Uflex UC 69-I Manual

InstallationandMaintenanceManual
(Dr.No.31851/b29/05/2020)
HYDRAULICCYLINDERSFOR
INBOARDENGINES
UC69-I
UC116-I
UC168-I
UC215-I
UC293-I
PARTNER

DearCustomer,
Wewould liketothankyouforchoosingan ULTRAFLEX SpAproduct.
ULTRAFLEX SpAhas beenaleaderinsteeringsystemsforpleasureandprofessionalboatsformany
years.
All ULTRAFLEX SpAproductsaredesignedandmanufacturedtoensurethebestperformance.
To ensureyoursafetyandtomaintainahighqualitylevel, ULTRAFLEX SpAproductsareguaranteedonly
iftheyareusedwithoriginalspareparts(see attacheddocument"ApplicationSpareParts").
Thequalitymanagementsysteminvolvesallthecompanyresourcesandprocesses startingfromthe
design,inorderto:
- ensureproductqualitytothecustomer;
-maintainandimprovethequalitystandardsconstantly;
-pursueacontinuousprocess improvementtomeetthemarketneedsandtoincrease thecustomer
satisfaction;
-constantlytesttheproductstoverifytheirconformitywiththe2013/53/EU.
"Establishedin1989 UFLEX USAis aleaderinsteeringandcontrolsystemsforthemarineindustry.
Withfull manufacturingcapabilities inSarasota, Florida, UFLEX USAcansupportall sectorsofthemarine
industryregardlessofvolumeand/orproductrequirements.And,as anaffliateofthe ULTRAFLEX Group,
UFLEX USAhas tremendousresources todrawuponfornewproductdevelopmentinhydraulics, electronics
andmanyothertechnologies.
Innovativeproductdesignandunparalleleddedicationtoqualitycustomerserviceandproductsconti-
nuetobecornerstoneof UFLEX USA'sgrowth.Todayourproductscanbefoundasoriginallyinstalled
equipmentonmanyofthemostwidelyknownandrespectedboatbrandsintheworld.
AftermarketpartscanbesourcedfromtrainedandexperienceddistributornetworktroughoutNorth
andSouthAmerica.
Ourdedicationtoprovidingthehighestqualityproductsandserviceis onlymatchedbyourcommitment
todevelopingnewproductsemployingthelastestmaterialsandtechnologytoenhanceourcustomer's
boatingexperience. Fromsteeringwheelstosophisticatedelectroniccontrols, UFLEX USAhas everything
youneedtomakesurethatyourboatlooksandperformit's bestformany,manyyears."
UFLEXUSA
Sarasota,FL34243 -6442 ParklandDrive

HYDRAULICCYLINDERSFORINBOARDENGINES -page3 of23
InstallationandMaintenanceManual
SECTION1-PRODUCTDESCRIPTION
1.1 HYDRAULICSTEERINGSYSTEMOPERATION..................................................................................7
1.2 WARNINGSFORTHECORRECTPRODUCTUSE......................................................................7
1.3 CYLINDERDESCRIPTION..............................................................................................................8
1.4 TECHNICALFEATURES..........................................................................................................................8
1.5 CYLINDERCHOICE......................................................................................................................................9
TABLEOFCONTENTS
SECTION2-TRANSPORT
2.1 GENERALWARNINGS.............................................................................................................................10
2.2 PACKAGINGCONTENTS....................................................................................................................10
SECTION5-MAINTENANCE
5.1 ORDINARY MAINTENANCE.................................................................................................................21
5.2 TROUBLESHOOTING.........................................................................................................................21
SECTION3-INSTALLATION
3.1 NECESSARY TOOLS..................................................................................................................11
3.2 CYLINDERINSTALLATION.......................................................................................................................11
3,3 HOSEINSTALLATION...............................................................................................................13
3,4 TYPEOFINSTALLATION.........................................................................................................................14
3.5 FILLINGANDPURGING.......................................................................................................................16
3,5,1 SINGLESTEERINGSTATION/SINGLECYLINDER.......................................................................................17
3.5.2 DUALSTEERINGSTATION/SINGLECYLINDER.........................................................................................18
3,5,3 SINGLESTEERINGSTATION/DUALCYLINDER.......................................................................................18
3.5.4 DUALSTEERINGSTATION/DUALCYLINDER.........................................................................................19
3.6 GENERALRECOMMENDATIONS................................................................................................................19
SECTION4-SAFETYWARNINGS
4.1 SAFETYWARNINGSDURINGUSEANDINSTALLATION.......................................................................20
4.2 CLOTHING....................................................................................................................20
SECTION6-DISMANTLING
6.1 DISMANTLING........................................................................................................................23
!
MANUALUSEANDSYMBOLSUSED................................................................................................................4
INTRODUCTION.................................................................................................................................5
WARRANTY................................................................................................................................5

InstallationandMaintenanceManual
page4 of23-HYDRAULICCYLINDERSFORINBOARD ENGINES
Inthis manualthefollowingsymbolsareusedtoensuretheusersafetyandtoguarantee thecorrect
operationoftheproduct:
MANUALUSEANDSYMBOLSUSED
THEINSTALLATIONANDMAINTENANCE MANUALis thedocumentaccompanyingtheproductfromitssale
toitsreplacementanddischarge.Themanualis animportantpartoftheproductitself.
It is necessarytoreadcarefullythemanual,beforeANYACTIVITY involvingtheproduct,handlingand
unloadingincluded.
STERN
BOW
STARBOARD PORT Thepictureasideexplainsthemeaningofsome
nauticalwordscontainedinthismanual.
DANGER ImmediatehazardswhichCAUSEseverepersonalinjuryordeath.
WARNING
CAUTION
Thesymbolasideindicates all theoperationswhichmustbecarriedout
byqualifiedorskilledstaff,inordertoavoidhazards.
Werecommendtrainingthestaff inchargeoftheproductinstallation
andcheckingtheirknowledge.
NOTICE Importantinformationforthecorrectinstallationandformaintenance,that
doesnotcauseanydamage.
Denotes thatahazard existswhichcanresult ininjuryordeathifproper
precautionsarenottaken.
Denotes areminderofsafetypracticesordirectsattentiontounsafe
practices whichcould result inpersonalinjuryordamagetothecraft or
componentsortotheenvironment.
LEGEND
m.p.h.=milesperhour
km/h=kilometresper
hour
10 m.p.h.=8,69 knots
10 m.p.h.=16,1km/h
10 knots =11,5m.p.h.
10 knots =18,5km/h
10 km/h=6,21 m.p.h.
10 km/h=5,4knots

HYDRAULICCYLINDERSFORINBOARDENGINES -page5 of23
InstallationandMaintenanceManual
TECHNICALASSISTANCE SERVICE
INTRODUCTION
UFLEX S.r.l.
ViaMiliteIgnoto,8A
16012 Busalla(GE)-Italy
Ph.: +39.010.962.0239 (Italy)
Ph.:+39.010.962.0244 (abroad)
Fax: [phone]
Email: [e-mail]
www.uflexgroup.it
North-South-CentralAmerica:
UFLEX USA
6442 ParklandDrive
Sarasota, FL34243
Ph.:+1.941.351.2628
Fax: [phone]
Email: [e-mail]
www.uflexusa.com
This installationandmaintenancemanualrepresentsanimportantpartoftheproductandmustbeavailable
tothepeopleinchargeofitsuse andmaintenance.
Theusermustknowthecontentofthis manual.
UFLEX USAdeclines all responsibilityforpossiblemistakes inthis manualduetoprintingerrors.
Apartfromtheessentialfeaturesofthedescribedproduct, UFLEX USAreserves therighttomakethose
modifications, suchas descriptions, detailsandillustrations, thatareconsideredtobesuitableforits
improvement,orfordesignorsales requirements, atanymomentandwithoutbeingobligedtoupdatethis
publication.
ALLRIGHTSARERESERVED.Publishingrights,trademarks, partnumbersandphotographsof UFLEX USA
productscontainedinthismanualare UFLEX USAproperty.
Greatcarehas beentakenincollectingandcheckingthedocumentationcontainedinthismanualto
makeitas completeandcomprehensibleas possible. Nothingcontainedinthis manualcanbeinterpreted
as warrantyeitherexpressedorimplied-including,notinarestrictedway,thesuitabilitywarrantyforany
specialpurpose. Nothingcontainedinthis manualcanbeinterpretedas amodificationorconfirmationof
thetermsofanypurchase contract.
Toensurethecorrectproductandcomponentoperation,theproductmustbeinstalledbyqualifiedstaff.
Incaseofpartdamageormalfunction,please contactthequalifiedstafforourTechnicalAssistance
Service.
WARNING
WARRANTY
1. TwoYearLimitedWarranty. UFLEX USA, Inc.warrantsthatallproductsmanufacturedby UFLEX USA,
Inc.or ULTRAFLEX S.p.A. andsold by UFLEX USAtotheretailpurchaser("Purchaser")thatfortwo(2)years
afterthedateofmanufacturetobefree fromdefectsduetomaterialorworkmanship,subjecttothe
exclusionsbelow.ImproperinstallationAVOIDSthis warranty.Installationshould onlybeattempetedby
atrainedandqualifiedtechnician.
2.Exclusions. Thislimitedwarrantydoesnotcoveranddoesnotextendtoanyofthefollowing:
(a) Failurecausedbynormalwearandtear,climaticconditions,misure,neglect,lackofproper
maintenance,accident,fireorothercasualtydamage,racing,overloading,negligence,modification,
beachingorgroundingofvessel,collision,impact,towing,actsofwarorhostilities;
(b) componentsnotmanufacturedby UFLEX USA, Inc., oritsaffiliates;
(c) costofremovalorreinstallationofanycomponent(includingcomponentsmanufacturedby UFLEX
USA,Inc.)ordisassemblyorreassemblyoftheunitcontainingthecomponent;
(d) componentsnotmanufacturedby UFLEX USA, Inc.or ULTRAFLEX S.p.A.,whetherornotwarrantedby
theothermanufacturer;
(e) anyproductwhichhasnotbeenproperlyinstalled.

InstallationandMaintenanceManual
page6 of23-HYDRAULICCYLINDERSFORINBOARD ENGINES
3. Limitations. THEREPAIROR REPLACEMENTOFDEFECTIVE PARTSSHALL BEPURCHASER'SSOLE AND
EXCLUSIVE REMEDY AND UFLEX USA, INC,'SSOLE ANDEXCLUSIVE LIABILITY UNDERTHISWARRANTY.
LABOR FOR REPLACEMENTISNOT INCLUDED. UFLEX USA, Inc.'s obligationunderthis warrantyis limited
totherepairorreplacement(at UFLEX USA, Inc.'s soleelection)ofanycovereditemfoundtobedefective,
whendeliveredbyPurchaserpursuanttowrittenauthorizationandinstructionsfrom UFLEX USA, Inc.,
shippingprepaidto UFLEX USA,Inc.'splantorotherdesignatedrepairfacility.Repairedorreplaced
itemsarewarrantedasprovidedhereinfortheunexpiredportionoftheapplicablewarrantyperiod.
THISWARRANTY, ANDTHERIGHTSANDREMEDIESUNDERIT, ISEXCLUSIVE ANDISGIVENINPLACE OF
ALL OTHERWARRANTIES,WHETHEREXPRESS OR IMPLIED, INCLUDINGANYIMPLIEDWARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE,WHETHERARISINGBY LAW,CUSTOM,
CONDUCTOR USAGEOFTRADE,PURCHASER'SREMEDIESSHALL BELIMITEDASSTATEDHEREINAND
UFLEX USA, INC.SHALL NOT BELIABLE FOR ANYINCIDENTAL,CONSEQUENTIALOR INDIRECTDAMAGES
OR LOSSESRESULTINGFROMDEFECTS.THERETAILSELLERISNOT ACO-WARRANTOR ANDISNOT
AUTHORIZEDBY UFLEX USA, INC.TO AMENDOR MODIFYTHISLIMITEDWARRANTY INANYMANNER.
4.TransferabilityofWarranty. Thislimitedwarrantymaynotbetransferredtosubsequentpurchasers.
5.Miscellaneous. UFLEX USA,Inc.isanaffiliateof ULTRAFLEX S.p.A. UFLEX,USA,Inc., reservestherightto
makechanges inthedesignandconstructionofitsproductsatanytime, withoutnoticeandwithoutany
obligationtoincorporatesuchchanges intoproductsofpriormanufacture. This limitedwarrantyapplies
tonewcomponentssold by UFLEX USA, Inc.. This limitedwarrantycontainstheentireagreementsbetween
UFLEX USA,Inc.andPurchaserandsuspersedesallprioragreements,discussions,negotiations,
commitmentsandrepresentations, whetheroralorwritten,betweenthemregarding UFLEX USA,Inc's
warranty.If anyprovisionofthis limitedwarranty,ortheapplicationofit,is determinedtobeinvalidof
unenforceableforanyreason,theremainderofthis limitedwarrantyandtheapplicationofitshall not
beaffected.
6.Ultron3000andPowerC. TheUltron3000and"PowerC-UserandInstallationManual"describes
activities,operations,technicalspecificationswhichmustbefollowedduringtheinstallationand/or
usageoftheproduct,inordertokeepavalidwarranty.Descriptionsanddrawingsinthatmanualare
suitabletoallowinstallationanduse oftheproducttoskilledpersons. Incase ofdoubtand/orforany
information,pleasecontactourTechnicalService.
AllcommunicationsandnoticesfromPurchaserregardingthislimitedwarrantyshouldbesentto: UFLEX
USA, INC., 6442 ParklandDrive, Sarasota, FL34243; [phone].
Returnpolicy
Anyproductthatis presumeddefectiveshould bereportedto UFLEX USAwithin48hoursofreceiptor
discoveryinthefield.Uponnotification UFLEX USAwill attempttotroubleshoottheproblemwithourcustomer
overthephone. If weareunabletoresolvetheproblem UFLEX willissueaReturnGoodsAuthorization
numberandwerequirethattheproductinquestionbereturnedto UFLEX withallitspartsinitsoriginal
packaging.Theproductshouldbereturnedfreightprepaidto:
UFLEXUSA
RGA Department-RGA #
6442 ParklandDrive
Sarasota,Florida34243
Uponreceipt UFLEX will examinetheproducttodeterminethecause ofthedefect.If theproductis determined
tohaveadefectinworkmanshipormaterial,itwill berepairedatourdiscretion.
Ourwarrantydoes notcoverlabor,towingorotherexpenses. Further,itdoes notcoverproductsthathave
beenimproperlyinstalled,damagedininstallation,misapplied,ormisused.
Ourproductsarenotintendedforuseinracingapplications.

HYDRAULICCYLINDERSFORINBOARDENGINES -page7 of23
InstallationandMaintenanceManual
NOTICE
Dualengineinstallationsrequiretheuse ofatie bar.
Dualstationinstallationsrequiretheuse of2helmswithnon-returnvalve.
UC69-I,UC116-I,UC168-I,UC215-IandUC293-Icylindersmustnotbeinstalledonraceboats.
CylinderUC69-Icanbeinstalledoninboardengines upto150 hpandonlywithsinglecylinderandsinglehelm.
All ULTRAFLEX steeringsystemsmustnotbeinstalledonboatsequippedwithengines whosemaximum
horsepowerishigherthanthehorsepowerratingapprovedbyboatmanufacturer.
1.2Warningsfortheproductcorrectuse
Donotmodifythesteeringcylinderinanywaytofitittoyourapplication,otherwise thecylinderwillno
longeroperateinsafetyanditwill endangertheboatandtheoccupants.
WARNING
WARNING
WARNING
DANGER
1PRODUCTDESCRIPTION
1.1Hydraulicsteeringsystemoperation
All UFLEX hydraulicsteeringsystemsaredesignedinconformitywithUNI-EN-ISO10592andA.B.Y.C.P21
regulations.AllUFLEX steeringsystemscanoperateattemperaturesbetween-18°C(0°F)and+77°C(+170°F).
Allthecomponentsaremadeforthemarineenvironment,usingmaterialsandworkingprocesses which
offerlonglifeandsafetyunderthemostextremeconditions.Ahydraulicsteeringsystemconsistsofasteering
pump,acylindertiedtotherudderortotheoutboardorsterndriveengine
andtheconnectinghoses(seepicture).Undernormaloperatingconditions,
aturnofthesteeringwheelwillpumptheoil,whichflowsinthroughthe
hosestothecylinder,accordingtotheturndirection.Withtheconsequent
cylindermovementtheoilwillflowtothepumpthroughthehosesandat
thesametimemovestheengineorthehelmwhichareconnectedtothe
cylinder.Thepumpsequippedwithavalvewhichpreventsoutgoingfluid
fromreturningalongthesamehose, allowtheoperationofthesteering
systemswithtwoormoresteeringstations.Thecylindersaredoubleacting
andmaybebalancedorunbalanced.Intheunbalancedcylindersthetwo
chambershavedifferentvolumesandsotheyneedadifferentnumberof
turnsofthesteeringwheelandadifferentrotationeffort.Thebalanced
cylindershavesamenumberofsteeringwheelturnsinordertomovethe
helmfromthecentertotheendstrokeinthetwooppositedirections. A
wellbalancedsteeringsystemneedsacorrectchoiceofthepumpforthe
cylinder. UFLEX producesdifferentpumpmodels, whichhavedifferent
capacity(cm3ofoilmovedeachsteeringwheelturn)andforeachtypeofinstallation.Whilechoosingthe
pumpitisimportanttoconsiderthecylindervolume.Thenumberofstarboard andportturnsisdetermined
bytheratio betweenthecylindervolumeandthepumpcapacity.
Example:ifthepumphas acapacityof28 cm3 [1,7cu.in.]andthecylinderhas avolumeof120 cm3 [7,3cu.in.],
theformulalookslikethis:120/28=4,2.Accordingly,thesteeringwheelwillturn4,2 times beforethe
cylinderwill completelyturnfromonesidetotheother.Incase ofinstallationswithdoublecylinders
connectedinparallelthecylindervolumemustbeadded.Applicationswithless than4turnsarenot
recommended,as theyneeda highereffort,applicationswithmorethan8turnsarealso notrecommended,
as theresponse oftheboattosteeris slowly.
pump
l
l
hydraulichose
l
cylinder
helm
l
Themaximumsystemtorquemustbecalculatedbytheuseraccordingtothetypeofapplicationused,the
helmnumberandfeatures, theboatspeed,thetypeofboat,etc.
NOTICE
All inboard cylinderscanuse standard KITOBonlyifusedwith UFLEX UPSeries hydraulicpumpswhose pressure
reliefvalve(maxpressure)issetat70bar(1000PSI)whiletheymustuse KITOBSVSifusedwithSVSSeries
pumpsorMasterDrivesystems.
WARNING

InstallationandMaintenanceManual
page8 of23-HYDRAULICCYLINDERSFORINBOARD ENGINES
1.3Cylinderdescription
Thehydrauliccylindersforinboard engineUC69-I,UC116-I,UC168-I,UC215-IandUC293-Imodelshave
beendesignedandmanufacturedtobeusedas acomponentinthehydraulicsteeringsystems, as described
inthepreviousparagraph.
Thecylinderwithmobilerodis installeddirectlytothearmofthehelmthroughtheproperball jointonthe
endpartofthecylinder.Ontheoppositesideitis fixeddirectlytotheboatthroughasupportwithplate(see
par.3.2).Forthedualhelmapplication,thesinglecylindermustbemountedwithatie bar.Thefollowing
pictureshowsthemaincylindercomponents:
1.4Technicalfeatures
Cylinderbody
Hoseandpurgeconnections
Balljoint
Supportwithmountingbracket
Rod
1
2
3
4
2
1
4
3
5
5
A
CB
D
E
*Thecylinderthrustindicatedis theoreticalcalculatedwithasystempressureas showninthetable. This
thrustdoesnotcorrespondtotheonegenerallyusedbythesystembutitrepresentsthelimitconditionofuse.
WARNING
SPECIFICATIONS UC69-I UC 116-I UC 168-I UC215-I UC 293-I
A 644 mm[25.33"] 741 mm [22.17"] 792 mm [31.18"] 941 mm[37.05"] 794mm [31.26"]
B 494 mm[19.43"] 563 mm [29.17"] 614 mm [24.17"] 713 mm[28.07"] 616mm [24.25"]
C(stroke) 150 mm[5.9"] 178 mm[7"] 178mm [7"] 228 mm[8.98"] 178 mm 7"]
D 40 mm[1.57"] 40 mm [1.57"] 40 mm[1.57"] 40 mm[1.57"] 40mm [1.57"]
E 73 mm[2.87"] 73 mm [2.87"] 105 mm[4.13"] 105 mm[4.13"] 125 mm [4.92"]
Volume 69 cc -4.2cu.in 116 cc -7cu.in 168 cc -10.25 cu.in 215 cc -13.12 cu. in 293cc-17.8cu. in
Maximumthrust* 3233 N-330 kg-
727 lbs@70 bar
6828 N-696 kg-
1534 lbs@ 105 bar
9895 N-1009 kg-
2224 lbs@ 105 bar
9895 N-1009 kg-
2224 lbs@ 105 bar
17317 N-1765 kg-
3892 lbs@ 105 bar
Bore 25 mm[0.98"] 32 mm [1.25"] 40 mm[1.57"] 40 mm[1.57"] 50mm [1.97"]
Oil OIL15 OIL15 OIL15 OIL15 OIL15

HYDRAULICCYLINDERSFORINBOARDENGINES -page9 of23
InstallationandMaintenanceManual
B
B
A
C
1.5Cylinderchoice
Thisparagraphshowssomeexamplesofapplicationforthecorrectchoiceofthecylinderandofitsarm
(A).Thetablebelowshowsthearmsforeachcylinderwithfourdifferentsizes(twoininches andtwoin
millimetres)toapproachas muchas possiblethedesiredconfiguration.Thenecessarytorquecanbe
definedaccordingtothesteeringhalf angle(B).Thedatagivenareonlyexemplifyingandso theyarenot
binding.
Themaximumtorqueis notthenormallyusedtorquebutitis themaximumtorqueallowedcalculatedwithamaximum
thrust,showninthetableonthenextpage, appliedtothecorrespondinghelmarm.
WARNING
Makesurethatthecylinderandnotthehelmreaches theendofstroke.
DANGER
A
B
C
Helmarm Steeringhalf
angle
Installationheight
attheendof
stroke
150mm 30° 130 mm [5.12"] 420 Nm 210 Nm
6" 30° 133 mm [5.22"] 429 Nm 215 Nm
130mm 35° 106 mm [4.18"] 343 Nm 172 Nm
5" 36° 102 mm [4.03"] 331 Nm 166 Nm
180mm 30° 156 mm [6.14"] 1068 Nm 356 Nm
7" 30° 154 mm [6.06"] 1053 Nm 351 Nm
150mm 36° 121 mm [4.76"] 825 Nm 275 Nm
6" 36° 124 mm [4.87"] 844 Nm 282 Nm
180mm 30° 156 mm [6.14"] 1546 Nm 516 Nm
7" 30° 154 mm [6.06"] 1524 Nm 508 Nm
150mm 36° 121 mm [4.76"] 1194 Nm 398 Nm
6" 36° 124 mm [4.87"] 1221 Nm 407 Nm
230mm 30° 200 mm [7.87"] 1977 Nm 659 Nm
9" 30° 198 mm [7.80"] 1962 Nm 654 Nm
200mm 35° 164 mm [6.46"] 1626 Nm 542 Nm
8" 34° 168 mm [6.61"] 1665 Nm 555 Nm
180mm 30° 156 mm [6.14"] 2709 Nm 903 Nm
7" 30° 154 mm [6.06"] 2668 Nm 890 Nm
150mm 36° 121 mm [4.76"] 2089 Nm 697 Nm
6" 36° 123 mm [4.84"] 2136 Nm 712 Nm
Maximumtorque*
Maximumtorque
normallyusedto
choosethe
cylinder**
** The maxiumtorque usuallyusedisthe maximumtorque that isnot generallyexceeded at cruisingspeed.
UC293-I
*concerning themaximumhelmngleposition allowableand withreferencetothearmchosen.
UC69-I
UC116-I
UC168-I
UC215-I

InstallationandMaintenanceManual
page10 of23-HYDRAULICCYLINDERSFORINBOARD ENGINES
2.1Generalwarnings
2TRANSPORT
Theproductweightwithitspackagingis about9kg(19 pounds)andso itcanbehandledmanually.
2.2Packagingcontents
Beforeusingtheequipmentcheckthattheproducthasnotbeendamagedduringtransport.
Also makesurethatallthestandardcomponentsareinthepackaging(see list).Incase ofdamage,
notifytheclaimtotheforwarderandinformthesupplier.
WARNING
Thestaff inchargeofhandlingmustoperatewithprotectivegloves andsafetyshoes.
The packagingmustbe disposed ofaccording to theexisting laws.
CAUTION
A
A)Cylinder
B)No.1plasticpipeforthehydrauliccircuitpurge
B

HYDRAULICCYLINDERSFORINBOARDENGINES -page11 of23
InstallationandMaintenanceManual
3.2Cylinderinstallation
WARNING
Alongerarmreducesthesteeringangle.
If thearmis notalreadymounted,see themountinginstructionsofthearmmanufacturer.
DANGER
Anarmshorterthantheoneindicatedcould movethehelminsteadofthecylinderuptotheendstrokeby
causingthebreakingofthesteeringguideandthefollowinglossofboatcontrol.
NOTICE
3INSTALLATION
3.1Necessary tools
To choose thearmaccordingtothetypeofapplicationusedseeparagraph1.6.
NOTICE
Torque
wrench
Openend
wrench
10 mm
Openend
wrench
13 mm
Openend
wrench
17 mm
Openend
wrench
22 mm
Openend
wrench
3/4"
Openend
wrench
15/16"
1Checkifthearm(1)andthehelmblade(2)arealigned,thencenter
themtothelongitudinalaxis"y".
1
l
l
2
y
2Startassemblingbyfollowingtheinstructionsinchapters
h1.4and1.5.
If necessaryscrewandunscrewtheswivelheadaccordingtothe
instructionsgivenintableonthenextpage.

InstallationandMaintenanceManual
page12 of23-HYDRAULICCYLINDERSFORINBOARD ENGINES
l
3
2
l
4
l
5
6l
l
3Checkifthe"z"axis ofthebracket(1)is
perpendiculartothe"x"axis ofthecylinder.Fix
thebracket(1)onapropersupportusingthrough
boltingM6(UC69-I) orM8(UC116-I,168-I,215-I,
293-I) (screwsandnutsnotsupplied)madeof
stainless steelofclassA2-70 (ISO3506-1)ora
higheroneandfastenthembymeansofstainless
steelself-lockingnutswiththesamemechanical
andcorrosionresistanceandthecorresponding
washerswithatighteningtorqueof10 Nmusing
a10 mm wrench(forbolt andnutM6UC69-I) or
of25 Nmwitha13 mm wrench(forbolt andnut
M8UC116-I,168-I,215-I,293-I).
NOTICE
Theoilfittingsmustbealwaysinhighposition.
4Connectthejoint(3)tothearm(2)keepingintoaccounttheholediameter:thearmmustbeunder
thejoint;(followtheinstructionsofthearmmanufacturer).
1
x
z
D*
l
E*
*see tableinpar.1.4
NOTICE
Thebolt (6)mustbemadeofmaterialsuitablefortheresistancetothesalinemistandforthemaximum
thrustindicatedinthetableofparagraph1.4; thesafetywasher(5)mustcomplywiththedimensionsas
prescribedbystandardABYCP21.
Connectiontothemotor
armasprescribedby
standard ABYCP21.
Bolts
Minimumclass
UC69-I
M6 A2-70
UC116-I
M8 A2-70
UC168-I
M8 A2-70
UC215-I
M8 A2-70
UC293-I
M8 A2-70

HYDRAULICCYLINDERSFORINBOARDENGINES -page13 of23
InstallationandMaintenanceManual
3.3Hoseinstallation
Thetwofittingsmountedonthecylinderbodyarealreadyorientedandarereadytobeused.
DANGER
Thefittingsmountedonthecylindercannotbeoriented.If theyare
unscrewed,theycould bebrokenandthecylinderis nomoreusable.
Checkifthecylinderinthetwo"A"and"B"
endstrokepositionsis alignedinhorizontal
position(paralleltothetransom).Movethe
helmforward andbackward inordertocheck
thefree movementofthecylinderandifthese
positionsareperfectlysymmetricaltothe"y"
axis.Be surethemovementoftheball joints
isnothindered.
DANGER
CAUTION
x
AB
y
= =
Checkifthecylinderandnotthehelmmoves uptotheendstroke.
Minimum radius250 mm
Afterinstallingthecylinderafineadjustmentcanbecarriedoutby
modifyingtheballjointposition.
DANGER
Theball joint(3)mustbelockedbymeansofthe
safetylocknut(4)accordingtotheinstructionsinthe
table.
CAUTION
Fineadjustmentmustnotexceedthevalue(A)
indicatedinthetable.
l
3
l
4
A
Maximumadjustment
spaceallowed(A)
Tighteningtorqueof
thesafetylocknut(4)
Wrenchtotightenthe
safetylocknut(4)
Wrenchtotighten the
balljoint(3)
Balljointholediameter
(3)
140 Nm 15/16" 22 mm 5/8"
22 mm 5/8"
140 Nm 15/16" 22 mm 5/8"
17 mm 10 mm
85 Nm 3/4" 3/4" 1/2"
50 Nm 17 mm
140 Nm 15/16"
UC168-I 19 mm [3/4"]
UC69-I 19 mm [3/4"]
UC116-I 22 mm [7/8"]
UC293-I 19 mm [3/4"]
UC215-I 19 mm [3/4"]

InstallationandMaintenanceManual
page14 of23-HYDRAULICCYLINDERSFORINBOARD ENGINES
SINGLE STATION/SINGLE CYLINDER
WITHDUALHELM:
TheUC69-I(onlysinglestationandsinglehelm),UC116-I, UC168-I,UC215-IandUC293-Ihydrauliccylindersforinboard engines
canbeinstalledwithdifferentconfigurationsaccordingtothenumberandthetypeofengines usedwithasingleordualsteering
system.Thepossibleconfigurationsare:
1. steeringstation
2. cylinder
3. Tfittingswithbleedvalves
4.KitOB
SINGLE STATION/SINGLE CYLINDER:
3.4Typeofinstallation
WARNING
Connecthoses as showninthefollowingpictures:
NOTICE
Withreferencetotheboat,thehosewhichisconnectedtotheportside(P)ofthepumpmustbealways
connectedtothefittingofthesideport(P),whilethehose whichis connectedtothestarboard side(S)ofthe
pumpmustbeconnectedtothefittingofthestarboard side(S),
2
l
1l
l
l
3
S
S
P
P
1
l
2
l
3
5
l
P
P
S
S
l
l
UFLEX
PUMP
1. steeringstation
2. cylinder
3. Tfittingswithbleedvalves
4.KitOB
5. tiebar
4
l
4l
l
l
CAUTION
Anexcessivehose bendcouldresult initsinternalbreakingwhich
will cause abadoperationofthesystem.Inthis case itis necessaryto
replacethedamagedhose.
ITheinstallationofthetubes (cutting,bendingandrouting)mustbe
carriedoutbyspecializedstaffbyfollowingtheinstructionsofthe
manufacturer.
Connectthehoses(1)notsuppliedtothecylinderconnections(2)
withatorqueof20[Nm](15[lbft]).accordingtothefollowing
instructions:
-minimumhose bendradius250mm;
-nointerferencewiththetransom;
NO
1
2
NOTICE

HYDRAULICCYLINDERSFORINBOARDENGINES -page15 of23
InstallationandMaintenanceManual
SINGLE STATION/DUALCYLINDER: DUALSTATION/DUALCYLINDER:
1.steeringstation
2.Tfittings
3.Tfittingswith
bleedvalves
1
2
1
l
l
l
3
2
l
l
l
l
l
l
l
l
3
l
5
4
l
l
l
l
5
6
1. mainsteering
station
2. additionalsteering
station
3.Tfittings
6
4.tie bar
5. kitOB-2S
6.kitOB
6
ll
4. Tfittingswithbleed
valves
5.tiebar
6.kitOB-2S
7.kitOB
l
l
7
l
l
34
4
S
P
S
P
SP
DUALSTATION/SINGLE CYLINDER
WITHDUALHELM:
DUALSTATION/SINGLE CYLINDER:
1
2
3
4
l
l
l
l
l
6
l
S
S
S
P
P
P
1
2
l
l
l
l
7
l
4
l
l
6
3
SP
S
S
P
P
l
l
l
4. Tfittingswithbleed
valves
5.KitOB
6.KitOB-2S
1. mainsteering
station
2. additional
steeringstation
3. cylinder
4. Tfittingswithbleed
valves
5.KitOB
6.KitOB-2S
7. tiebar
l
l5
5
l
l
l
l
l
66
1. mainsteering
station
2. additional
steeringstation
3. cylinder

InstallationandMaintenanceManual
page16 of23-HYDRAULICCYLINDERSFORINBOARD ENGINES
3.5Fillingandpurging
Afterthefirstinstallationandaftermaintenanceoperationsitis necessarytofill thesystemwithhydraulic
oil.Thisoperationmustavoidtheairinthesystem,toensurethegoodsystemoperation.Thehydraulic
systemmustbefilledfromthehighestpointofthesystem,whichmeansfromtheuppersteeringstation.
CAUTION
WARNING
To avoidairbubblesintheoil,itis necessarytofillthetankslowly.
Thefillingandbleedingoperationsmustbecarriedoutatleastbytwooperators
DANGER
Use UFLEX oilorothercompatibleoils.
NOTICE
ThefillingandpurgingoperationscanbefacilitatedbyusingtheautomaticpurgingequipmentBUBBLE
BLUSTERâ (suppliedseparately).
HydraulicoilOIL15has beenspecificallyformulatedfor UFLEX toensurehighqualityperformancelevelof
UFLEX productsthroughouttime.
Thespecialmix ofanti-wearandstabilizingcomponentsofOIL15 allowensuringgreatresultsas faras the
productdurationandperformances areconcernedinseveralenvironmentalconditions. UFLEX isnottobe
held responsibleforanydamagesorperformancedeteriorationifoilsdifferentfromOIL15areused.
Do NOT use ATFDexronII transmissionoilsorbrakeoilswhichcould cause thesteeringsystemseizing.
OilswhicharecompatiblewithOIL15 UFLEX are:
-Shell TellusT15 andShell TellusT22
-MobilDTE11M
DANGER
UFLEX will notbeabletoensurethecompatibilityoftheabovementionedoilswithOIL15 iftheoil
manufacturersvarytheirformulation.Undernocircumstances UFLEX is tobeheldresponsibleforany
damages orperformancedeterioration.
Inthedaysafterthefilling,checktheoillevel;ifnecessarytopoff thesystem.
Atthebeginningtheoillevelcanlower,assmallamountsofaircanbereleasedinahomogeneousway.
Accordingtothetypesofinstallation,itisnecessarytocarryoutthedifferentbleedingprocedures,asit
follows.
NOTICE

HYDRAULICCYLINDERSFORINBOARDENGINES -page17 of23
InstallationandMaintenanceManual
3.5.1Singlesteeringstation/singlecylinder
1
NOTA
3
4
2
-Unscrewthetwobleedvalvesandmanuallypushthecylinderbodyto
onesideuntilitstopsas showninpicture1.
-Positiontheoilbottleas explainedinthepicture.
-Close thebleedvalveonthecylinderendstrokesideandputapurged
oiltankneartheotherbleedvalve(as showninpicture2).
-Turnthesteeringwheelslowly(as showninpicture2)so thattheoilcan
comeoutofhoses,
-Whentheoilcomes outofthebleedvalve(withoutairbubbles),close the
bleedvalveandcontinuetoturnthesteeringwheelinthesamedirection
tofill thecylinderchamber(picture3).
Duringthis phase thecylinderbodywill movetotheoppositedirectionup
totheendstroke.
NOTICE
Hold thecylinderbodywiththehandtopreventmovementscausedbythe
airpresentinthecylinderchamber(picture2).
-Opentheotherbleedvalveandmovepurgedoiltanktotheotherside.
Holdingthecylinderbodyinthis position,turnthesteeringwheelas
showninpicture4,untiloilwithoutairbubbles comes outofthebleed
valve.
Thenclosethebleedvalve.
-Repeattheentireproceduretoensuretheabsenceofairinthesystem.

InstallationandMaintenanceManual
page18 of23-HYDRAULICCYLINDERSFORINBOARD ENGINES
3.5.2Dualsteeringstation/singlecylinder
-Repeattheprocedureatleast3times toensuretheabsenceofairinthesystem.
WARNING
WARNING
Forthe(lower)additionalsteeringstationtankuse onlythenon-ventplug.Forthe(upper)mainsteering
stationtankuse onlytheventplug.
-Manuallyunscrewthetwobleedvalves
on thecylinder"T"fittingsandpushthe
cylinderuptotheendofstroke.
-Positiontheoilbottlenearthe(upper)
mainsteering stationaccordingto
whatispreviouslydescribed.
Waituntiltheoilreaches thelowertankand
bothtanksarefilled.
-Followthesamebleedingprocedure
describedinparagraph3.5.1 starting
fromthelowerstationandrepeatitfor
theupperstation.
bleed
valves
vent plug
non-vent plug
l
l
l
l
3.5.3Singlesteeringstation/dualcylinder
-Manuallyunscrewthetwobleedvalves on
thecylinder"T"fittingsandpushthe
cylinderstoonesideuptotheendof
stroke.
-Positiontheoilbottleasdescribedin
paragraph3.5.1.
-Followthesamebleedingprocedure
describedforthesinglesteeringstation/
singlecylinder(paragraph3.5.1).While
turningthesteeringwheelbecareful
becausebothcylindersmove.
-Repeattheentireprocedureseveraltimes
toensuretheairabsenceinthesystem.
l
l
bleed
valves

HYDRAULICCYLINDERSFORINBOARDENGINES -page19 of23
InstallationandMaintenanceManual
3.6Generalrecommendation
It is veryimportanttochecktheabsenceofairinthesystembeforeusingtheboat! Werecommendtrying
tomanuallymovetheenginetowardsportandstarboard,makingsurethatthereisnomovementofthe
cylinderbodyonthemaincylindershaft.
If thecylinderbodymoves morethan1/6inches (15mm),thereis still airinthesystem.Theairpresencein
thesystemcancause badresponsestothecontrolsandso itcancause damage, injuries ordeath.
WARNING
3.5.4Dualsteeringstation/dualcylinder
-Manuallyunscrewthetwobleedvalves
onthecylinder"T"fittingsandpushthe
cylinderstoonesideuptotheendof
stroke.
-Positiontheoilbottlenearthemain
steeringstation(upper)accordingtowhat
isdescribedinparagraph3.5.1.
Waituntiltheoilreaches thelowertankand
bothtanksarefilled.
-Followthesamepurgingprocedure
describedinparagraph3.5.1
starting fromthelowerstation
andrepeatitfortheupper
station.
WARNING
Fortheadditionalsteeringstation(lower)
tankuse onlythenon-ventplug. Forthemain
steeringstation(upper)tankuse onlytheventplug.
-Repeattheentireprocedureatleast4times toensuretheabsenceofairinthesystem.
l
l
l
l
bleed
valves
vent plug
non-vent plug
WARNING

InstallationandMaintenanceManual
page20 of23-HYDRAULICCYLINDERSFORINBOARD ENGINES !
ATTENZIONE
4SAFETYWARNINGS
Thissectionshowsthesafetyruleswhichmustbefollowedforthecorrectequipmentoperation.
Werecommendreadingcarefullythis sectionandalso theothermanualssuppliedwiththesteeringsystem
components.
4.1Safetywarningsduringuseandinstallation
RESPECTSTRICTLYthefollowingsafetyrules:
UFLEX declinesall responsibilityincase theuserdoesnotfollowtheserulesanditis notresponsiblefor
negligenceduringtheuse ofthesystem.
-DO NOT PUT HANDSBETWEENTHEMOVINGPARTS.
-Do notdisablethesafetydevices.
-Do notmodifyoradddevices tothesystem,without UFLEX writtenauthorisationortechnical
interventionwhichwillprovethemodification.
-Do notuse theequipmentforapurpose differentfromtheoneithas beendesignedfor,whichis
specifiedintheinstallationandmaintenancemanual.
-Do notletnon-specializedstaff performtheinstallation.
-Donotdisassemblethehydraulicconnectionsbeforebleedingtheoilinthesystemcompletely.
Thehoses cancontainhighpressureoil.
DANGER
WARNING
Duringinstallation,inspectionormaintenance,
ITISSTRICTLYFORBIDDENtowearnecklaces,braceletsorclotheswhichcould getcaughtinthemoving
parts.
4.2Clothing
WARNING
-Do notputthefeetonthecylinder.
-Checkthesystemaftertheinstallationandthepurgingbutbeforeoperatingthevessel.Turnthe
steeringwheeluntilthecylinder/sreaches/reachtheendstroke.
Turnthesteeringwheeltotheoppositedirection.Repeatoneachinstalledhelmtoverifythe
correctinstallationandthesystemoperation.
-Carefullyuse sealingfluid(suchas Loctite).If itreaches thehydraulicsystem,itmaycause
damageandmechanicalfailure.
-Do notuseteflontapeoradhesivetapetosealthefittings, asthismaterialmaybeinjested,by
causingthesystemfail.
-Duringthesysteminstallation,preventforeignmattersfromenteringthesystem.
Evenalittleobjectmaycause lastingdamagethatarenotdetectedimmediately.
-Avoidtoo narrowbendradiusofhoses.
- Avoidthehosecontactwithedgesorsharp corners.
- Avoidthehosecontactwithheatsources.