Had to cut radar cable...

yobub

Well-Known Member
Jul 29, 2016
952
Northern Illinois
Boat Info
1998 400 Sundancer
Engines
Cat 3116's
In order to transport my boat, I had to cut the cable between the radar array and the display. Long story. The array is a Raymarine 92655 open array which has a flat, 8 lead connector with very small gauge (24?) wire, connecting to a C120 display, and the wire is cut about an inch from the antenna connection.

I'm wondering what the best way to reattach is. I couldn't find a replacement cable to rerun the entire thing, but I have the original connector with about an inch of wire lead on it, and I purchased a replacement connector fitting. I think my options are to 1) rewire to the new connector, or 2) use quick connects inline, or 3) solder the wires back together.

Does anyone have experience with this?

I understand that the quality of the signal could be affected by the quality of the repair, which is why I'm interested in experience from someone who has done it before.

Thanks.
 
If I’m not mistaken, the flat connector on the antenna end is reusable. I know it was on my Raymarine open array. You should be able to use a small jewelers screwdriver to release each wire, pull your 1” sections out, and then strip and push back in the wires from the main cable in the same order.

These flat connectors were designed to be removed to aid in routing the original main cable between the display and the array antenna.
 
In order to transport my boat, I had to cut the cable between the radar array and the display. Long story. The array is a Raymarine 92655 open array which has a flat, 8 lead connector with very small gauge (24?) wire, connecting to a C120 display, and the wire is cut about an inch from the antenna connection.

I'm wondering what the best way to reattach is. I couldn't find a replacement cable to rerun the entire thing, but I have the original connector with about an inch of wire lead on it, and I purchased a replacement connector fitting. I think my options are to 1) rewire to the new connector, or 2) use quick connects inline, or 3) solder the wires back together.

Does anyone have experience with this?

I understand that the quality of the signal could be affected by the quality of the repair, which is why I'm interested in experience from someone who has done it before.

Thanks.

I also had to cut my radar antenna cable 2 years ago in an emergency while it's working.

20160719_185909.jpg


Thank god the 10 amp red blade fuse saved the C80 and antenna and then I soldered the cut wires and it's working since2 years without any problem.

So you should be ok with the number 3 route but not sure if it's differ if yours is a digital unit.

HTH
 
If I’m not mistaken, the flat connector on the antenna end is reusable. I know it was on my Raymarine open array. You should be able to use a small jewelers screwdriver to release each wire, pull your 1” sections out, and then strip and push back in the wires from the main cable in the same order.

These flat connectors were designed to be removed to aid in routing the original main cable between the display and the array antenna.

Thanks, I didn't realize that the wires could come out of the connector. I will try that option first. I also found that a replacement cable doesn't seem to be available separately online, but I can find replacement arrays with cables on ebay for about $650 or so. It's a lot to spend just to replace a cable, but I would end up with a radome as part of the deal.

I've considered just replacing the whole system with a new digital system, but I think I would end up replacing the transducer as well, and that would end up requiring a haul out and paying the yard, which would bring the price way up from just doing the wiring myself.

I appreciate the comments and will circle back with updates once I tackle this.
 
It is a flat connector with 8 wires. 6 of the wires are individual, and then there is a thin coax wire that has a black wire and white wire coming out of it. It is for a Raymarine 92654-S
View attachment 56455

Yes yobub, that is the connector I was referring to in my earlier reply. That is designed to be reusable. As I mentioned, you need to insert a small jewelers screwdriver or eyeglass screwdriver into those slots to remove/install wires. You should be all set to go.

PS - I agree, the radar cable alone is very difficult to find.
 
When you resemble the connector, be sure to use a knife or small screwdriver to lift the little tang on each metal pin before you insert it back into the plastic connector. When you push down on them to remove the pin, they will bend down a little. When you reinsert each pin, you should feel it click into place. Try to gently pull the pin back out of the connector after you insert it. You should not be able to pull it back out unless you press the little tang down again.
 
I have to put my radar array back as the previous owner took it down for transport.
It seems impossible. There is no way I can get my hand in the arch and be able to insert the 4 bolts then be able to turn them. Once they get started I can get a ratchet on them, but any ideas on how to get them started?
Thanks
 
Couple of tricks for tight spots: 1) put the bolt in the short socket - if to deep back with some paper that you can pull out. 2) use duct tape on the bottom of a closed end wrench - tape should hold bolt enough to thread. 3) Ask wife or kid with smaller hands. 4) Bigger access panel.

While you are at it - if it is this big of a pain and you may have to remove in future you may want to consider adding a flip down mount plate while it is off.

-Kevin
 
I may have a replacement cable for sale if you don't have luck splicing, PM ME.
 
I have to put my radar array back as the previous owner took it down for transport.
It seems impossible. There is no way I can get my hand in the arch and be able to insert the 4 bolts then be able to turn them. Once they get started I can get a ratchet on them, but any ideas on how to get them started?
Thanks
Steve, I just did this on m 1998 400 Sundancer. I used a closed ratchet (like an open wrench but with a ratchet) on the nut inside the arch to hold it and ultimately to tighten, and a socket on the bolts which were inside my array. You might have a different set up.
 
Thanks, Ill try that. I had my daughter try and she couldn't get her hand in there either.......who designs this stuff?
 
When you resemble the connector, be sure to use a knife or small screwdriver to lift the little tang on each metal pin before you insert it back into the plastic connector. When you push down on them to remove the pin, they will bend down a little. When you reinsert each pin, you should feel it click into place. Try to gently pull the pin back out of the connector after you insert it. You should not be able to pull it back out unless you press the little tang down again.

Thanks for the advice on this. The holes to release the tab are very small so I used a small punch from Hearbor Freight, but was able to get the wires in. I still have a problem with no image, but the rest of the controls operate. I think I might have missed on getting one of the coax wires in correctly. I'll post a pic when I get a chance to help anyone searching this in the future. Thanks again.
 
So I got everything wired up. The E120 recognizes the scanner, and the scanner reacts to controls from the E120, but when the radar scans it doesn't paint any image. Everything on the E120 seems to be working, and the chartplotting functions all see to work. Any thoughts as to why I might not be getting radar returns?
 
I just replaced my scanner - that little tiny coax wire in the connector is probably the culprit; double check it.
Also FYI, checkout maxmarineelectronics.com for tested used marine electronics and hard to find cables. Also you can run the system diagnostics which will check the operational aspects of both the cable and the scanner.
 
Also, since this is an open array antenna, make sure that the small metal “pin” on the bottom of the scanner arm is not damaged, and that it is properly aligned and inserted in the antenna base.
 
To close the loop on this, I FINALLY got the radar working yesterday. I pulled all the connections, stripped them clean, and reconnected everything from scratch. Getting pretty good at it now.

For anyone who finds this thread who ends up in the same situation, here are some tips:
  • Don't cut the cable, just disconnect the wires from the connector. It will make it much easier.
  • Harbor Freight sell a small pick set with orange handles ($1.99) that was perfect for sticking in the little hole to open the connector. I used the right angled one, because I could keep it in place. Really helped out.
  • Hold the connector together with vice grips when you are using the pick to open the connector, otherwise the connector can break apart. This helped alot.
  • Connect the small black coax lead first (will be bare wire if you cut the cable), then connect the white coax, then the rest.
  • Use a razor blade to strip some of the insulation on the white coax to get it to fit better in the hole. Don't strip it bare, but pare it down. It's a really hard fit otherwise (Thanks to Raymarine tech support for that tip)
  • This will sound strange, but for the black wire and the white wire, push the connector onto the wire, rather than pushing the wire into the connector. I don't know why it is different, but it is. For all other other colors, those go in easily.
  • Don't cut the cable. Did I say that?
I'll edit with pictures when I have a chance.
 
Last edited:
I'll be doing this in the next few days. e80 display with open array radar which had to be removed for transport. It's been about 13 years since I've done this type of work and hopefully it all comes back to me. Took a quick peak this afternoon and the array is in two pieces, the array and the base. They didn't cut the wires but there appears to be about 6-8 little wires which I need to find a home for within the base. I'm sure the order of colors/wire is vital but something tells me the connector plug is not color coded inside the base.
 
I'll be doing this in the next few days. e80 display with open array radar which had to be removed for transport. It's been about 13 years since I've done this type of work and hopefully it all comes back to me. Took a quick peak this afternoon and the array is in two pieces, the array and the base. They didn't cut the wires but there appears to be about 6-8 little wires which I need to find a home for within the base. I'm sure the order of colors/wire is vital but something tells me the connector plug is not color coded inside the base.
Take a look at Post #6.
 

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