Ultraflex T85 Manual

Installationandmaintenancemanual
ULTRAFLEX
PARTNER
R
T85
STEERING
SYSTEM
ENGLISH
(Dr./Dis./Des. n°15079/b17/02/2015)
ITALIANOFRANÇAIS
I
UK F
page. 2 pag.14 page. 27

DearCustomer,
We wouldliketo thankyoufor choosingan ULTRAFLEX product.
ULTRAFLEX hasbeenaleader insteeringsystemsforpleasureandprofessionalboatsfor manyyears.
ULTRAFLEX productionissinceeversynonimousof reliabilityandsafety.
All ULTRAFLEX productsare designedandmanufacturedtoensurethebestperformance.
To ensure yoursafety andto maintainahighquality level, ULTRAFLEX productsare guaranteedonlyif
theyareusedwithoriginalspareparts.
ULTRAFLEX and UFLEX QualityManagementSystemsare certifiedCISQ-IQNet bytheItalianShipping
Registry(RINA),inconformitywiththeUNIENISO9001:2008 rule. ULTRAFLEX certificationNo.6669/02/S
(former420/96). UFLEX certificationNo.8875/03/S.
Thequality managementsysteminvolvesall thecompanyresourcesandprocessesstartingfromthe
design,inorderto:
- ensure productqualitytothecustomer;
-maintainandimprove thequality standardsconstantly;
-pursueacontinuous process improvementto meet themarket needsandto increasethecustomer
satisfaction
ULTRAFLEX EnvironmentalManagementSystemiscertifiedCISQ-IQNet bytheItalianShippingRegistry
(RINA),inconformitywiththeUNIENISO14001rule. ULTRAFLEX certificationNo.EMS-1282/S.
Productsforpleasure boatsare constantlytestedtochecktheirconformitywiththe2013/53/EU.
ULTRAFLEX S.p.A.
ULTRAFLEX
16015Casella(Genova)Italia -ViaCrose,2
"ULTRAFLEX hasover 80 yearsof experience inthemarineindustry andisaworldleader intheproduction
ofmechanical,hydraulicandelectronicsteeringsystems,controlboxesandsteeringwheelsforany
kindof pleasure,fishingor commercialboats.
Thekey factorswhichexplaintheincreasingsuccess of ourproductsall over theworldare thereliability
of ourproductsandthebefore andafter saleservice,thequality of thecompanyorganizationandof the
humanresourcesandthecontinuousspendinginresearchanddevelopment".
ENGLISH

T85 STEERINGSYSTEM -page3 OF39
Installationandmaintenancemanual
ULTRAFLEX
ENGLISH SECTION1-PRODUCTDESCRIPTION
1.1 DESCRIPTIONOFTHEPRODUCTANDWARNINGSFORTHECORRECTUSE...........................................6
1.2 DIMENSIONS..........................................................................................................................................6
TABLEOFCONTENTS
SECTION2-TRANSPORT
SECTION5-MAINTENANCE
5.1 ROUTINEMAINTENANCE.................................................................................................................13
5.2 EXTRAORDINARY MAINTENANCE.....................................................................................................13
SECTION3-INSTALLATION
3.1 NECESSARY TOOLS.................................................................................................................................8
3.2 POSITIONINGOFTHESTEERINGSYSTEM.................................................................................................8
3,3 CONNECTIONOFTHECABLETO THESTEERINGSYSTEM...................................................................10
SECTION4-SAFETYWARNINGS
SECTION6-DISMANTLING
6.1 DISMANTLING.........................................................................................................................13
!
MANUALUSEANDSYMBOLSUSED...................................................................................................4
INTRODUCTION................................................................................................................................5
WARRANTY...............................................................................................................................5
2.1 GENERALWARNINGS.............................................................................................................................7
2.2 PACKAGINGCONTENTS.......................................................................................................................7
4.1 SAFETYRULESDURINGINSTALLATIONANDUSE...............................................................12
4.2 CLOTHING.............................................................................................................................12

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MANUALUSEANDSYMBOLSUSED
Inthis manualthefollowingsymbolsareusedtoensuretheusersafetyandtoguarantee thecorrect
operationoftheproduct:
THEINSTALLATIONANDMAINTENANCE MANUALis thedocumentgivenwiththeproductfromitssaletoits
replacementanddischarge.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.

T85 STEERINGSYSTEM -page 5 OF39
Installationandmaintenancemanual
ULTRAFLEX
ENGLISH
WARRANTY
INTRODUCTION
Toensurethecorrectproductandcomponentoperation,theproductmustbeinstalledbyqualifiedstaff.
Incase ofpartdamageormalfunction,please contactthequalifiedstaff orourTechnicalAssistance Service.
WARNING
This installationandmaintenance manualrepresentsanimportantpartoftheproductandmustbeavailable
tothepeopleinchargeofitsuse andmaintenance.
Theusermustknowthecontentofthis manual.
ULTRAFLEX declines all responsibilityforpossiblemistakes inthis manualduetoprintingerrors.
Apartfromtheessentialfeaturesofthedescribedproduct, ULTRAFLEX reserves therighttomakethose
modifications, suchas descriptions, detailsandillustrations, thatareconsideredtobesuitableforits
improvement,orfordesignorsales requirements, atanymomentandwithoutbeingobligedtoupdatethis
publication.
ALL RIGHTSARE RESERVED.Publishingrights, trademarks, partnumbersandpictures of ULTRAFLEX products
includedinthis manualare ULTRAFLEX property.
Greatcarehas beentakenincollectingandcheckingthedocumentationcontainedinthismanualto
makeitas completeandcomprehensibleaspossible. Nothingcontainedinthis manualcanbeinterpreted
as warrantyeitherexpressedorimplied-including,notinarestrictedway,thesuitabilitywarrantyforany
specialpurpose.Nothingcontainedinthismanualcanbeinterpretedasamodificationorconfirmationof
thetermsofanypurchasecontract.
ULTRAFLEX guarantees thatitsproductsarewell designedandfree frommanufacturingandmaterialdefects,
foraperiodoftwoyearsfromthedateofmanufacturing.
Fortheproductswhichareinstalledandusedonworkingorcommercialboatsthewarrantyis limitedto
oneyearfromthedateofmanufacturing.
If duringthis periodtheproductproves tobedefective duetoimpropermaterialsand/ormanufacture,the
manufacturerwillrepairorreplacethedefective partsfree ofcharge.
Directorindirectdamageis notcoveredbythiswarranty.Inparticularthecompanyisnotresponsibleandthis
warrantywill notcoverthedamageresultingfromincorrectinstallationoruseoftheproduct(exceptfor
replacementorrepairofdefective partsaccordingtotheconditionsandtermsabove).
This warrantydoesnotcover theproductsinstalledonraceboatsorboatsusedincompetitions.
Thedescriptionsandillustrationscontainedinthis manualshouldbeusedasgeneralreferenceonly.
ForanyfurtherinformationpleasecontactourTechnical Assistance Service.
ULTRAFLEX steeringsystemcomponentsaremarkedaccordingtotheDirective 2013/53/EU.
Weremindyouthatonly markedsteeringsystemsmustbeusedontheboatsmarked.Weinform
youthatthe ULTRAFLEX warrantyis null ifsomeULTRAFLEX componentsareinstalledonasteeringsystem
togetherwithproductsofotherbrands.
TECHNICALASSISTANCE SERVICE
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.ultraflexgroup.it
North-South-CentralAmerica:
UFLEX USA
6442ParklandDrive
Sarasota,FL34243
Ph.:+1.941.351.2628
Fax: [phone]
Email: [e-mail]
www.uflexusa.com

Installationandmaintenancemanual
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ENGLISH
1.2DiMENSIONS
T85mechanicalsteeringsystemwithsteeringcableis designedtocontrolboatsequippedwithoutboard,inboard
andsterndrivepowerassistedengines.T85steeringsystemmustbeusedwithUltraflex M66 steeringcable
Thefollowingpictures showthedimensionsofT85steeringsystem.
T85
PERICOLO
1PRODUCTDESCRIPTION
1.1Descriptionoftheproductandwarningsforthecorrectuse
WARNING
WARNING
T85 steeringsystemis nottobeusedonboatsequippedwithengines thatexceedthemaximumhorsepower
ratingoftheboatorthespeedof50 knots(57.5 mph).
DO NOTDISASSEMBLEANYPARTOFTHESTEERINGSYSTEMDURINGTHEINSTALLATIONOFTHE
CABLE.THEDISASSEMBLYOFTHECOMPONENTSCANGENERALLYCAUSESERIOUSDAMAGETO
OBJECTSORPEOPLE.THISPROCEDURECAUSESTHEWARRANTYLOSS OFTHEPRODUCT.
PERICOLO
DANGER
93 (3.6")
176 (6,9")max
ƒ
ƒ
ƒ
150 (5.91")
ƒ148,2 (5.84")
ƒ
ƒ
Ø103 (4.06")
162 (6.38")
ƒ
102.5 (4")
ƒ
ƒ
ƒ

T85 STEERINGSYSTEM -page7 OF39
Installationandmaintenancemanual
ULTRAFLEX
ENGLISH
Contentsofthesteeringsystempackagings:
C
T85
A
D
H
I
E
L
F
M
GNO
B
Theproductweightwithitspackagingis 2,5 kg (5.5 pounds);therefore, itcanbemanuallyhandled.
Thestaff inchargeofhandlingmustwearprotectivegloves andsafetyshoes.
Beforeusingtheequipmentcheckthattheproducthas notbeendamagedduringtransport.
Also makesurethatall thestandard componentsareinthepackaging(see list).Incase ofdamage,
notifytheclaimtotheforwarderandinformthesupplier.
2.2Packagingcontents
2TRANSPORT
2.1Generalwarnings
Thepackagingmustbedisposedofaccordingtotheexistinglaws.
PERICOLO
WARNING
PERICOLO
CAUTION
REF T85
A1steeringsystem
B1bracket
C1mounting bezel
D4washers6,4x12,5
E4nutsM6
F4screwsM6x35
G1nutM12
H2self-threadingscrews
I1washer
L4screwsM6x12
M1tube
N1bushing
O1woodruffkey

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3INSTALLATION
3.1Necessary tools
Starscrewdriver Pliers Openend
wrench
10mm [0,395”]
Drill
4Byusingthesupplieddrillingtemplate
positionthesteeringsysteminthechosen
placeandcreate4holes ofdiameter7mm (0,
28")andoneofdiameter67 mm (2,64")
3.2Steeringsystempositioning
1 Thesteeringcablemustbeinstalledonthesideoftheboatclosertothesteeringwheelshaft.
2Selectadirectpathwithaminimalnumberofbends
3 Makesurethedistances betweentheaxis
oftheshaft ofthesteeringsystemandthe
bulkheadsareequalorlongerthanthose
indicatedinthepicture.
WARNING
Openend
wrench
18mm [0,71”]
Theminimumbendradiusforasteeringcableis 8"(200mm).
Amoreseverebendwillcause steeringfrictionandreducecablelife.
100mm
150mm
255mm
(3.94")
(5.9")
(10.04")

T85 STEERINGSYSTEM -page9 OF39
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5Tightenthe bracket(1)tothe dashboard using
fourscrewsM6x35 (hexagonalhead)(2),four
washers(3)andfourself stoppingnutsM6(4)with
torqueof6Nm(53 lbsin).
6 Insertthehelmshaft fromthebacksideof
thedashboard throughtheholeofthemounting
bracket.Thehelmcanbefixedineightdifferent
positions(every45°).Therightpositionwill be
determinedbythemountingsideofthecable.
Placethehelmintheselectedpositionandalign
theholes formounting.Tightenthehelmtothe
bracketwithfourM6x12screws(5)withtorque
of6Nm(53
lbsin).
7Insertthebezel(6)andmakeittouchthe
dashboard(7).
Fixthebezel(6)tothedashboard(7)withtwo
self-threadingscrews(8).
8Insertthesteeringwheel(10)onthehelm
shaft (11)aligningtherecess ofthehubwiththe
key(9)oftheshaft.
Insertthewasher(12),screwtheM12 nut(13)on
thehubofthesteeringwheelwithtorqueof35-
40Nm(310-354 lbsin).
Do notuse asteeringwheelwithdiameterwiderthan16"(406mm)andwithdepthexceeding5"(127mm).
WARNING
1
2
3
4
5
6
8
7
9
10
12
13
11
9

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3.3Cableconnectiontothesteeringsystem
1Determinethecorrectcableentrypositionintothehelmaccordingtothepropersteeringsystem.
2RemoveprotectivetubefromUltraflex M66
cable endandinsertthehelix cable intothe helm.
3Turnthesteeringwheelso as to"pull"the
cableintothe helm,aligningtheendfittingrecess
Awithscrewholeinhelmbase (14).
4Locktheendfittingwiththescrew(15)andnut
(16)withtorqueof6Nm(53 inlbs)
PUSHOR PULL TURNINGDIRECTIONS
14
A
16
15

T85 STEERINGSYSTEM -page11 OF39
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ENGLISH
6Alignthebushingrecess(17)withChole
andlockitbymeansofthescrew(18)andthe
nut(19)withtorqueof53 in.lbs(6Nm).
7Inserttheprotectiontube(20)ontothe
bushing(17)
17
B18
19
C
20
8Fixtheconduitevery2mt(6').Theconduit
mustnotbefixedtoelectricwires.
Bulkheadopeningsrequireaminimum38mm
(11/2)holediameter.
DANGER
9
DANGER
2m 2m
5Slidethebushing(17)overthehelix cableand
introduceitintotheholeofthehelmB.
Preventanydustorforeignmaterialfrom
contactingtheexposedhelix cableend.
Makesuretheconduitdoes notenterincontactwith
cuttingedgesthatcould damageit.
Make sure the directionofthe steering wheelrotationcorresponds to the boatdirection.
This controlmustbe performed before the boatis operated inthe water.
WARNING

Installationandmaintenancemanual
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page12 of39-T85 STEERINGSYSTEM
ENGLISH
4SAFETYWARNINGS
4.1Safetyrulesduringinstallationanduse
DANGER
WARNING
Duringinstallation,inspectionormaintenance, ITISSTRICTLYFORBIDDENtowearnecklaces, braceletsor
clothes whichcould getcaughtinthemovingparts.
4.2Clothing
WARNING
Thissectionshowsthesafetyruleswhichmustbefollowedforthecorrectequipmentoperation.
Werecommendreadingcarefullythis sectionandalso theothermanualssuppliedwiththesteeringsystem
components.
OBSERVE STRICTLYthefollowingsafetyrules:
ULTRAFLEX declines all responsibilityincase theuserdoes notfollowthese rules anditis notresponsiblefor
negligencewhileusingthesystem.
-DONOTPUTYOURHANDSBETWEENMOVINGPARTS.
-Do notdisablethesafetydevices.
-Donotmodifyoradddevices tothesystem,without ULTRAFLEX writtenauthorisationortechnical
interventionwhichwillprovethemodificationinthereport.
-Do notuse this equipmentforapurpose differentfromtheoneithas beendesignedfor,whichis
specifiedintheinstallationandmaintenancemanual.
-Do notletunskilledstaff performtheinstallation.
-Duringinstallation,keepthesystemclean,topreventanyforeignbodytodamageit.Eventhesmallest
objectcouldcause permanentbutnotimmediatelyperceivabledamages.
-Avoidcablebends 200 mm (8")
-Avoidcontactofcableswithsharpenededges
-Avoidcontactwithsources ofheat.

T85 STEERINGSYSTEM -page13 OF39
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ENGLISH
5.1Ordinarymaintenance
5MAINTENANCE
Poorinstallationandmaintenancemayresult inlossofsteeringandcause propertydamageand/orper-
sonalinjury.Maintenancerequirementschangeaccordingtoclimate,frequencyandtheuse.Inspections
arenecessaryatleasteverytwoyearsandmustbecarriedoutbyspecializedmarinetechnicians.
Carryoutthefollowingmaintenanceoperations:
-Periodicallywashwithwaterandsoapthecomponentsbyremovinganysalt deposit.
-Everymonthcheckandifnecessarytightenall thenutsfasteningthesystem.
WARNING
DANGER
Release orseparationofoneofthefastenerscancause failureofsteeringsystemresulting
inpropertydamage,injuryordeath.
-Periodicallychecktheabsenceofcorrosiononthemetalpartsofthecableendfittingsandofabrasions
ontheconduit.
-Replacethedamagepartsthatcouldcompromisethesteeringsystemintegrity.
TechnicalSupport
Foranyinformationorforassistancewithunusualapplicationsplease contactourtechnicalsupportstaff
(See paragraph"Introduction").
5.2Extraordinarymaintenance
6DISMANTLING
6.1Dismantling
Whenforanyreason,thesystemisputoutofservice,itis necessarytofollowsomerules inorderto
respecttheenvironment.
Conduits, pipelines, plasticornon-metalliccomponentsmustbedisassembledanddisposedofseparately.