Ultraflex UC 81 Manual

page 2 pag.43 page 85
Installation and Maintenance Manual
HYDRAULIC CYLINDER
FOR OUTBOARD MOTORS
UC 81
ITALIANOFRANÇAIS ENGLISH
I
UK F
(REV 04 - 04/02/2015)
PARTNER
(dr./dis./des. n°29602d 04/02/2015)

Dear Customer,
Thank you for choosing one of our products .
The has long been a landmark in steering systems in the field of both leisure and
professional boating.
Always production is synonymous with great reliability and safety.
All products are designed and manufactured to guarantee the best performance
possible, according to the purposes they are designed and intended for.
To protect your safety and to keep a high quality level warrants its products only
when used with original spare parts (see the "Application Spare Parts" herein attached).
The Quality Management Systems and CISQ-IQNet certified by RINA Italian
Naval Register, in accordance with UNI EN ISO 9001:2000 rule. Certified No.
6669/02/S (formerly 420/96). Certified No. 8875/03/S.
The Quality management system involves all the resources and business processes, starting
from design, and aimed at:
• ensuring the customer the quality of the product;
• set the actions to maintain and improve over time the quality standards;
• pursuing continuous improvement in the effectiveness and efficiency of the processes to
always readily meet the requirements of the market and increase customer satisfaction;
• monitoring compliance with requirements imposed by Directive 2003/44/EC, by UNI EN ISO
10592 rule and ABYC standards (American Boat and Yacht Council).
with more than 70 years of experience in the marine industry today is a global leader in
the production of mechanical, hydraulic and electronic steering systems, control units and steering
wheels for powerboats, as well as fishing and working boats of every size and type of engine.
The reliability of our products and before and after sales service, the quality of the business
organization and human resources, together with continuous investment in research and
development are key factors to explain the increasingly growing success of our products all
over the world.
16015 Casella (Genova) Italia - Via Crose, 2
S.p.A.

Installation and Maintenance Manual
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GENERAL INDEX
DOCUMENT REVISIONS............................................................................................................................4
USE OF THE MANUAL AND SYMBOLS USED..............................................................................................5
INFORMATIONLETTER..............................................................................................................................6
WARRANTY..............................................................................................................................................7
SECTION 1 - PRODUCT DESCRIPTION
1.1 OPERATION OF A HYDRAULIC STEERING SYSTEM....................................................................8
1.2 INFORMATION FOR CORRECT USE OF THE PRODUCT................................................................9
1.3 CONFIGURATIONS...................................................................................................................9
1.4 DESCRIPTIONOFTHECYLINDER.............................................................................................10
1.5 TECHNICALFEATURES............................................................................................................11
SECTION 2 - TRANSPORT
2.1 GENERAL WARNINGS FOR PRODUCT HANDLING....................................................................12
2.2 PACKAGING CONTENT............................................................................................................12
Section 3 - INSTALLATION
3.1 COCKPITMINIMUM REQUIREMENTS......................................................................................14
3.2 REQUIRED TOOLS..................................................................................................................15
3.3 INSTALLATION OF THE CYLINDER..........................................................................................16
3.3.1 SWITCHING TO “PORT” CONFIGURATION ...............................................................................16
3.3.2 ASSEMBLY OF THE CYLINDER................................................................................................20
3,4 INSTALLATION OF TUBES.......................................................................................................29
3.5 FILLINGANDBLEEDING.........................................................................................................31
3.5.1 POSITIONING THE OIL BOTTLE...............................................................................................33
3.5.2 OIL FILLING AND BLEEDING PROCEDURE..............................................................................34
SECTION 4 - SAFETY WARNINGS
4.1 SAFETY PRECAUTIONS DURING INSTALLATION AND USE......................................................36
4.2 CLOTHING.............................................................................................................................37
SECTION 5 - MAINTENANCE
5.1 ROUTINE MAINTENANCE.........................................................................................................37
5.2 STEERING WHEEL DISMANTLING............................................................................................38
5.3 TROUBLESHOOTING................................................................................................................38
SECTION 6 - DISMANTLING
6.1 DISMANTLING.......................................................................................................................42

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DOCUMENT REVISIONS
REV. DATE REVISION DESCRIPTION
012/09/2013 First edition.
107/05/2014 Upgrade to 39kn (45mph).
228/11/2014 Update compatible oils.
303/02/2015 Added 4 O-Rings in the cylinder (page 18) and 4 spare O-Rings to be
used in case of starboard/port configuration change.
Added tightening torque for mounting the plug with extension.
Added the prohibition of lubricating screws, in order to preserve the
thread blocking compound effect.
404/02/2015 Changed the tightening torque for mounting the nuts on the motor
tube rod and on the cylinder stem.

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USE OF THE MANUAL AND SYMBOLS USED
The INSTALLATION AND MAINTENANCE MANUAL is the document accompanying the product
from the time of its sale until replacement and disposal. It must be therefore considered an
integral part of it.
It is recommended to read the manual before carrying out ANY ACTIVITIES involving the
product, including its handling and unloading from the vehicle.
In order to protect the user's safety and to ensure the proper operation of the product, in this
manual the symbols described below were adopted.
The figure below is designed to facilitate the interpretation of some nautical terms contained in this
manual.
PORT
STARBOARD
BOW
STERN
LEGEND
m.p.h = miles per hour
Km/h = kilometres per hour
10 m.p.h = 8,69 knots
10 m.p.h = 16,1 km/h
10 knots = 11,5 m.p.h
10 knots = 18,5 km/h
10 km/h = 6,21 m.p.h
10 km/h = 5,4 knots
Denotes a reminder of safety practices or unsafe practices which could
result in personal injury or damage to the product or to the environment.
CAUTION
DANGER
Denotes that an estreme intrinsic hazard exist which would result
inhight probability of death or irreparable injury if proper precautions
ano not taken.
NOTE
Important information to highlight for adequate installation and
maintenance, but not the cause of damage.
Denotes that a hazard exist which can result in injury or death if
proper precautions are not taken.
WARNING
The symbol aside indicates all the operations which must be carried
out by qualified or skilled staff, in order to avoid hazards.
We recommend training the staff in change of the product installation
and checking their knowledge.

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INFORMATION LETTER
This installation and maintenance manual is an integral part of the product and must be
readily available for use by staff appointed to both use and maintenance.
The user is required to be familiar with the contents of this manual.
disclaims any liability for inaccuracies due to typographical errors in the manual.
Without prejudice to the essential characteristics of the product described,
reserve the right to make any changes to descriptions, details and illustrations, as it deems
them proper to improve the product itself, or to meet manufacturing or commercial nature
requirements, at any time and without being required to readily update this publication.
ALL RIGHTS RESERVED. Publishing rights, trademarks, part numbers and product photos
in this manual are the property of which prohibits any reproduction, even partial.
Every care has been applied in compiling and checking the documentation in order to make
this manual as complete, comprehensive and clear as possible. Nothing contained in this
publication should be construed as a warranty or condition, express or implied, not limited
to, for suitability for a special purpose.
Nothing contained in this publication can also be interpreted as modifying or stating the
terms of any purchase contract.
WARNING
In order to ensure the proper operation of the product and its components, it must be
installed by trained personnel. In case of breakage of constituting parts or malfunction,
please consult qualified service staff or contact our Technical Service Department.
TECHNICAL SERVICE DEPARTMENT
UFLEX S.r.l.
Via Milite Ignoto,8A
16012 Busalla (GE)-Italy
Ph: +39.010.962.0239 (Italy)
Ph: +39.010.962.0244 (Abroad)
Fax: +39,010,962.0333
Email: [email protected]
www.ultraflexgroup.it
North - South - Central America:
UFLEX USA
6442 Parkland Drive
Sarasota, FL 34243
Ph: +1,941,351.2628
Fax: +1,941,360.9171
Email: [email protected]
www.uflexusa.com

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WARRANTY
warrants that its products are manufactured in a workmanlike manner and that they are
free from defects in workmanship and materials.
This warranty is valid for a period of 2 years from the date of manufacture of the products, with the
exception of cases in which they are installed and used on working boats or in any case on boats
used for commercial purposes, in which case the warranty is limited to 1 year from the date of
manufacture.
This warranty is limited to free replacement or repair of that or those components that, by that
established date, will be returned prepaid and deemed by our technicians as actually defective in
material and / or workmanship.
The guarantee does not cover any and other direct or indirect damage. In particular, the warranty
does not cover and we disclaims any liability (except to replace or repair any defective components
under the terms and conditions mentioned above) where their failure or malfunction is attributable
to faulty installation, careless or incorrect use.
This warranty does not cover products installed on racing boats or in any case used in competitive
environments. The descriptions and illustrations in this manual are given as an indication only.
For detailed information please contact our Service Department.
The components of the steering systems are marked as required by Directive
2003/44/EC and comply with UNI EN ISO 10592 rule and ABYC (U.S.A.) standards.
Please note that on the boats marked it is required to install steering systems whose components
are marked (See Article 3 and Article 5 of Directive 2003/44/EC.). We inform you that the warranty
will be automatically voided if any components are installed in a steering
system together with products of other brands.

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1 - PRODUCT DESCRIPTION
1.1 Operation of a hydraulic steering system
The hydraulic systems are designed in accordance with UNI EN ISO 10592 rule and A.B.Y.C.
standards P21.
The steering systems are able to operate in an ambient temperature ranging between
-18°C (0°F) and +77°C (+170°F), all of their components were specifically manufactured for the marine
environment, using materials and applying processes that offer great durability and safety even in
extreme conditions.
The hydraulic steering system mounted on a
boat schematically consists in:
• a pump placed on the dashboard;
• a cylinder positioned at the stern and
connected to the motor or to the helm;
• pair of connection hydraulic tubes (see
figure).
The rotation of the steering wheel causes
the pumping of the oil that, depending on the
direction of rotation, flows into the cylinder
through the tubes.
Theconsequent movementofthe cylindermakes
the oil flow towards the pump through the tubes
and at the same time moves the engine or the
helm of the boat connected to the cylinder itself.
The pumps are equipped with a non-return
valve, which has the function of preventing the
flow of oil to the pump if the latter is not running. In unbalanced cylinders the two chambers have different
capacities, and therefore require, considering the same displacement in the two directions, a different
number of turns of the steering wheel and a different rotation torque on the steering wheel. The balanced
cylinders require the same number of turns of the steering wheel to move the helm from the centre to the
end of stroke in the two opposite directions.
A balanced and easily manoeuvrable steering system requires a proper choice of the type of pump to be
coupled to the cylinder. builds different models of pumps, which differ for the flow rate (cm3
of oil handled at each turn of the steering wheel) and for the type of installation. While choosing the pump
you must consider the capacity of the cylinder: the number of steering wheel turns from left to right is in
fact determined by the ratio between the volume of the cylinder and the pump flow.
Example: if the pump has a flow rate of 18 cm3 [1.2 cu.in.] and the cylinder has a capacity of 81 cm3
[5.7cu.in], then the following formula applies: 81/18=4,5. Therefore the steering wheel will rotate about
4 and a half times before the cylinder is completely shifted from side to side. Couplings with less than
4 turns are not recommended as they require excessive driving strength, neither those with more than
8 turns are advisable as they make the board slow in responding to the steering gear. The maximum
operating pressure is equal to 5,5MPa (55 bars) (800 psi).
pump motor
cylinder
hydraulic tubes
example of application

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1.2 Information for correct use of the product
CAUTION
Before starting the installation, re-check the mounting compatibility of the UC81 cylinder to the
motor consulting the attached "Application Guide" contained in the package.
WARNING
In any case do not make changes to the steering cylinder in order to make it better suit your
specific application. In this case the pump will not operate safely and endanger the boat and
its occupants.
The steering systems should not be used on boats equipped with engines that exceed the
maximum horsepower rating provided on site.
The UC81 cylinder is not recommended for installation on racing boats or boats with particularly low
dead-rise angle.
1.3 Congurations
The hydraulic cylinder UC81 must ONLY be installed on a steering system with a single outboard
motor and single steering station and ONLY used together with pump UP18 supplied in the GOTECH™
kit. The hydraulic cylinder UC81 is supplied in starboard configuration, i.e. with the extension arm
assembled on the starboard side; however, if correct installation is prevented by any element on the
boat, it can be assembled port side, i.e. with the extension arm on the left hand side.
STARBOARD CONFIGURATION PORT CONFIGURATION
CAUTION
The UC81 hydraulic cylinder should not be mounted on boats with motor exceeding 115hp and / or
45mph (39kn).
For information on "port" configuration please refer to section 3.3 - "Installing the cylinder" of this
manual.

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7
10
8
11
9
3
4
5
6
1
2
12
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1.4 Description of the cylinder
The UC81 hydraulic cylinder is a front mounted hydraulic cylinder designed and built to be
used as a component of a hydraulic steering system as described in the previous section.
The cylinder is applied to the tilt tube of motors available on the market, as set out in the
"Application guide" annex. In fact, thanks to the possibility to reverse the side of the idler
arm and the use of a series of specially sized spacers, it is possible to adapt the cylinder for
any type of installation.
The following figure shows the main components of the cylinder.
Cylinder body
Rod
Fitting vent (2x)
Fitting (2x)
Vent plugs and fittings (4x)
“Bullhorn” bracket (2x)
“Link arm” extension
“Link arm” nut and screw
Motor tube rod (bar Tilt)
Fine adjustment ring nut
Spacers
Key
5
2
4
3
1
6
7
8
9
11
10
12
9

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574 mm - 22,6 ‘‘
77 mm - 3’’
1.5 Technical features
SPECIFICATIONS
UC81
Capacity 81 cc - 4,9 cu. in
Max thrust 222 kg - 489 Ibs (@55 bar)
Inner diameter 27.4 mm - 1,08”
Stroke 186 mm - 7,3”
Oil OL150 ULTRAFLEX
Operating max pressure
5,5 MPa (55 bar) (800 psi)
CAUTION
The cylinder’s thrust is a theoretical thrust calculated with a system pressure of 55 bar, obtainable using
UP18 pumps. This thrust does not correspond to the one of the system’s normal operation but represents
the operational limit condition.

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2 - TRANSPORT
2.1 General warnings for product handling
The weight of the product, including the packaging, is 8 Kg (18 pounds) and therefore it can
be handled manually.
CAUTION
The staff handling the load must operate using all required PPE (individual protection devices) as
required by the applicable standard on accident prevention at the workplace.
2.2 PACKAGING CONTENT
Before use, check that the equipment has not been suffered damage due to transport or storage
conditions.
Also make sure that all standard components are actually inside the packaging (see list).
In case of damage or incomplete delivery, notify your claim to the carrier and also to your
supplier.
CAUTION
The packaging must be disposed of according to applicable directives.

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CONTENT OF THE STANDARD PACKING:
No. 1 cylinder
"Bullhorn" brackets
1 motor tube shaft kit composed of:
• motor tube shaft (2 pieces)
• 2 self-locking nuts + 2 washers
• 1 key for motor shaft
No. 1 spacers kit consisting of:
• No. 10 plastic spacers
• No. 2 steel spacers
• No. 1 fine adjustment ring nut fitted with screw and nut
No. 1 kit screws consisting of:
• No. 2 self-locking nuts + No. 2 washers + No. 2 bushes
• No. 1 screw
• No. 1 self-locking nut
• n°4 O-Rings (to be used in case of starboard/port configuration change)
• No. 1 label
Instructions:
• Installation and Maintenance Manual
• Application guide
B
F
A
C
D
E
E
D
B
C
A

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
90
°
B
A
A

90
°
B
A
A
C
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MINIMUM DIMENSIONS REQUIRED BY THE COCKPIT
A B C
152 mm - 5,98” 152 mm - 5,98” 590 mm - 23,23”
3 - INSTALLATION
3.1 Cockpit minimum requirements
Before installing the cylinder it is necessary to ascertain that the dimensions of the cockpit are well
suited to the upwards rotation of the outboard motor (Tilt) without the cylinder comes into contact
with the cockpit itself.
Here following are the minimum dimensions of the cockpit and of the transom to ensure proper
rotation and operation of cylinder into the motor.

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3.2 REQUIRED TOOLS
CAUTION
During the phases of installation only use stainless steel tools in order to avoid oxidation of
the metal parts.
Open end wrench
17 mm
Open end wrench
14 mm
Torque wrench Allen wrench
4 mm
MOLYKOTE ® 1000
or
MARINE GREASE
Torx wrench T30
Wrench with 14
mm long socket
wrench
WARNING
MOUNTING THE MOTOR TO THE TRANSOM WITH JACK PLATE.
The installation of a jack plate will change all of the clearances required for the application.
A new check of clearances must be completed with the rotation of the motor in conjunction with the
vertical movement of the jack plate in all possible positions. If the cylinder comes into contact with
the cockpit, transom, and / or the jack plate, immediately stop the installation!
Use the instructions of the jack plate manufacturer to limit the upper or lower direction in
which the interference occurs. If this is not possible, contact qualified staff.

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3.3 INSTALLATION OF THE CYLINDER
WARNING
Before proceeding with the installation of the product, ensure that you meet the requirements for
a correct application mentioned in section 1.3 - "Configurations" and 3.1 - "Cockpit minimum
requirements".
NOTE
is not liable for any damages caused by the contact between the cylinder and motor and/
or boat parts.
3.3.1 SWITCHING TO "PORT" CONFIGURATION
Here following is the description of the procedure required to reverse the position of the extension
arm in "port" configuration, if you want to mount the cylinder in a "starboard" configuration please
directly refer to section 3.3.2 - "Assembly of the cylinder."
CAUTION
Never remove the screw (A) to change the configuration of the cylinder.
NOTE
If switching from "starboard" to "port" configuration occurs after the first installation (e.g.
in case the motor is replaced), you must follow the procedure described AFTER you have
removed the cylinder and the related bullhorns.
CAUTION
Under no circumstances should the fastening screws on the heads (B) be dismantled more than
once. If a further change from port to starboard is necessary, or if gaskets need to be replaced, you
must buy the specific “change seals” kit.
Contact support.
NOTE
To pass to port configuration, do not attach the label unless at the end of the procedure.

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STARBOARD CONFIGURATION PORT CONFIGURATION
1Push the stem unit it stops.
2Using the Torx T30 wrench remove the screws (1) and the relevant washers in stainless
steel (2).
B
A
1
2
A
B

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3
Pull the cap with extension (3) and remove the 4 O-Rings (4) from their seats.
CAUTION
When removing the cap with the extension (3) it is necessary to hold the rod (5) so that the head does not
protrudes (6).
4Insert the 4 new O-Rings provided (7) into their seats.
CAUTION
When handling the cylinder, make sure that the O-Rings do not come out from their seats.
Turn the extension plug 180° and re-insert it on the cylinder, as outlined in the figure.
7
3
5
6
4

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5Fasten the plug with the extension on the new position with the relevant screws and
washers, with a tightening torque of 10 Nm (7,4 lb ft).
CAUTION
Take care that the key (8) and the head (9) coincide.
In repositioning the cap the plastic head should NOT be rotated or moved.
In order not to reduce the effectiveness of the thread blocking compound, DO NOT lubricate the screws.
6Turn the cylinder by 180'.
9
8

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7The cylinder is now in "port" configuration.
WARNING
The hex head screw (10) is fixed at the bottom with a safety punching; DONOT try to unscrew for
any reason.
8Proceed installing the cylinder.
1After removing the protective caps of the fittings (1), manually centre the rod (2) with
respect to the body of the cylinder (3).
CAUTION
During this phase a small amount of oil may spill from the fittings, that this oil must never be
poured into the environment.
3.3.2 Assembly of the cylinder
10
1
23
a
a
1