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MAVIMARE GM2-MRA01 Quick start guide

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All Mavimare steering systems are certified CE by the Italian
Shipping Register (Rina) in conformity with the 2013/53/EU rule.
Installation instructions
and owner’s manual
Hydraulic Steering Systems
Rev. 10
EN
3
MAVIMARE
CONTENTS
– General safety rules and warranty pag. 4
– Important points to note – minimum splashwell dimensions pag. 5
– Steering pump installation pag. 6
– MC 150 cylinder installation pag. 9
– MC 90B cylinder installation pag. 10
– MC 150BR cylinder installation pag. 12
– MC 150R – MC300R cylinder installation pag. 14
– MC 300BHD–CHD–BV Evolution cylinder installation pag. 15
– Kit. X.344 installation pag. 17
– Double cylinder MC 300BHD installation schemes pag. 19
– Twin engines application with tie bar Art.358.02 pag. 20
– Triple engine application pag. 21
– MC 300HD - MC 350HD cylinder installation pag. 22
– Twin engines application with tie bar Art.358.00 - 358.06 pag. 24
– MC 300HD - MC 350HD double cylinder installation schemes pag. 25
– Inboard Cylinder installation for GE30 - GE50 - GE75 - GE100 pag. 27
– MC 150E - MC 150BE - MC 300BE stern drive cylinder installation pag. 28
– CE50S cylinder installation pag. 29
– Hoses / ttings installation - pump connection pag. 30
– Connection schemes for double cylinder application -- Art.X.351 / X.352 pag. 33
– Hydraulic uid pag. 34
– Filling and purging – outboard cylinder pag. 34
– Filling and purging – inboard / sterndrive cylinder pag. 37
– Valves installation pag. 39
– Double station installation pag. 39
– Catamaran outboard system pag. 40
– Faults and solutions pag. 43
– Maintenance pag. 44
– Technical informations pag. 44
4
MAVIMARE
EN
Thank you for having chosen a MAVIMARE product.
The present installation and maintenance manual is an integral part of the product and must be easily available for use by staff assigned
in use and maintenance of the same. The user is required to know the contents of the manual. MAVIMARE disclaims all responsibility
for any inaccuracies due to printing errors contained in this manual. Without prejudice to the essential characteristics of the product
described, MAVIMARE reserves the right to make any changes to descriptions, information, and illustrations that should be
determined for the improvement of the same, or for manufacturing or commercial requirements at any time and without being
required to update this publication.
Before proceeding with the installation, read these instructions thoroughly. MAVIMARE cannot accept responsibility for installations
where instructions have not been followed, where substitute parts have been used or where changes have been made to our products.
The hydraulic steering system shall be installed by authorised and skilled technicians. Particularly the interventions on the hydraulic
piping system shall be carried out of expert technician only.
MAVIMARE declines any responsibility for losses or damages resulting from the incorrect use of the product.
For eventual anomalies or problems in the system operation, please call the authorised technicians immediately.
MAVIMARE guarantees its products have been built to perfection and have no manufacturing and material defects.
The warranty period is of two years, starting from the date of production with the exception of the cases in which these are installed and
used on working or commercial boats where the warranty is limited to a year from the manufacturing date and limited to substitution
or free-of-charge repair of the part which, during the said period, will be mailed back to and which we will ascertain is really defective
in materials and/or manufacturing.
This warranty does not cover the products installed on race boats or boats used in competition.
General safety rules and warranty
Safety warnings
YOU MUST STRICTLY RESPECT the precautions and the advisable safety criteria here below. MAVIMARE declines every responsibility
in the case you do not observe them and also for any case of negligence that might be committed during the utilization of the system.
– Keep hands clear of moving parts.
– Do not deactivate and do not make safety devices inoperative in any way.
– Do not change or add devices to the system, without written authorization or previous technical intervention of MAVIMARE which
shall approve of it.
– Do not use the system for any other purpose than for what specied in the installation and maintenance manual.
– Do not allow non-specialised personnel to perform installation.
– Do not disassemble the hydraulic connections without having completed the oil discharge in the system before. The piping can
contain high-pressure oil.
ATTENTION
– Do not step onto the cylinder.
– After installation and bleeding the system, check before you start the navigation. Turn the steering wheel until the cylinder or
cylinders are at the stroke end. Repeat the maneuver rotating the steering wheel in the opposite direction.
– Take the utmost care when applying liquid gluing material (e.g. Loctite). In case of introduction in the hydraulic system, this would
cause damages and disruptions.
– To seal the ttings, do not use (under any circumstances) Teon tape or any type of tape that could be sucked in by the system and
cause irreparable damage to the same.
– During installation of the system take special care to maintain maximum cleaning, to prevent foreign matter from entering the
system. Even the smallest object could result in permanent damage not immediately detectable.
– Avoid bending the tubes too tight.
– Avoid contact with piping edges or sharp corners.
– Keep pipes away from sources of heat.
EN
5
MAVIMARE
Very important points to note
– DO NOT USE BRAKE FLUID – IT WILL DAMAGE SEALS AND OTHER COMPONENTS.
USE ONLY MAVIMARE SHELL TELLUS T15 HYDRAULIC OIL.
WARNING:
Use of alternative hydraulic uids may result in premature seal wear and possibly cause damage to your system.
DO NOT USE Automatic Transmission Fluid.
– DO NOT RE-USE OIL FROM BLEEDING THE SYSTEM without rst ltering it to remove foreign material (which will come out of
the system), and ALWAYS allow the air to settle out of it rst. YOU WILL REQUIRE FAR MORE OIL TO BLEED THE SYSTEM THAN
YOU NEED TO FILL THE SYSTEM. Allow about 2 litres, for a small single station unit and about 5 litres for a small dual station unit.
– WHEN INSTALLING MAVIMARE STEERING SYSTEMS YOU MUST USE ONLY MAVIMARE HOSES.
The performance of the steering can be seriously affected by the wrong tubing being installed. Before making any change to the
tubing specs, contact your authorised MAVIMARE dealer or the factory direct.
– IMPORTANT NOTES REGARDING OUTBOARD MOTORS: All outboard motors are equipped with small “TRIM” tabs immediately
behind the propeller. In some motors, these also act as anodes. DO NOT UNDERESTIMATE THE IMPORTANCE OF THESE
SMALL ITEMS.
These must be adjusted once the motors are installed on the boat, and should be done for the normal cruising speed of the vessel.
For high horsepower/performance motors, these are of critical importance as incorrect position can INCREASE steering torques as
much as 500%. They are NOT factory set and MUST be done after proper installation. Experimentation is the only means of arriving
at the best results.
– BE CLEAN when installing the unit. Strain all oil - even if is new (unless out of new PLASTIC containers). It only takes a few moments
to do this.
Keep the ller cap and the plugs in the pump at all times until the tubing is ready for attachment. Never leave the pump with the ller
cap open or ttings uncovered to avoid dirt, sawdust etc. from entering the pump unit.
Ensure that pipe joints and ttings are tight. Avoid the use of Teflon Tape as it can be introduced into the system by inexperienced
installers. THIS MAY CAUSE VALVE FAILURE.
– After installation, check the security of all bolts, nuts, and split pins on the steering mechanism. Vibration can often result in nuts
becoming loose. This should be carried out every 6 months.
– Use compressed air and blow out all tubing to remove dust and debris from storage. DO NOT CUT WITH A HACHSAW – USE ONLY
PIPE CUTTER.
– Where the tubing is to be bent, you should use a proper tube – bender to avoid kinking the tubing, which could result in rm steering.
Before attempting installation, ensure that the splashwell of your boat has the following minimum dimensions.
Minimum Splashwell Dimensions
MINIMUM SPLASHWELL DIMENSIONS
Number of engines
6
MAVIMARE
EN
Select a suitable position for the steering pump and the steering wheel.
Make sure that there is enough manoeuvring space for the steering wheel, for the steering pump and its connections and pipes. You
must mount the helm unit in horizontal axis, with a 20° inclination maximum authorised. The filler plug must always be in the uppermost
position. Cut a hole for the steering pump housing of diam.78 mm for standard helm mounting or 123 mm with a back mount kit and
four holes diam. 6,5 mm for the fixing bolts. Use the template. Use only self-locking fasteners.
The pump is supplied with two 90° ORB fitting.
Do not overtighten the fitting plug.
Keep the filler cap and the plugs in the pump at all times until the tubing is ready for attachment. Never leave the pump with
the filler cap open or fittings uncovered to prevent dirt, sawdust etc. from entering the pump unit.
Installation of the steering pump GM2-MRA01 / GM2-MRA03 / GM2-MRA04 / GM2-MRA05
GM2 - MRA01/03/04 standard helm mounting configuration
Back mounting configuration
for GM2 - MRA01/03/04
Important:
perform the bleeding procedure manually and with the helm
pump inclinated no more of 10° (X).
EN
7
MAVIMARE
GM0 - MRA installation
GM0-MRA 01
VALVE PORTS CONNECTION:
Port marked “C“: connections to the cylinder/s
Port marked “DS“: connections to the additional stations or autopilot
DS
CC
DS
CONNECTION FOR
DOUBLE STATION / AUTOPILOT
CONNECTION FOR
DOUBLE STATION / AUTOPILOT
CONNECTION
TO THE CYLINDER
CONNECTION
TO THE CYLINDER
GM3 - MRA installation
S.S.
washer
black nylon
washer
8
MAVIMARE
EN
Re-Positionable ORB pump and cylinder fitting installation
1Back off lock nut (1), counterclockwise, until it stop as shown
in the picture.
2Thread fitting into helm pump holes (2) until fitting washer (3)
touches the surface of the helm pump holes (4).
•Warning
DON’T USE Teflon tape or any type of scotch tape.
DON’T APPLY any type of sealant such as Loctite 542 or similar.
3Re-position fitting (5) to desired orientation by turning it
counterclockwise to a maximum of 1 full turn.
After that, torque the fitting locknut (6) with a wrench.
1
3
4
2
6
5
EN
9
MAVIMARE
Proper cylinder installation is the key to the successful operation of the hydraulic steering system.
An incorrectly installed cylinder is subject to rapid seal and bearing wear and non-repairable damage.
Protect cylinder rods from nicks and scratches, which can cause cylinder to leak, and result in loss of steering.
Installation:
– Ensure that the motor tilt tube is perfectly dry and clean.
– Grease the extension rod (1) with good-quality marine grease. Insert the extension rod on left side of motor tilt tube. Screw the
extension rod (1) onto the cylinder shaft and fix it with the pin (6). Screw the cylinder to the left threaded side of motor tilt tube,
keeping the bleeders on the upper side of the cylinder. Tighten the adjusting-nut (5) to the cylinder.
– Connect the tiller arm (14) to the extension rod as shown in the drawing.
– Put the cylinder and the motor in middle of its stroke, and adjust the tiller arm distance. Connect the tiller arm to the motor with
screw, washer and self-locking nut (15).
All the systems are not intended for racing boat application.
Installation instructions of the cylinder type MC 150
WARNING:
Remove the red caps in order to install
the hose’s fittings.
WARNING:
It is important to check periodically, at
least every 3 months (or every month
for professional uses), the right torque
of this bolt and of the self-locking nut.
REF. QUANTITY DESCRIPTION
11Extension rod
2-Motor tilt tube
41 Cylinder
5-Adjusting nut
61 Pin
14* 1Tiller arm*
15 1Screw, washer, self-locking nut
*Attention:
The tiller arm is not supplied
6
2
4
5
14
15
1
10
MAVIMARE
EN
Installation instructions of the cylinder type MC 90B
Proper cylinder installation is the key to the successful operation of the hydraulic steering system.
An incorrectly installed cylinder is subject to rapid seal and bearing wear and non-repairable damage.
Protect cylinder shafts from nicks and scratches, which can cause the cylinder to leak, and result in loss of steering.
Installation:
– Ensure that the motor tilt tube is perfectly dry and clean, grease the tilt tube rod (1) and make it slide into the tilt tube. Use good-
quality grease. Completely screw the brass nut (3) to the left threaded side of the tilt tube.
– Grease the end holes of the support brackets (6) and connect them to the tilt tube rod with the cylinder in the middle of its stroke
(7). Use washers (11) and nuts (12) to fix the assembly.
– Ensure that the cylinder body is centered on the rod and that the engine is perpendicular to the transom. Adjust the link arm length
to meet the connection to the motor. Connect the link arm to the motor.
– Control the space between motor tilt tube (2) and support brackets (6) whether on the left or on the right of the motor tilt tube; then
compensate the gap for expansion by adding a combination of plastic spacers (5). Warning: Always leave a minimum clearence
between spacers and brackets in order to allow the rod tilting in the tilt tube. Between motor tilt tube (on the right side) and first
spacer put a stainless steel washer (10).
– Make sure that the brackets completely enter in their housing on the tilt tube rod (1) without being obstructed by the spacers.
– Use washers (11) and self-locking nut (12) to fix all (before that fix the self-locking nuts (9) of the shaft).
– Do not over tighten the self-locking nuts (12). In fact, this may imply the fixing of the support brackets (6) against the motor tilt
tube (2), whereas they should be free to turn when you tilt the engine. Failing to observe this warning may cause problems when
you tilt the engine.
– Unscrew the brass nut (3) in order to balance the remaining clearance and tighten the brass nut (3). Dot not use any tool for this
operation.
– Check once again the fastening of all the self-locking nuts which however must not obstruct the turnover of the motor and its
oscillation.
– Make sure that the motor can turn side to side without any interference.
– Check that all mechanical parts of the cylinders are not in contact with the motor and are not strained in their movement.
The cylinder arm ( 14 ) should
be attached on the top
of the engine tiller arm on
most brands of outboards.
In the event that the tiller
interferes with other parts
of the outboard, then it can
be mounted under the tiller
instead.
REF. QUANTITY DESCRIPTION
11Support rod
2-Motor tilt tube
31Adjusting nut
56Plastic spacer
62Support brackets
WARNING:
It is important to check
periodically, at least every 3
months (or every month for
professional uses), the right
torque of this bolt and of the
self-locking nut.
REF. QUANTITY DESCRIPTION
71 Cylinder
8-11 2+2 Washer
9-12 2+2 Self-locking nut
10 2Stainless steel washer
WARNING:
Remove the red caps in order
to install the hose’s fittings.
1211
6
510
10 5
6
1112
98
89
1
7
3
14
2