Octopus 44364 User manual

TYPE R AUTOPILOT DRIVE UNIT SYSTEM PACKS
INSTALLATION MANUAL
OC15269 REV F 27 JULY 2012
POWERBOAT & SAILBOAT SYSTEMS

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Revision History
Revision Description
ERedesign in booklet format
F
See DCR # 0961
© 2012 Octopus Products Inc. All rights reserved.
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. Octopus Products Inc will nor be liable for
errors contained herein or for incidental or consequential damages in connection
with the furnishing, performance or use of this document.

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CONTENTS
A Introduction
A1 SystemOverview.............................................4
A2 CompatibilityInformation.......................................4
A3 ImportantSafetyFeatures......................................5
A3a ManualRelease.......................................5
A3b ManualOverride.......................................5
B Mechanical Installation
B1 Available Space - Physical Envelope & Orientation . . . . . . . . . . . . . . . . . .6
B1a DriveInstallation.......................................7
B2 OutboardEnginedBoats.......................................8
B2a Enginecompatibility....................................8
B2b SuppliedParts ........................................8
B2c Installation............................................8
B3 Sterndrive Boats Mercruiser DHB 1994+. . . . . . . . . . . . . . . . . . . . . . . . . .12
B3a Enginecompatibility...................................12
B3b SuppliedParts .......................................12
B3c Installation...........................................13
B4 Sterndrive Boats Volvo Gasoline & Diesel USA 1997 Onwards . . . . . . . .16
B4a Enginecompatibility...................................16
B4b SuppliedParts .......................................16
B4c Installation...........................................17
B5 Sterndrive Boats Mercruiser Saginaw 1983-93 . . . . . . . . . . . . . . . . . . . . .20
B5a Engine compatibility ...................................20
B5b SuppliedParts .......................................20
B5c Installation...........................................21
B6 Sterndrive Boats Volvo Diesel Europe. . . . . . . . . . . . . . . . . . . . . . . . . . . .24
B6a Engine compatibility ...................................24
B6b SuppliedParts .......................................24
B6c Installation...........................................25
B7 Inboard Engined Boats & Sailboats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
B7a Compatibility .........................................28
B7b SuppliedParts .......................................28
B7c Installation...........................................29
B7d Quick Release .......................................32
B7e Specification .........................................32
B8 RoutingSteeringCable.......................................33
B8a Cable Length Calculation ...............................33
B9 Connecting Steering Cable To Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
B10 Rudder Feedback Unit (RFB) Installation & Calibration . . . . . . . . . . . . . .35
B10a Universal RFB Setup ..................................35
B10b Calibration and Installation ..............................36
B11 Interference Evaluation (Outboard Engines Only) . . . . . . . . . . . . . . . . . . .37
C Electrical Installation
C1 Connecting Drive To Autopilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
C2 RudderFeedbackUnit........................................38
C2a Connection - non Simrad autopilots .......................38
C2b Connection - Simrad autopilots ..........................39
D Appendix
D1 Accessories................................................40
D2 GeneralMaintenanceGuide ...................................41

A INTRODUCTION
A1 System Overview
The Octopus Type R Remote Drive is a rotary mechanical autopilot drive system which
makes it simple and economical to fit an autopilot on smaller powerboats with
mechanical push-pull cable steering or small sailboats with a steering quadrant or tiller.
The type R drive unit incorporates a drive motor, solenoid clutch and integrated rudder
feedback (RFB) capability. Its design means that the drive can be mounted in a
convenient position, meaning it will fit a large number of boats which because of
design constraints or size were not practical to have an autopilot fitted before.
The system uses a steering cable and connection kit which is fitted in addition to
the existing manual steering cable for cable steered boats or directly to the steering
quadrant for sailboats. This allows the system to be easily installed on most types of
boat without having to interfere with the existing steering system. There are five Type
R packs available which include the drive unit, 6ft (1.8m) steering cable and relevant
connection kit:
Part Number Type Compatibility
MDRESYS-A* Sterndrive Mercruiser 1994 onwards, Volvo Gasoline engines
and Volvo Diesel engines USA 1997 onwards
* We recommend changing the steering cable for a 9ft version when installing on to a twin engined boat.
MDRESYS-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) / 13,200lbs (6,000kg) displacement
A2 Compatibility Information
• The Type R Remote Drive is recommended for use on vessels with a maximum
speed of 44mph (65km/h) and should not be fitted to vessels which can exceed this.
• It should not be fitted to boats where the engine max horsepower exceeds the
max horsepower rating for the vessel as stated on the vessel manufacturer’s tag.
• The existing steering system MUST be capable of being back driven. The Type R
Remote Drive cannot be fitted if the steering system is a NFB (no feed back) type.
• The drive is designed to produce a maximum cable push/pull of 300lbs (136kg),
which makes it suitable for the vast majority of cable steered vessels. However
some vessels fitted with push pull cable steering systems have very stiff steering
or steering which is heavily loaded in one direction due to hull design and engine
considerations. Generally speaking, the Type R drive will steer vessels that do not
require more than a 15lb force on the rim of a 14in diameter steering wheel to hold
a course, this equals 105in-lb of torque. If the steering wheel input torque exceeds
this figure we would recommend that the vessel be fitted with a hydraulic linear
actuator drive system instead.
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A3 Important Safety Features
The Helmsperson should be made aware of the two following safety features before
using the Autopilot:
A3a Manual Release
The drive features a manual release in case the Autopilot is switched to manual
mode by mistake, which could result in a dangerous manoeuvre or violent move-
ment of the steering wheel on a powerboat due to propeller action or trim forces.
While the drive is under consistent load from the boat’s steering system in one direc-
tion or no movement, the drive unit clutch will remain engaged when the Autopilot is
switched to manual mode.
To disengage the drive a small joggle action (turning the wheel/tiller from side to
side) will release the clutch and allow manual control.
IMPORTANT The helmsperson should always be ready to take manual control of
the boat when the Autopilot is returned 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 disengage the drive.
A3b Manual Override
IMPORTANT It is STRONGLY advised that the helmsperson be familiarized with
this manual override procedure before proceeding to sea.
In the event of uncontrolled automatic steering or any other emergency situation
where it is imperative that manual control be reassumed immediately, the helmsper-
son can override the steering action of the drive unit by exerting force on the steer-
ing wheel in the opposite direction to the drive. This action will cause the drive unit
thrust limit to “slip” allowing the helmsperson to take control.
NOTE The manual override does not disengage the autopilot - to resume full manual
control the autopilot should be switched to standby as soon as is practically pos-
sible.
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VERTICAL MOUNTHORIZONTAL MOUNT
Fig B1 - Mounting options
B MECHANICAL INSTALLATION
B1 Available Space - Physical Envelope & Orientation
The selected installation site should provide adequate space to accommodate the
drive unit including the entry and exit points for the steering cable. The drive can be
mounted at any angle. Note that no access for maintenance 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.
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Fig B2 - Physical drive envelope
BASEPLATE PERPENDICULAR MOUNT
BASEPLATE PARALLEL MOUNT
NOTE If the ports are reversed, the steering action will also be reversed. This can
be compensated for by adjusting the autopilot software or the drive motor wiring.

B1a Drive Installation
The design of the Type R Autopilot Drive System gives a high degree of flexibility in
the location of the drive unit relative to the steering mechanism, however factors
such as the optimum steering cable route and also the length of the steering cable
(6ft / 1.8m standard, other lengths available) will influence the final location.
It is recommended that the steering cable connection is the final stage of the
mechanical installation, but it is advisable to take into account the points raised in
section B8 regarding steering cable routing when planning the drive unit location.
i) Position the drive unit in the final location. Verify that there is sufficient clear-
ance for the steering cable entry and 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 should be sturdy enough to
support the drive unit.
iii)
The drive base plate can be fitted in two possible orientations - perpendicular
or parallel. Assemble the base plate to the drive using the most suitable ori-
entation for the installation and torque the fasteners to 30-35in-lb (3.4-4.0Nm).
iii) Mark out the fixing pattern from the drive base plate and drill appropriate
sized pilot holes into the mounting structure (Fig B3). The mounting holes
are suitable for 1⁄4in or 6mm fasteners.
iv) Position the drive unit and install using suitable fasteners. Ensure they are
tightened securely.
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Fig B3 - Mounting plate drilling dimensions

B2 Outboard Engined Boats
The Outboard Installation Kits can be fitted to mechanical push-pull cable steered
vessels that are powered by MOST of the popular Yamaha (MDRESYS-C) and
Mercury/Mariner/Suzuki (MDRESYS-D) models of outboard engine. It is recom-
mended for use on vessels with a maximum speed of 44mph and should NOT be fit-
ted to vessels where the maximum horsepower of the engine exceeds the maximum
horsepower rating for the vessel as stated on the vessel manufacturer’s tag.
The installation kit allows the second steering cable for the Type R drive to be fitted
to the outboard steering system.
B2a Engine Compatibility
The MDRESYS-C kit is suitable for use on Yamaha 115-220 HP produced from
1984 onwards. The Yamaha engine has M6 (metric system) threaded fittings.
The MDRESYS-D kit is suitable for use on Mercury Black Max outboards 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-40 Type R Remote Rotary Autopilot Drive Unit
OC15SUK15A Yamaha Outboard Installation Kit (MDRESYS-C) OR
OC15SUK15B Mercury-Mariner-Suzuki Outboard Installation Kit (MDRESYS-D)
OC15109-6 6ft (1.8m) Secondary Steering Cable*
* Other lengths are available as optional accessories
B2c Installation
• Prepare the engine mounting site
i) Use the helm to centre the engine.
ii) Ensure that the area in front of the
tilt tube is clear of obstructing wires,
hoses etc. Reroute if necessary.
iii) There are four threaded holes on
the front face of the tilt tube (Fig B4),
ensure that these are free from paint
etc - retap if necessary:
MDRESYS-C M6 metric
MDRESYS-D 1⁄4in-28 UNF
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Fig B4 - Threaded mounting holes on front face
of tilt tube
Threaded
mounting holes
Tilt tube

• Remove steering link arm
i) To simplify the re-assembly proce-
dure, make a note of the connections
between the steering link arm and the
manual steering cable and engine tiller.
ii) Disconnect the steering link arm from
the manual steering cable and the
engine tiller.
iii) Retain the link arm and fixings etc for
later 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 UNF bolts and lockwashers are
supplied in the kit.
ii) Torque the bolts to 100in-lb (11Nm).
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Fig B5 - Removing steering link arm
Steering
link arm
Fig B6 - Fitting the cable mount bracket
Primary
steering cable
Mount bracket

• Fit the cable guide tube to the cable mount bracket
i) Both the locknuts and the guide tube thread should be lubricated with marine
quality grease before assembly.
ii) Slide the guide tube into the cable mount bracket as shown (Fig B7).
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iii) Adjust the position of the guide
tube so that the exit end of the
guide tube aligns with the exit end
of the engine tilt tube (Fig B8)
iv)Tighten the two locknuts and
torque 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 guide tube
i) Both the cable nut, the guide tube
thread and the inside of the guide
tube should be liberally lubricated
with marine quality grease before
assembly.
ii) Insert the rod end of the secondary
steering cable into the threaded end
of the guide tube (Fig B9).
iii) Hand tighten the cable nut and
torque to 175in-lb (20Nm). The nut
has an internal locking thread which
increases the amount of torque required
initially as the thread is cut. Fig B9 - Secondary steering cable
Cable
nut
Secondary
steering
cable