunction with a secondary steering ram. [. . . ] Use flexible pipe to connect the pump to the boat's steering system - this avoids strain on the pipes. All ports on the autopilot pump are 1/4 in BSP parallel threaded. If you need to convert to 1/4 in NPT, use the three BSP to NPT adaptors (supplied). · · Hydraulic Pump - Installation Guide 9 · 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: WARNING: Before disconnecting any pipes on pressurized systems, you MUST release the pressure at the reservoir by following the manufacturer's instructions. · · · Follow the manufacturer's instructions if you fit any T-pieces. 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: Do not use PTFE tape on hydraulic pipe connections. If necessary use a pipe-sealing compound to ensure a leakproof joint. CAUTION: 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'. 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 (sometimes 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) as shown in Figure 5. A double pilot check valve may also be necessary on long tubing runs - otherwise tubing expansion may cause poor autopilot performance. Install the check valve as shown in Figure 5. · · Note: If the boat has two steering positions, it will already have check valves installed so the two wheels can operate independently. 10 Hydraulic Pump - Installation Guide 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 we describe typical connection points 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. Two line systems Figure 5 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 5. Helm pump Check valve (if required) Reservoir pipe Ram pipes Autopilot pump Steering ram D5163-1 Figure 5: Autopilot pump location for two line systems Hydraulic Pump - Installation Guide Two line pressurized systems 11 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 6. Note: Refer to the manufacturer's instructions for de-pressurizing and re-pressurizing the system. Helm pump Pressurized reservoir Reservoir pipe Ram pipes Steering ram Autopilot pump D5162-1 Figure 6: Autopilot pump location for two line pressurized systems 12 Three line systems Hydraulic Pump - Installation Guide 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. 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 9). Connect the bypass valve to the CLUTCH terminals on the course computer using at least 1. 5 mm2 (16 AWG) copper cable. Hydraulic Pump - Installation Guide 15 Note: Follow the manufacturer's instructions for mounting the hydraulic ram and reservoir. Secondary steering ram Bypass valve Manual steering system Autopilot pump connect to CLUTCH on course computer connect to MOTOR on course computer D5172-2 Figure 9: Connecting to a secondary steering ram 5. Post-installation check WARNING: Keep clear of moving steering systems at all times. [. . . ] 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 get the best possible performance from your Raymarine equipment, guidelines are given in the installation instructions, to enable you to ensure minimum interaction between different items of equipment, i. e. ensure optimum Electromagnetic Compatibility (EMC). Always report EMC-related problems to your nearest Raymarine dealer. [. . . ]