Ultraflex UC 128-TS Manual

HYDRAULICCYLINDERFOR
OUTBOARDENGINES
UC128-TS
(Dr.No.20429/p27/07/2018)
InstallationandMaintenanceManual
R
I
UK F
page.2 pag. 27 page. 53
FRANÇAIS ITALIANO ENGLISH
PARTNER
(REV.1)

ULTRAFLEX S.p.A.
ULTRAFLEX
16015 Casella(Genova)Italy-ViaCrose,2
DearCustomer,
Wewould liketothankyouforchoosingan ULTRAFLEX product.
ULTRAFLEX hasbeenaleaderinsteeringsystemsforpleasureandprofessionalboatsformanyyears.
ULTRAFLEX productionissinceeversynonimousofreliabilityandsafety.
All ULTRAFLEX productsaredesignedandmanufacturedtoensurethebestperformance.
To ensureyoursafetyandtomaintainahighqualitylevel, ULTRAFLEX productsareguaranteedonly if
theyareusedwithoriginalspareparts.
ULTRAFLEX and UFLEX QualityManagementSystemsarecertifiedbytheDetNorskeVeritas-Germanischer
Lloyd(DNV-GL),inconformitywiththeUNIENISO9001:2015rule.
Thequalitymanagementsysteminvolvesallthecompanyresourcesandprocesses startingfromthe
design,inorderto:
- ensureproductqualitytothecustomer;
-maintainandimprove thequalitystandardsconstantly;
-pursueacontinuousprocess improvementtomeetthemarketneedsandtoincrease thecustomer
satisfaction
ULTRAFLEX EnvironmentalManagementSystemis certifiedbytheDetNorskeVeritas -GermanischerLloyd
(DNV-GL),inconformitywiththeUNIENISO14001:2015rule.
Productsforpleasureboatsareconstantlytestedtochecktheirconformitywiththe2013/53/EU.
"ULTRAFLEX has over80 yearsofexperience inthemarineindustryandis aworld leaderintheproduction
ofmechanical,hydraulicandelectronicsteeringsystems,controlboxesandsteeringwheelsforany
kindofpleasure, fishingorcommercialboats.
Thekey factorswhichexplaintheincreasingsuccess ofourproductsall overtheworld arethereliability
ofourproductsandthebeforeandaftersaleservice, thequalityofthecompanyorganizationandofthe
humanresourcesandthecontinuousspendinginresearchanddevelopment".

HYDRAULIC CYLINDERFOROUTBOARD ENGINE -page 3 of 78
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SECTION1-PRODUCTDESCRIPTION
1.1 HYDRAULICSTEERINGSYSTEMOPERATION.................................................................................7
1.2 WARNINGSFOR THECORRECTPRODUCTUSE......................................................................7
1.3 CONFIGURATIONS.........................................................................................................................8
1.4 UC128-TSCYLINDERDESCRIPTION......................................................................................................9
1.5 TECHNICAL FEATURES..........................................................................................................................9
TABLEOFCONTENTS
SECTION2-TRANSPORT
2.1 GENERALWARNINGS.............................................................................................................................10
2.2 PACKAGINGCONTENTS....................................................................................................................10
SECTION5-MAINTENANCE
5.1 ORDINARY MAINTENANCE................................................................................................................22
5.2 HEADREPLACEMENT.........................................................................................................................22
5.3 TROUBLESHOOTING.........................................................................................................................23
SECTION3-INSTALLATION
3.1 MINIMUMTRANSOMREQUIREMENTS.........................................................................................11
3.2 NECESSARYTOOLS.......................................................................................................................11
3,3 STANDARD (STARBOARD)CYLINDERINSTALLATION................................................................12
3,4 HOSEINSTALLATION................................................................................................................................15
3.5 TYPEOFINSTALLATION...........................................................................................................................16
3.6 FILLINGAND PURGING.......................................................................................................................17
3.6.1 POSITIONINGOFTHEOILBOTTLE...................................................................................18
3,6,2 SINGLESTEERINGSTATION/SINGLECYLINDER......................................................................................18
3.6.3 SINGLE STEERINGSTATION/DUALCYLINDER..............................................................................19
3.6.4 DUALSTEERINGSTATION/SINGLECYLINDER.........................................................................................19
3.6.5 DUAL STEERINGSTATION/DUAL CYLINDER............................................................................................20
3.7 GENERAL RECOMMENDATIONS................................................................................................................20
SECTION4-SAFETYWARNINGS
4.1 SAFETY WARNINGSDURINGUSEAND INSTALLATION.......................................................................21
4..2 CLOTHING................................................................................................................................21
SECTION6-DISMANTLING
6.1 DISMANTLING...............................................................................................................................25
!
DOCUMENTREVISION......................................................................................................................................4
MANUALUSEANDSYMBOLSUSED................................................................................................................5
INTRODUCTION.................................................................................................................................6
WARRANTY................................................................................................................................6
IMPORTANT:
Theadditionaldocuments"ApplicationGuide"and"SparePartsList" areattachedtothismanual.

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DOCUMENTREVISIONS
Rev. Date Revisiondescription
0
1
20/02/2006
27/07/2018
Firstedition
Newversionwith removableheads

HYDRAULIC CYLINDERFOROUTBOARD ENGINE -page 5 of 78
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Inthismanualthefollowingsymbolsareusedtoensuretheusersafetyandtoguarantee thecorrect
operationoftheproduct:
MANUALUSE AND SYMBOLSUSED
THEINSTALLATION AND MAINTENANCE MANUAL is thedocumentaccompanyingtheproductfromitssale
toitsreplacementanddischarge.Themanualis animportantpartoftheproductitself.
It is necessarytoreadcarefully themanual,beforeANY ACTIVITYinvolvingtheproduct,handlingand
unloadingincluded.
STERN
BOW
STARBOARD PORT Thepictureasideexplainsthemeaningofsome
nauticalwordscontainedinthismanual.
DANGER ImmediatehazardswhichCAUSEseverepersonalinjuryordeath.
WARNING
CAUTION
Thesymbolasideindicates all theoperationswhichmustbecarriedout
byqualifiedorskilledstaff,inordertoavoidhazards.
Werecommendtrainingthestaffinchargeoftheproductinstallation
andcheckingtheirknowledge.
NOTICE Importantinformationforthecorrectinstallationandformaintenance,that
doesnotcauseanydamage.
Denotes thatahazard existswhichcanresult ininjuryordeathifproper
precautionsarenottaken.
Denotesareminderofsafetypracticesordirectsattentiontounsafe
practices whichcould result inpersonalinjuryordamagetothecraft or
componentsortotheenvironment.

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WARRANTY
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.
Weinformyouthatthe ULTRAFLEX warrantyis null ifsomeULTRAFLEX componentsareinstalledonasteering
systemtogetherwithproductsofotherbrands.
TECHNICALASSISTANCE SERVICE
INTRODUCTION
UFLEX S.r.l.
ViaMiliteIgnoto,8A
16012 Busalla(GE)-Italy
Tel:[phone]
Fax: [phone]
Email: [e-mail]
www.ultraflexgroup.it
North-South-CentralAmerica:
UFLEX USA
6442ParklandDrive
Sarasota,FL34243
Tel:[phone]
Fax: [phone]
Email: [e-mail]
www.uflexusa.com
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, partnumbersandphotographsof ULTRAFLEX
productscontainedinthismanualare ULTRAFLEX property.
Greatcarehas beentakenincollectingandcheckingthedocumentationcontainedinthismanualto
makeitas completeandcomprehensibleaspossible. Nothingcontainedinthis manualcanbeinterpreted
as warrantyeitherexpressedorimplied-including,notinarestrictedway,thesuitabilitywarrantyforany
specialpurpose.Nothingcontainedinthismanualcanbeinterpretedasamodificationorconfirmationof
thetermsofanypurchasecontract.
Toensurethecorrectproductandcomponentoperation,theproductmustbeinstalledbyqualifiedstaff.
Incaseofpartdamageormalfunction,please contactthequalifiedstafforourTechnicalAssistance
Service.
WARNING

HYDRAULIC CYLINDERFOROUTBOARD ENGINE -page 7 of 78
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ULTRAFLEX hydraulicsteeringsystemsshouldnotbeusedinracingapplications.
To avoidproductdamage,donotdisassemblepre-assembledcomponents.
All ULTRAFLEX steeringsystemsmustnotbeinstalledonboatsequippedwithengines whosemaximum
horsepoweris higherthanthehorsepowerratingapprovedby boatmanufacturer.
1.2 Warningsfortheproductcorrectuse
Beforebeginningtheinstallation,checkthemountingcompatibilityoftheUC128-TScylindertotheengine
byconsultingtheattachteddocument"ApplicationGuide"containedinthepackaging.
Do notmodifythesteeringcylinderinanyway tofitittoyourengineapplication,otherwise thecylinderwill
nolongeroperateinsafetyanditwillendangertheboatandtheoccupants.
WARNING
WARNING
WARNING
DANGER
DANGER
1PRODUCTDESCRIPTION
1.1Hydraulicsteeringsystemoperation
All ULTRAFLEX hydraulicsteeringsystemsaredesignedinconformitywithUNI-EN-ISO10592 andA.B.Y.C. P21
regulations. AllULTRAFLEXsteeringsystemscanoperateattemperatures between-18°C(0°F)and+77°C
(+170°F).All thecomponentsaremadeforthemarineenvironment,usingmaterialsandworkingprocesses
whichofferlonglifeandsafetyunderthemostextremeconditions. Ahydraulic steeringsystemconsistsof
asteeringpump,acylindertiedtotherudderortotheoutboard or
sterndriveengineandtheconnectinghoses(seepicture).Under
normaloperatingconditions, aturnofthesteeringwheelwill pump
theoil,whichflowsinthroughthehosestothecylinder,according
totheturndirection.Withtheconsequentcylindermovementtheoil
will flowtothepumpthroughthehoses andatthesametimemoves
theengineorthehelmwhichareconnectedtothecylinder.The
pumpsareequippedwithavalve,whichpreventsoutgoingfluid
fromreturningalongthesamehose. Italsoallowstheoperationof
thesteeringsystemswithtwoormoresteeringstations.The
cylindersaredoubleactingandmaybebalancedorunbalanced.In
theunbalancedcylindersthetwochambershave differentvolumes
andsothey needadifferentnumberofturnsofthesteeringwheel
andadifferentrotationeffort.Thebalanced cylindershavesame
numberofsteeringwheelturnsinordertomove thehelmfromthe
centertotheendstrokeinthetwooppositedirections. Awell balanced steeringsystemneedsacorrect
choice ofthepumpforthecylinder. ULTRAFLEX produces differentpumpmodels,whichhave differentcapacity
(cm3ofoilmovedeachsteeringwheelturn)andforeachtypeofinstallation.Whilechoosingthepumpitis
importanttoconsiderthecylindervolume.Thenumberofstarboard andportturnsis determinedbythe
ratio betweenthecylindervolumeandthepumpcapacity.
Example:ifthepumphas acapacityof28cm3 [1,7cu.in.]andthecylinderhas avolumeof120cm3 [7,3cu.in.],the
formulalookslikethis:120/28=4,2. Accordingly,thesteeringwheelwillturn4,2timesbeforethecylinder
willcompletelyturnfromonesidetotheother.Incaseofinstallationswithdoublecylindersconnectedin
parallelthecylindervolumemustbeadded.Applicationswithlessthan4turnsarenotrecommended,as
theyneedahighereffort,alsoapplicationswithmorethan8turnsarealso notrecommended,as the
response oftheboattosteeris slowly.Themaximum operatingpressureis 7,0MPa(70bar)(1000PSI).
l
engine
hydraulic
hose
cylinder
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1.3Configurations
Thehydrauliccylinderforoutboard engineUC128-TSmodelcanbeinstalledwithdifferentconfigurations
accordingtothenumberandthetypeofengines usedwithasingleordualenginesteeringsystem.
Thepossibleconfigurationsare:
Onrequest,tripleoutboardengineapplicationsareavailable.Fordetailedinformation,pleasecontact
ULTRAFLEX Assistance Service.
NOTICE
STEERINGSTATION
NUMBER
S
I
N
G
L
E
S
T
A
T
I
O
N
ENGINE NUMBER
With SINGLE STANDARDCYLINDER(starboardversion)
With SINGLESTANDARDCYLINDER( starboardversion )
and TIEBAR
With DUALCYLINDER(starboard+port)
upto300hpmax
orupto
55 m.p.h.
non-counterrotating
engines upto
300hpmaxofcombined
horsepowerorupto
55 m.p.h.
counterrotating
enginesupto500 hp
maxofcombined
horsepowerorupto
55 m.p.h.
non-counterrotating
engines upto
500hpmaxofcombined
horsepowerorupto
55 m.p.h.
counterrotating
enginesupto600 hp
maxofcombined
horsepowerorupto
65 m.p.h.
MAINSTATION
ADDITIONAL
STATION
D
U
A
L
S
T
A
T
I
O
N
DANGER
Dualengineinstallationsrequiretheuse ofatiebar.
D
U
A
L
E
N
G
I
N
E
S
I
N
G
L
E
E
N
G
I
N
E

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1
2
3
7a
7c
4
5
6
7b
1.4UC128-TScylinderdescription
UC128-TSisahydraulicoutboard frontmountcylinderwhichhasbeendesignedandmanufacturedtobe
usedasacomponentinthehydraulicsteeringsystems,asdescribedinthepreviousparagraph.
Thecylinderis installedtothetilt tuberodoftheavailableengines onthemarketas shown intheattached
document"Applicationguide".Itis possibletomeetall thedifferentcylinderapplicationsduetothethree
differentlinkarmsandaproperspacerkit.Forthedualengineapplication,thesinglecylindermustbe
mountedwithatie bar(see par.1.3)ortwocylinders(standard +port) connectedbyatie barcanbeused.
Inthestandard versionthelinkarmis mountedonthestarboard side, whileintheportversionitis mounted
ontheportside(see pictureinpar.1.5).Thefollowingpictureshowsthemaincylindercomponents:
Cylinderbody
Bleeders
Bull horns
Tilttuberod
Spacers
Adjustmentcollar
Straightlinkarm(UC128-TS/1)
Shapedlinkarm(UC128-TS/2)
Curvedlinkarm(UC128-TS/3)
1
2
5
6
3
4
7a
7c
7b
1.5Technicalfeatures
544 mm (21.43")
76.2 mm (3.00")
STANDARDVERSION(STARBOARD) PORT VERSION
SPECIFICATIONS UC128-OBF/1 -/2 -/3
Volume 120 cc -7.8 cu.in
Outputforce 450 Kg-992 lbs (@70 bar)
Inside diameter 35 mm -1.37"
Stroke 198 mm -7.79"
Oil
OL150 Ultraflex
*Thecylinderoutputforceisatheoreticalforcewithasystempressureof105bar.Thisforce doesnot
correspondtotheonenormallyusedbythesystembutitrepresentsthelimitingconditionsofuse.
CAUTION

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Thepackagingmustbedisposedofaccordingto theexistinglaws.
CONTENTSOFTHESTANDARDPACKAGING:
A)No.1cylinderbodywithrod,fittingsandbullhorns;
B)No.1linkarmkitcomposedof:
-No.1linkarm;
-No.2allenscrewswithNo.1safetyscrewand
lock washer;
-No.1bolt+nut;
-No.1kitforSuzukiengines (notTS/3version);
C)No. 1spacerkitcomposedof:
-No.8plasticspacers;
-No.2 steelspacers;
-No.1ringnutforadjustementcollar;
D)No.2capsforthecylinderbody;
E)No.2bolts+No.2lockwashers;
F)No.2locknuts+n°2washers;
2.1 Generalwarnings
2TRANSPORT
2.2 Packagingcontents
Beforeusingtheequipmentcheckthattheproducthasnotbeendamagedduringtransport.
Alsomakesurethatallthestandardcomponentsareinthepackaging(seelist).Incaseofdamage,
notifytheclaimtotheforwarderandinformthesupplier.
WARNING
Thestaffinchargeofhandlingmustoperatewithprotectivegloves andsafetyshoes.
CAUTION
Theproductweightwithitspackagingis 8kg (18 pounds)andso itcanbehandledmanually.
A
B
D
E-F
C

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3INSTALLATION
3.1Minimumtransomrequirements
Thefollowingpictureshowstheminimum splashwell dimensions. These dimensionsmustberespectedin
ordertopreventthecylinderfrombeingdamagedwhentheoutboard engineis completelytiltedupwards.
Thepictureshowsalso theminimum transomdimensions, neededfortheinstallationandthecorrect
operationoftheenginesteeringcylinder.
ENGINE JACK PLATE APPLICATION TO THETRANSOM.
Ajackplateinstallationwill changeall theapplicationclearances. Anewclearance checkmustbecompleted
withthetiltingoftheengineinconjunctionwiththeverticalmovementofthejackplateinall thepossible
positions.Ifthesteeringcylindercomesintocontactwiththesplashwell,transomand/orjackplate, stop
theinstallationimmediately! Usethejackplatemanufacturer'sinstructionstolimittheupperorlower
directioninwhichtheinterferenceoccurs.Ifthisisnotpossiblepleasecontactspecializedstaff.
WARNING
EngineNo. A B C
1560 mm -21.25" 152 mm - 5.98" 152 mm - 5.98"
2 1110 mm - 43.70" 152 mm - 5.98" 152 mm - 5.98"
MINIMUM SPLASH WELL DIMENSION REQUIREMENTS
3.2Necessary tools
C
B
A
³
90°
Allenwrench
[1/8”]
Allenwrench
8mm [5/16”]
Openend
wrench
19mm
Pliers
Openend
wrench
11/16”
Openend
wrench
9/16"
Phillips
screwdriver
Torquewrench
MOLYKOTE® 1000
Openend
wrench
3/4"
Openend
wrench
14mm

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3
4
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3.3 Standard(starboard)cylinderinstallation
Duringtheinstallationphases use only stainless
steeltoolstoavoidthecorrosionofthemetalparts.
CAUTION
1Incase ofsinglecylinderinstallationmountthe supplied
capsonthecylinderbodyasshowninthepicture.
CAUTION
Duringthisphaseanoilleakfromthefittingscan
occur.Thisoilmustnotbedischargedintothesea in
anycase.
2Afterremovingtheprotectivecapsofthe
fittings, manuallycentertherod(1)onthecylinder
body(2).
3Mountthelinkarm(3)onthecylinderbodyas
shown inthepictureby meansofthesuppliedscrews
(4). Tightenthe suppliedscrews byusinga 8mmAllen
wrenchwithatorqueof76[Nm](56[lb ft]).
4Positionthelockwasher(5)andtightenitwith
thescrew(6),byusingLoctite 270(torque 3[Nm](2
[lb ft]).
5Positiontheenginestraightsothatitsarmis
perpendiculartothetransom.
Theoperationsdescribedinpoints3and4mustbe
carriedoutonlyduringthefirstinstallation.Thechoice
ofthelinkarmdependsontheenginetype(see
attachedApplicationGuide).Donotdisassemblethe
armfromthecylinderbody inanycase.
WARNING
7
8
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6Withreferencetotheapplicationinstructions
containedintheApplicationGuide,connectthelink
armtothetillerarmbymeansofthescrew(8),
tightenitby usinga14mmwrenchwithatorqueof
54[Nm](40 [lb ft]).Tightentheself-lockingnut(7)by
usinga9/16"wrenchwithatorqueof27[Nm](20
[lb ft]).Aftertighteningthelocknut(7),check forthe
righttorque54[Nm](40 [lb ft]) ofthescrew(8). 7Grease thetilt tuberod(9),by usingmarine
grease.
8Insertthetilttuberod(9)intothetilt tube.
Inordertotightenscrew(8)andtheself-locking
nut(7)onthetillerarm,askyourmechanicthe
maximum allowedtorque. If itis lowerthanthat
showninthismanual,alwaysusethetorque
indicatedbyyourmechanic.
WARNING
Itisimportanttocheckperiodically,atleastevery3
months(orevery monthforprofessionaluses),the
righttorqueofthis screw(8)andofthelocknut(7).
WARNING
If theself-lockingnut(7)is disassembled,replace
it.(Contactourtechnicalassistanceservice,see
page6).
CAUTION
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Boththestainless steelspacersmustbepositioned
towardsthetilt tubeontheoppositesideofthe
bull hornstoavoidtheirwearduringenginelifting
andlowering.
9Fitthesetscrew(10)ontheadjustmentcollar
(11)andscrewittotherightsideofthetilttube
untilitcomesintocontactwiththetilttubestop
nut,evenincaseofportapplications.
10Withreferencetothe'"ApplicationGuide"
choosethespacersforthetilt tuberod.
11Inserttherightandleftbullhorns(12)by
connectingtherodandthetilt tuberodas shown
inthepicturewithouttighteningthem.
12Choose andcheckthespacerstofill thegap
betweenringnutandbullhorndandd2 between
tilt tubeandbullhornconsideringthethickness of
thestainless washer.
13Once thecorrectspacershavebeenchosen,
removethebull horns.
WARNING
14Inserttheplasticandstainlesssteelspacers
andthetwostainless washeronthetilt tuberod.
15Inserttherightandleft bull horns(12)by
connectingrodandtilttuberodas shown inthe
picture.
Inthis phase ensurethatthecylinderbodyis
centeredontherodandthattheengineis
perpendiculartothetransom.
NOTICE
Alwaysleaveaminimumclearancebetween
spacers andbullhorninorderto allowtherodtilting
inthetilt tube.
NOTICE
LARGE MEDIUM SMALL
1,6 mm /0,06"
3,2 mm /0,12"
8,1 mm /3,1"
Thenumberandpositionofthespacersshown in
theApplicationguideareindicativeonly.
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10
11
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12
12
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2
d
12
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15
16
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13
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16Insertthewashers(13)onthetwoendsofthe
tilt tuberod,grease thenutthread(14)with
someanti-seize greasetype MOLYKOTE® 1000ora
similarone,screwthembyusinga3/4"wrench
andtightenthemwithatorqueof70[Nm](52[lb ft]).
19Unscrewtheadjustmentcollar(11)andbring
itintocontactwiththestainless washer,untilthe
clearanceiseliminated,
20Check thecorrectcylinderinstallationbymoving
manually theengineontherightandontheleft.
WARNING
22Bendthetabsofthe
lockwashers(15)
bringingtheminto
contactwiththescrew
headandtakingcarenot
todamagethebull horns
whileusingthepliers.
Theenginemuststopthroughthe
cylinderendstrokewithout
comingintocontactwiththe
mechanical stop(17)onthe
engine.
17
l
NOTICE
Otherwise itis necessarytomodifytheinstallation,
bychangingthethicknessofthespacersandby
repeatingtheprocedurefrompoint13.
23Checkagainthecorrectenginemovement
bothduringtheright/left rotationandduringthe
tilting.
WARNING
Inthis phase clearance should beenoughtoavoid
frictionsbutitshould notbeexcessive since itcould
cause engineinstability. Incase ofcontactwiththe
transom,stoptheinstallationandcontactthe
specializedstaff.
NO CONTACT
NOTICE
Do notuse anytoolforthis operation.
NOTICE
Therotationmustbeassymmetricas possible
betweenportandstarboard so thatthesteering
angleis thesameonbothsides.
If theself-lockingnuts(14)aredisassembled,
replace them.(Contactourtechnicalassistance
service,see page6).
WARNING
17Positionthelockwashers(15)andlockscrew
(16)byusinga 19mmwrenchwitha torqueof70[Nm]
(52[lb ft])aftergreasingthemwithanti-seizegrease
typeMOLYKOTE® 1000orasimilarone.
Ifwhiletiltingtheengineisblocked,reducethe
overall dimensionsofthespacers.
NOTICE
Thelockwashertabsmustbebentafterwards(see
point22).
WARNING
18Checkthecorrecttiltingoftheengine.
21Tightenthesetscrew(10)ontheadjustment
collar(11)bya1/8"Allenwrenchwithatorqueof
3[Nm](2[lb ft]).
NOTICE
Checkperiodicallytheclearanceabsencebetween
theringnutandthetilttubeotherwise eliminate
theclearance throughtheadjustmentringnut(11).
10
11
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HYDRAULIC CYLINDERFOROUTBOARD ENGINE -page 15 of 78
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3.4Hoseinstallation
Thetwofittingsmountedonthecylinderbodyarealreadyorientedandarereadytobeused.If forpractical
reasonstheorientationmustbechanged,doasfollows:
1.loose thelocknut(A)byusinga11/16"wrench;
2.orientthefittingsaccordingtotherequirements;
DANGER
Do notunscrewthefittingsmorethanoneturn(360°).
3.tightenagainthestopnutwithatorqueof20[Nm](15[lb ft]) untilthewashercomes intocontactwithit.
Screwthehoses onthecylinderfittingswithatorqueof20[Nm](15[lb ft]) accordingtothefollowinginstructions:
-minimumhosebendradius250mm;
- nointerference duringenginetilting;
-nointerference withthetransom;
NO
WARNING
Anexcessivehosebendcould result initsinternalbreakingwhich
will cause abadoperationofthesystem.Inthis case itis necessaryto
replace thedamagedhose.
min. bend
radius 250 mm
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3.5Typeofinstallation
TheUC128-TShydraulic cylinderforoutboard engines canbeinstalledwithdifferentconfigurationsaccording
tothenumberandthetypeofengines usedwithasingleordualsteeringsystem.Thepossibleconfigurations
are:
CAUTION
Connecthosesasshowninthefollowingpictures:
SINGLE STATION/DUALCYLINDER:
SINGLE STATION/SINGLE CYLINDER:
DUALSTATION/DUALCYLINDER:
1.helm
2.starboardcylinder
3."T"fittings
4.kitOB
1.helm
2.starboardcylinder
3.portcylinder
4."T"fittings
1.upperstationhelm
2.lowerstationhelm
3.starboardcylinder
4."T"fittings
5.kitOB-2S
6.kitOB
3
4
1
2
1
23
2
2
3
1
l
1
l
l
l
3
l
l
l
ll
5
DUALSTATION/SINGLE CYLINDER:
4
l
l
l
4
l
l
l
l
l
l
l
l
l
l
l
l
5
6
l
76
l
l
l
l
7
8
5l
1.upperstationhelm
2.lowerstationhelm
3.starboardcylinder
4.portcylinder
5."T"fittings
9
l
l
4
4
5. "T"fittings
6. tie bar
7. kitOB-2C
8.kitOB
8
l
8
l
6l
6l
6
l
6l
6."T"fittings
7.tie bar
8.kitOB-2C
9.kitOB-2S
10.kitOB
l
10
l
10
l
10
10 l

HYDRAULIC CYLINDERFOROUTBOARD ENGINE -page 17 of 78
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ENGLISH
3.6Fillingandpurging
Afterthefirstinstallationandaftermaintenance operationsitisnecessarytofill thesystemwithhydraulic
oil.This operationmustavoidtheairinthesystem,toensurethegoodsystemoperation.Thehydraulic
systemmustbefilledfromthehighestpointofthesystem,whichmeansfromtheuppersteeringstation.
To avoidairbubbles intheoil,itisnecessarytofill thetankslowly.
Thefillingandbleedingoperationsmustbecarriedoutatleastbytwooperators
Use ULTRAFLEX oilorothercompatibleoils.
ThefillingandpurgingoperationscanbefacilitatedbyusingtheautomaticpurgingequipmentBUBBLE
BLUSTERâ (suppliedseparately).
HydraulicoilOL150 hasbeenspecifically formulatedfor ULTRAFLEX toensurehighqualityperformance
levelof ULTRAFLEX productsthroughouttime.
Itsspecial"ZincFree"formulaenhancesprotectionagainstmarineoxidation.Thespecialmixofanti-wear
andstabilizingcomponentsofOL150allowensuringgreatresultsasfarastheproductdurationand
performancesareconcernedinseveralenvironmentalconditions. ULTRAFLEX hydraulicoilcomplieswith
standard ISO10592concerninghydraulic steeringsystems. ULTRAFLEX isnottobeheldresponsibleforany
damages orperformance deteriorationifoilsdifferentfromOL150areused.
Do NOT use ATFDexronII transmissionoilsorbrakeoilswhichcouldcause thesteeringsystemseizing.
OilswhicharecompatiblewithOL150 ULTRAFLEX are:
-Shell TellusT15 andShell TellusT22
-MobilDTE 11M
ULTRAFLEX will notbeabletoensurethecompatibilityoftheabove mentionedoilswithOL150 iftheoil
manufacturersvarytheirformulation;inparticular,itwill notbeabletoensureitscompliance withstandard
ISO10592 concerninghydraulic steeringsystems. Undernocircumstances ULTRAFLEX is tobeheld responsible
foranydamages orperformancedeterioration.
Inthedays afterthefilling,checktheoillevel;ifnecessarytopoff thesystem.
Atthebeginningtheoillevelcanlower,assmallamountsofaircanbereleasedinahomogeneousway.
Accordingtothetypesofinstallation,itis necessary tocarry outthedifferentbleedingprocedures,as itfollows.
CAUTION
WARNING
DANGER
NOTICE
DANGER
NOTICE

InstallationandMaintenanceManual
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ENGLISH
3.6.1 Positioningoftheoilbottle
pin
oilbottle
hose
spout
filling
connection
-Removethepumpcapandinsertthefittings.
- Attachthespouttoanewbottleofhydraulic oilandconnectthehose tothe
fittingsandthebottlespout.
-Turnthebottleupsidedown andpierce itwiththepin,as shown inthe
picture,toeasetheoilpassagetowardsthepump.
Fill thepumpuntilnoairbubbles arevisibleinthehose.
Whilereplacingtheoilbottle,duringthefillingprocess,closeallthebleed
valvesofthecylinder/s. To bleedthesystem,checkthatoilis always present
inthefillinghose. If someairis inthesystemduringthebleedingprocess, the
wholebleedingprocessmustbestartedagain.
WARNING
Replacethebottlebeforeitemptiesanduserecoveredoilonly after24 hours.
CAUTION
To carry outthis operation,itis necessary touse theoilfillingkit(1needle, 1transparent
pipe, 1pipeconnectionand1spoutfortheoilbottle).This kitis NOTsupplied.
-Unscrewthetwobleedvalve protectionsandloosen1.5 turnsmax. thenuts
"A"ofthetwobleedvalves.
- Unscrewthetwobleedvalvesandmanuallypushthecylinderbodytoone
sideuntilitstopsas shown inpicture1.
-Positiontheoilbottleasexplainedinparagraph3.6.1.
-Close thebleedvalve onthecylinderendstrokesideandputapurgedoil
tankneartheotherbleedvalve(as shown inpicture2).
-Turnthesteeringwheelslowly(as shown inpicture2)so thattheoil
cancomeoutofhoses,
-Whentheoilcomes outofthebleedvalve (withoutairbubbles),close the
bleedvalve andcontinuetoturnthesteeringwheelinthesamedirectionto
fillthecylinderchamber(picture3).
Duringthis phase thecylinderbodywill move totheoppositedirectionupto
theendstroke.
3.6.2Singlesteeringstation/singlecylinder
1
NOTICE
Holdthecylinderbodywiththehandtopreventmovementscausedby theair
presentinthecylinderchamber(picture2).
3
2
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HYDRAULIC CYLINDERFOROUTBOARD ENGINE -page 19 of 78
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-Opentheotherbleedvalveandmove purgedoiltanktotheotherside.
Holdingthecylinderbodyinthisposition,turnthesteeringwheelas shown
inpicture4, untiloilwithoutairbubbles comes outofthebleedvalve.
Thenclose thebleedvalve.
-Repeattheentireproceduretoensuretheabsenceofairinthesystem.
Thedescribedprocedureis thesameevenincase ofsinglestation,dualengine,
singlecylinderandtiebar.
NOTICE
4
3.6.3Singlesteeringstation/dualcylinder
-Manuallyunscrewthetwobleedvalveson
thecylinder"T"fittingsandpushthe
cylinderstoonesideuptotheendstroke.
-Positiontheoilbottleasdescribedin
paragraph3.6.1.
-Followthesamebleedingprocedure
describedforthesinglesteeringstation
/singlecylinder(paragraph3.6.2).
Whileturningthesteeringwheelbecareful
becausebothcylindersmove.
-Repeattheentireprocedureseveral times
toensuretheairabsence inthesystem.
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l
bleed
valves
3.6.4 Dualsteeringstation/singlecylinder
-Manuallyunscrewthetwobleedvalves on
thecylinder"T"fittingsandpushthe
cylindertoonesideuptotheendstroke.
-Positiontheoilbottlenearthemainsteering
station(upper)accordingtowhatis
describedinparagraph3.6.1.
Waituntiltheoilreaches thelowertankand
bothtanksarefilled.
-Followthesamebleedingprocedure
describedinparagraph3.6.2 startingfrom
thelowerstationandrepeatitfortheupper
station.
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l
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bleed
valves
blackvent plug
silver non-vent
plug
WARNING

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page 20 of 78-HYDRAULIC CYLINDERFOROUTBOARD ENGINE
ENGLISH
3.6.5Dualsteeringstation/dualcylinder
-Manuallyunscrewthetwobleedvalves
onthecylinder"T"fittingsandpushthe
cylinderstoonesideuptotheendstroke.
-Positiontheoilbottlenearthemain
steeringstation(upper)accordingtowhat
isdescribedinparagraph3.6.1.
Waituntiltheoilreaches thelowertankand
bothtanksarefilled.
-Followthesamepurgingprocedure
describedinparagraph3.6.2 startingfrom
thelowerstationandrepeatitfortheupper
station.
WARNING
ATTENZIONE
-Repeattheentireprocedureatleast4timestoensuretheabsence ofairinthesystem.
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l
bleed valvers
blackvent plug
silver
non-vent plug
WARNING
3.7Generalrecommendation
It is veryimportanttochecktheabsence ofairinthesystembeforeusingtheboat! Werecommendtrying
tomanually move theenginetowardsportandstarboard,makingsurethatthereisnomovementofthe
cylinderbodyonthemaincylindershaft.
If thecylinderbodymoves morethan1/6inches (15mm),thereis still airinthesystem.Theairpresence in
thesystemcancausebadresponsestothecontrolsandsoitcancausedamage,injuries ordeath.
WARNING
Fortheadditionalsteeringstation(lower)tankuse onlythesilvernon-ventplug(suppliedwiththe"kitOB-
2S").Forthemainsteeringstation(upper)tankuse onlytheblackventplug.
-Repeattheprocedureatleast3times toensuretheabsence ofairinthesystem.
Thepurgingprocedureisthesamefordualstation,dualmotor,singlecylinderandtiebar.
WARNING
Fortheadditionalsteeringstation(lower)tankuse onlythesilvernon-ventplug(suppliedwiththe"kitOB-
2S").Forthemainsteeringstation(upper)tankuse onlytheblackventplug.
NOTICE