Octopus 44364, Installation Manual

Page 1: ...type r autopilot drive unit system packs installation manual OC15269 REV F 27 July 2012 Powerboat sailboat Systems...

Page 2: ...erved The information contained in this document is the sole property of Octopus Products Inc Any reproduction in part or whole without the written permission of Octopus Products Inc is prohibited Oct...

Page 3: ...ercruiser Saginaw 1983 93 20 B5a Engine compatibility 20 B5b Supplied Parts 20 B5c Installation 21 B6 Sterndrive Boats Volvo Diesel Europe 24 B6a Engine compatibility 24 B6b Supplied Parts 24 B6c Inst...

Page 4: ...B Sterndrive Mercruiser Saginaw 1983 93 Volvo Diesel engines Europe 1994 onwards MDRESYS C Outboard Yamaha 70hp MDRESYS D Outboard Mercury Mariner Suzuki MDRESYS E Inboard Sailboat Up to 32ft 9 75m 13...

Page 5: ...ed to manual mode DOCKSIDE TESTING Due to the Manual Release safety feature when the vessel is not in motion it might be necessary to joggle the wheel tiller move from side to side to engage or diseng...

Page 6: ...ntenance purposes is required The steering cable entry and exit ports are reversable so the cable entry and exit ports can be selected for the best installation arrangement on the particular vessel 6...

Page 7: ...d the spent cable tube as well as access for the electrical connections ii Although there are no loads transferred to the drive unit mounting when the autopilot is in operation the selected location s...

Page 8: ...rds from 1980 onwards Mariner outboards from 1980 onwards Mercury Mariner 2 4 all models and Suzuki DT75 DT225 and DF60 DF140 These engines have 1 4in 28 UNF threaded fittings B2b Supplied Parts MDR 4...

Page 9: ...er use Fit the secondary steering cable mount bracket to the engine tilt bracket i The bracket attaches to the four threaded mounting holes on the front face of the tilt tube Fig B6 Four M6 1 4in 28 U...

Page 10: ...ue to 175in lb 20Nm Grease the fitting Fig B7 Fitting the cable guide tube Cable guide tube Locknuts Fig B8 Cable guide tube alignment TOP VIEW Align Greaser Attach the secondary steering cable to the...

Page 11: ...e of the washers must be in contact with each other Fig B10 iv Torque the nuts to 180 200in lb 20 22Nm 11 of 44 Subject to change without notice OC15269 REV F WWW OCTOPUSDRIVES COM www octopuseurope c...

Page 12: ...cruiser DHB The installation kit allows the second steering cable for the Type R drive to be fitted to the sterndrive steering system B3a Engine compatibility Mercruiser DHB steering cylinders are fit...

Page 13: ...ii Slacken the clamp screw and lock nut on the fitting kit drive collar iii Fit the spacer bush on to the steering cylinder sleeve ensure it is correctly oriented refer to Fig B14b iv Slide the drive...

Page 14: ...ng the drive unit should be the final stage of the mechanical assembly i Remove the shoulder screw from the drive collar ii Position the connection kit assembly above the steering cylinder and engage...

Page 15: ...cylinder Fig B17 Tighten the drive collar clamp screw and torque to 175in lb 19Nm Tighten the drive collar lock nut and torque to 45in lb 5nm 15 of 44 Subject to change without notice OC15269 REV F W...

Page 16: ...ll cable controlled sterndrive power assisted steering cylinders made by Volvo for Gasoline engines and also Diesel engines in the USA since 1997 The installation kit allows the second steering cable...

Page 17: ...it the spacer bush on to the steering cylinder sleeve ensure it is correctly oriented refer to Fig B20b The spacer bush is not required on Volvo models 3862513 and 3862514 which were fitted from Sept...

Page 18: ...e at this point as fine adjustments to the drive collar positioning are necessary and the backdrive friction from the drive unit will make this more difficult Connecting the drive unit should be the f...

Page 19: ...Fig B23 Tighten the drive collar clamp screw and torque to 175in lb 19Nm Tighten the drive collar lock nut and torque to 45in lb 5nm Fig B23 Positioning the drive collar Guide Tube 7 3in 185mm when st...

Page 20: ...ical push pull cable controlled sterndrive power assisted steering cylinders fitted to Mercruiser Alpha One Generation II and Bravo Sterndrives between 1983 and 1993 Saginaw The installation kit allow...

Page 21: ...Note that the nut has an internal locking thread which increases the amount of torque required initially as the thread is cut There should be NO movement between the outer cable jacket and the guide t...

Page 22: ...ointing down Fig B28 iv Fit the bolt through the bottom of the clevis block through the cable rod end and out the top of the block Fit the anti vibration washers in the correct order with the serrated...

Page 23: ...n engaged in the GREEN color coded slots of the secondary cable guide tube ii Lower the connection kit assembly onto the cylinder and clevis bracket as shown Ensure that the clevis pin is also locking...

Page 24: ...e pack can be fitted to mechanical push pull cable controlled sterndrive power assisted steering cylinders made by Volvo for Diesel engines in Europe The installation kit allows the second steering ca...

Page 25: ...ote that the nut has an internal locking thread which increases the amount of torque required initially as the thread is cut There should be NO movement between the outer cable jacket and the guide tu...

Page 26: ...ointing down Fig B35 iv Fit the bolt through the bottom of the clevis block through the cable rod end and out the top of the block Fit the anti vibration washers in the correct order with the serrated...

Page 27: ...e ensure that both clamps remain engaged in the YELLOW color coded slots of the secondary cable guide tube ii Lower the connection kit assembly onto the cylinder and clevis bracket as shown Ensure tha...

Page 28: ...e than 13 200lbs 6 000Kg In all cases the primary steering system must be capable of being back driven with a torque of less than 105in lb 12Nm If the amount of force required to maintain course is gr...

Page 29: ...ase the amount of force required to move the rudder which may slow the lock to lock time of the autopilot iii The kit features a universal hub which offers 360 freedom of movement in the horizontal pl...

Page 30: ...30 of 44 Subject to change without notice OC15269 REV F WWW OCTOPUSDRIVES COM www octopuseurope com Fig B40 Inboard kit installation envelope...

Page 31: ...lly as the thread is cut iv Remove the quick release locking pin from the bracket Fit the steering cable to the guide tube i The cable nut guide tube thread and inside of the guide tube should be libe...

Page 32: ...e can be quickly disconnected from the tiller by pulling out the hitch pin and then removing the locking pin B7e Specification Maximum stroke 8 5in 216mm Peak Thrust 330Ibs 136kg Max Rudder Torque 185...

Page 33: ...ombined total angle of all bends is no more than 270 B8a Cable Length Calculation All Type R Drive System Packs are supplied as standard with a 6ft 1 8m steering cable which should be suitable for mos...

Page 34: ...to hold the cable in place v If undue force is required to insert the cable this may be caused by the end of the inner cable fouling the outer face of the nylon guide If this is the case remove the ca...

Page 35: ...icated RFB is not available for a brand of autopilot the OC15SUK27 Universal RFB should be suitable This module is configured to the particular autopilot using DIP switch settings 35 of 44 Subject to...

Page 36: ...at using the manual helm you may need to run the engine to do this iii Calibrate the RFB by aligning the two red paint marks on the underside of the unit Fig B49 iv Remove the RFB blanking cap from th...

Page 37: ...e steering wheel from full lock to full lock the other person should observe the outboard engine movement and ensure that there is no physical interference between any parts across the full steering l...

Page 38: ...R drive requires a 12V input for both the motor drive and the clutch Do not use with a 24V system C2 Rudder Feedback Unit C2a Connection non Simrad Autopilots i Connect the RFB Module wires to autopi...

Page 39: ...nized by the Course Computer If this occurs perform the Autopilot Reset procedure refer to Simrad autopilot manual ii Determine suitable site to mount the Signal Conversion Module Shorten or insert su...

Page 40: ...ser Saginaw up to 1993 and Volvo Diesel drives Europe from 1994 Yamaha 115 220 O B Installation Kit for Second Steering Cable Connection to Outboard Mercury Mariner Suzuki O B Installation Kit for Sec...

Page 41: ...y remove the cable clean the connector tube and thoroughly lubricate with a waterproof grease Inspect the cable for cracks splits or other damage DO NOT cover cracks in the cable outer sheath with tap...

Page 42: ......

Page 43: ......

Page 44: ...OC15269 REV F Octopus Products Inc Vancouver Canada Tel 604 940 2010 Fax 604 952 2650 www octopusdrives com www octopuseurope com...