Summary of Contents for MAVIMARE GM2-MRA01
- Page 1 Hydraulic Steering Systems Rev. 10 Installation instructions and owner’s manual All Mavimare steering systems are certified CE by the Italian Shipping Register (Rina) in conformity with the 2013/53/EU rule.
- Page 3 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 MAVIMARE...
- Page 4 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.
- Page 5 ALWAYS allow the air to settle out of it first. 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. –...
- Page 6 Installation of the steering pump GM2-MRA01 / GM2-MRA03 / GM2-MRA04 / GM2-MRA05 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°...
- Page 7 VALVE PORTS CONNECTION: Port marked “C“: connections to the cylinder/s Port marked “DS“: connections to the additional stations or autopilot CONNECTION FOR DOUBLE STATION / AUTOPILOT CONNECTION CONNECTION TO THE CYLINDER TO THE CYLINDER CONNECTION FOR DOUBLE STATION / AUTOPILOT MAVIMARE...
- Page 8 DON’T APPLY any type of sealant such as Loctite 542 or similar. Re-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. MAVIMARE...
- Page 9 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. MAVIMARE...
- Page 10 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. MAVIMARE...
- Page 11 Attention: use Kit X.342 for Yamaha / Tohatsu 40/50/60/70 engine. X342 Attention: with some motors, the s.s. lever of the cylinder must be installed under the engine tiller plate with the addition of some washers. MAVIMARE...
- Page 12 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. MAVIMARE...
- Page 13 Attention: use Kit X.342 for Yamaha / Tohatsu 40/50/60/70, Honda 115/130 HP engines and Mercury Optimax 90/115. X342 Attention: with some motors, the s.s. lever of the cylinder must be installed under the engine tiller plate with the addition of some washers. MAVIMARE...
- Page 14 Make sure that the motor can turn side to side without any interference. Check that all the mechanical parts of the cylinder are not in contact with the motor or force in their movements. All the systems are not intended for racing boat application. MAVIMARE...
- Page 15 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 cylinder to leak, and result in loss of steering. MAVIMARE...
- Page 16 Ensure that the motor and the cylinder are free to rotate on their own axis. Do not use a wrench of any type on the adjusting ring nut. Tight it by hand only. Lock the ring nut inplace by securely tightening the set screw MOTOR TUBE Kit X.344 see pag. 20 MAVIMARE...
- Page 17 If interference is present between the end of the steering cylinder and the motor well wall and there is not enough clearance sideways for the hoses, it could be eliminated with Kit X.344 90° fittings. Straight fitting must be substituted with elbow fitting. Use a pipe sealant such as Loctite 577 or equivalent on 1/4NPT thread fittings. MAVIMARE...
- Page 18 Notice for salt water applications MAVIMARE strongly recommends use of a ground strap on any outboard hydraulic steering cylinder with an exposed shaft where the vessel will be used in salt water. This ground strap will provide added protection against corrosion caused by stray current.
- Page 19 Double cylinder MC 300BHD installation scheme Diagram A Diagram B MAVIMARE...
- Page 20 Do not block the threaded rod against the rod end terminal. The threaded rod should be able to rotate freely. Do not apply Loctite. Failing to observe this warning may result in damage of the tie bar while tilting one of the two enginess. mavi-mare MAVIMARE...
- Page 21 Do not block the threaded rod against the rod end terminal. The threaded rod should be able to rotate freely. Do not apply Loctite. Failing to observe this warning may result in damage of the tie bar while tilting one of the two engines. MAVIMARE...
- Page 22 Make sure that the motor can turn side to side without any interference. – Check that all mechanical parts of the cylinder are not in contact with the motor and are not forced in their movements. All the systems are not intended for racing boat application. MAVIMARE...
- Page 23 Notice for salt water applications MAVIMARE strongly recommends use of a ground strap on any outboard hydraulic steering cylinder with an exposed shaft where the vessel will be used in salt water. This ground strap will provide added protection against corrosion caused by stray current.
- Page 24 Do not block the threaded rod against the rod end terminal. The threaded rod should be able to rotate freely. Do not apply Loctite. Failing to observe this warning may result in damage of the tie bar while tilting one of the two engines. MAVIMARE...
- Page 25 Do not block the threaded rod against the rod end terminal. The threaded rod should be able to rotate freely. Do not apply Loctite. Failing to observe this warning may result in damage of the tie bar while tilting one of the two engines. MAVIMARE...
- Page 26 Typical lnboard Steering System MAVIMARE...
- Page 27 Move the tiller and check that the cylinder stroke is free. Check that ball joints are free. When linking two tillers by tie rod, the cylinder may be mounted on the tie rod or on each tiller. Protect cylinder shafts from nicks and scratches, which can cause cylinder to leak and result in loss of steering. MAVIMARE...
- Page 28 REMOVAL CYLINDER INSTRUCTIONS Attention: In case you want to remove the cylinder, rotate the nut (5) counterclockwise holding the cylinder pressed against the nut itself. Failure to observe this warning may result in the breaking of the nut itself. MAVIMARE...
- Page 29 Install code A.185 (2) if it’s not already installed on the boat. – Screw the cylinder (1) to the ball joint with adjustable flange (2) and connect the support rod (3) to the tiller arm All the systems are not intended for racing boat application. MAVIMARE...
- Page 30 Hydraulic hose installation MAVIMARE recommends the use of MAVIMARE steering hoses only. Always try to route the hoses via the shortest path in order to avoid any possible loss of power. In order to make the air bleed off the system more easily, it is suggested to mount the hoses horizontally with an inclination of about 3 cm per meter;...
- Page 31 Also make sure that the internal sheathing of the tubing is not squeezed while tightening the screw. 3 Check there is no internal interference putting a small screwdriver info the tube coupling before proceeding with hose installation to helm or cylinder. MAVIMARE...
- Page 32 MC300HD - MC350HD for MC150 / MC150E / MC150BE / MC150R / MC300R for CE30 / 50 / 75 / 100 for MC150BR - MC90B Hose connection (double cylinder) Upper helm station Compensating line helm station or autopilot MAVIMARE...
- Page 33 Connection scheme for double hydraulic cylinder code X.351 Connection scheme for double hydraulic cylinder code X.352 MAVIMARE...
- Page 34 Hydraulic Fluid Recommended oils for your steering system are: MAVIMARE HYDRALUIC FLUID SHELL TELLUS T15 (CL T15 HIV) Viscosity 15 cst Viscosity index Solidification point c° -38 Note: Automation transmission fluid Dexron II may be used in case of emergency.
- Page 35 Now check the steering system. Turn the wheel (any one multi-steering station) and pressurise very hard to port. Apply enough force to the wheel to exceed pressure relief valve pressure. While pressure is maintained on steering wheel, check all port (left) fittings and line connections for leaks. MAVIMARE...
- Page 36 Oil requirement: 4-5 bottles. CYLINDER NO.2 CYLINDER NO.1 Station no.1 TWIN STATION - TWIN CYLINDER Follow the same procedure as the one for single-station/twin Station no.2 cylinder, beginning from station no.1 and repeat entire procedure for station no.2. CYLINDER NO.2 CYLINDER NO.1 MAVIMARE...
- Page 37 Step no.4 Continue turning the steering wheel counter-clockwise until the Turn counter- clockwise cylinder rod is fully extended to the right. (Steering wheel will come to a stop) Open the right bleeder. Open right side bleeder MAVIMARE...
- Page 38 Oil requirement: 4-5 bottles. CYLINDER NO.2 CYLINDER NO.1 Station no.2 TWIN STATION - TWIN CYLINDER Station no.1 Follow the same procedure as the one for single-station/twin cylinder, beginning from station no.1 and repeat entire procedure for station no.2. CYLINDER NO.2 CYLINDER NO.1 MAVIMARE...
- Page 39 (collision, hammer-blows, etc.) – In double stations, the lower helm fill-vent plug must be replaced with a non-vent plug, which is included in a dual station fitting kit MRD4 Valve Outboard double Inboard double station scheme station scheme with MRD4 valve MAVIMARE...
- Page 40 Due to plumbing requirements, ”Liquid Tie Bar” systems should use 27cc helm pump (GM2-MRA01). Even though there are physically two cylinders in the system, the total volume of the system is that of one cylinder. Use of a 32cc (like GM2-MRA03) helm will result in heavier steering effort.
- Page 41 Open the valve. Continue to turn the wheel hard over to port: only cylinder A will move, reaching hard over. Close the valve. BALANCED CYLINDERS UNBALANCED CYLINDERS MBY4 Valve MBY4 Valve CYLINDER A CYLINDER B CYLINDER A CYLINDER B MAVIMARE...
- Page 42 This fault most often occurs when first installing and bleeding the unit, or after carrying out some other service work requiring re-bleeding of the system. The entry of such foreign materials is not covered by warranty, and good cleanliness would have avoided the problem. MAVIMARE...
- Page 43 (movable rod cylinders) or the body (fixed cylinder rod) Impurities into the valve. Contact Mavimare assistance of the cylinder do not move Service. A small amount of hydraulic drift when helm pump reaches its stop point (cylinder is full stroke out) is normal. The helm pumps are not 100% locking.
- Page 44 Warning: Following the routine maintenance schedules as outlined below, in the time frame noted will ensure years of service from your Mavimare Steering System, as well as keep you and your passengers safe from the dangers that are present on and off water.
- Page 45 MAVIMARE & MANCINI S.r.l. Bureau de vente Mavimare Via Manzoni, 26 20089 Rozzano (MI) - Italie Tel. +39.02.8259190 Fax +39.02.8241633 E.mail: info@mavimare.com Web: www.mavimare.com...
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