Ultraflex B 301 Manual

SINGLELEVERCONTROL
Installationandmaintenancemanual
PARTNER
R
B301
B302
ENGLISH
(Dr.No.23166/d01/10/2017)
I
UK F
page.2 pag. 17 page. 33
ITALIANO
FRANÇAIS

ULTRAFLEX S.p.A.
ULTRAFLEX
16015Casella(Genova) Italia-ViaCrose,2
ENGLISH
DearCustomer,
Wewould liketothankyouforchoosingan ULTRAFLEX product.
ULTRAFLEX hasbeenaleaderinsteeringsystemsforpleasureandprofessionalboatsformanyyears.
ULTRAFLEX productionissinceeversynonimousofreliabilityandsafety.
All ULTRAFLEX productsaredesignedandmanufacturedtoensurethebestperformance.
To ensureyoursafetyandtomaintainahighqualitylevel, ULTRAFLEX productsareguaranteedonly if
theyareusedwithoriginalspareparts.
ULTRAFLEX and UFLEX QualityManagementSystemsarecertifiedCISQ-IQNetby theItalianShipping
Registry(RINA),inconformitywiththeUNIENISO9001:2008 rule. ULTRAFLEX certificationNo.6669/02/S
(former420/96). UFLEX certificationNo.8875/03/S.
Thequalitymanagementsysteminvolvesallthecompanyresourcesandprocesses startingfromthe
design,inorderto:
- ensureproductqualitytothecustomer;
-maintainandimprove thequalitystandardsconstantly;
-pursueacontinuousprocess improvementtomeetthemarketneedsandtoincrease thecustomer
satisfaction
ULTRAFLEX EnvironmentalManagementSystemis certifiedCISQ-IQNetby theItalianShippingRegistry
(RINA),inconformitywiththeUNIENISO14001rule. ULTRAFLEX certificationNo.EMS-1282/S.
Productsforpleasureboatsareconstantlytestedtochecktheirconformitywiththe2013/53/EU.
"ULTRAFLEX has over80 yearsofexperience inthemarineindustryandis aworld leaderintheproduction
ofmechanical,hydraulicandelectronicsteeringsystems, controlboxes andsteeringwheelsforany
kindofpleasure, fishingorcommercialboats.
Thekey factorswhichexplaintheincreasingsuccess ofourproductsall overtheworld arethereliability
ofourproductsandthebeforeandaftersaleservice, thequalityofthecompanyorganizationandofthe
humanresourcesandthecontinuousspendinginresearchanddevelopment".

SINGLELEVERCONTROL B301 AND B302 -page 3 of 47
Installationandmaintenancemanual
ULTRAFLEX
ENGLISH
SECTION1-PRODUCTDESCRIPTION
1.1 PRODUCTDESCRIPTIONANDRECOMMENDATIONSFORUSE............................................................6
1.2 DIMENSIONS...................................................................................................................6
TABLEOFCONTENTS
SECTION2-TRANSPORT
2.1 GENERALWARNINGS.............................................................................................................................7
2.2 PACKAGE CONTENTS....................................................................................................................7
SECTION6-MAINTENANCE
6.1 ORDINARYMAINTENANCE.................................................................................................................15
6.2 SPECIALMAINTENANCE.....................................................................................................15
SECTION3-INSTALLATION
3.1 TOOLSREQUIRED........................................................................................................................8
3.2 CONTROL BOXINSTALLATION........................................................................................................8
3,3 ADJUSTMENT OFTHELEVER INCLINATION..........................................................................8
3,4 CONNECTINGCONTROLCABLE.............................................................................................9
3.5 INSTALLATIONOFCABLESC14AND MACH14.................................................................................9
3.5.1 SHIFTCABLECONNECTION............................................................................................................9
3,5,2 THROTTLE CABLECONNECTION.......................................................................................................11
3.6 ADJUSTINGTHECLUTCH.................................................................................................................12
3.7 LEVERCONTROL BOXMOUNTING........................................................................................12
3.8 INSTALLATIONOFTHENEUTRAL SAFETY SWITCH..................................................................13
SECTION5-SAFETYWARNINGS
5.1 SAFETYRULESDURINGINSTALLATIONANDUSE....................................................................14
5.2 CLOTHING..........................................................................................................................14
SECTION7-DISMANTLING
7.1 DISMANTLING.........................................................................................................................15
!
USEOFTHISMANUALANDSYMBOLS...............................................................................................................4
INTRODUCTION.................................................................................................................................5
WARRANTY................................................................................................................................5
SECTION4-LEVERUSE
4.1 LEVERUSE............................................................................................................................14
!
IMPORTANT:
Theadditionaldocuments"ApplicationGuide"and"SparePartsList" areattachedtothismanual.

Installationandmaintenancemanual
ULTRAFLEX
page 4 of 47-SINGLELEVERCONTROL B301 AND B302
ENGLISH
Inordertoprotecttheuser's safetyandguarantee correctfunctioningoftheproduct,this manualuses the
symbolsdescribedbelow.
USE OFTHISMANUALAND SYMBOLS
THEINSTALLATION AND MAINTENANCE MANUAL is thedocumentaccompanyingtheproductfromsaleto
replacementanddisposal,andshouldbeconsideredanintegralpartoftheproduct.
ReadthemanualbeforeundertakingANY ACTIVITY involvingtheproduct,includingmovementandunloading
fromthevehicleonwhichitisdelivered.
STERN
BOW
STARBOARD PORT
Thepictureasideexplainsthemeaningofsome
nauticalwordscontainedinthismanual.
DANGER ImmediatehazardswhichCAUSEseverepersonalinjuryordeath.
WARNING
CAUTION
Operationswhichshould beperformedbyqualifiedorspecialized
personneltoavoidrisksareidentifiedby thesymbolshownhere.
Providethepersonnelwhowill beinstallingtheproductwithappropriate
trainingandmakesurethattheyunderstandandimplementthe
instructionsprovided.
NOTICE Importantinformationforthecorrectinstallationandformaintenance,that
doesnotcauseanydamage.
Denotes thatahazard existswhichcanresult ininjuryordeathifproper
precautionsarenottaken.
Denotesareminderofsafetypracticesordirectsattentiontounsafe
practices whichcould result inpersonalinjuryordamagetothecraft or
componentsortotheenvironment.

SINGLELEVERCONTROL B301 AND B302 -page 5 of 47
Installationandmaintenancemanual
ULTRAFLEX
ENGLISH
WARRANTY
ULTRAFLEX warrantsthatitsproductsarebuilt accordingtothestandardsofgoodworkmanshipandarefree
ofdefectsinmaterialsandworkmanship.
This warrantyis validfortwoyearsstartingonthedateofmanufacturewiththeexceptionofcases inwhich
productsareinstalledandusedonworkingvesselsoronvesselscommercialuse,inwhichcase the
guaranteeis limitedto1yearfromthedateofmanufacture.
This warrantyis limitedtofreereplacementorrepairoftheitem,whichmustbereturnedcarriagepaid,
providedwefindittobeeffectively defectiveinmaterialsand/orworkmanship.
Thewarrantydoes notcoveranydirectorindirectdamages, Thewarrantyspecificallydoesnotcover,and
weshall notbeliablefor(exceptforreplacementorrepairofdefective itemsunderthetermsandconditions
setforthabove),malfunctioningofourproductsiftheirfailureorpoorfunctioningis attributabletoincorrect
installationortonegligentorimproperuse.
Thiswarrantydoes notcoverproductsinstalledonracingboatsorusedinacompetitivecontext.The
descriptionsandillustrationsinthis manualareindicativeonly.
Please contactourAssistance Service formoredetailedinformation.
Thecomponentsof ULTRAFLEX steeringandcontrolsystemswithEC markedcomponents. (See Art.3andArt.
5ofdirective 94/25/EC.)Notethatthe ULTRAFLEX warrantyshallbeautomaticallyforfeitedifany ULTRAFLEX
componentsareinstalledinasteeringandcontrolsystemalongwithproductsofotherbrands.
INTRODUCTION
This installationandmaintenancemanualconstitutesanintegralpartoftheproductandmustbemade
easilyaccessibleforpersonnelusingtheproductandperformingmaintenancework onit.
Theusermustknowthecontentofthis manual.
ULTRAFLEX shall notbeheld liableforanyinaccuraciesduetoprintingerrorsinthemanual.
Withoutalteringthebasic featuresoftheproductdescribed ULTRAFLEX reserves therighttomakeanychangesto
descriptions,detailsandillustrationsthatitmayconsiderappropriateforitsimprovementorformanufacturing
orcommercialreasonsatanytime, withoutbeingrequiredtoupdatethis publicationimmediately.
ALL RIGHTSRESERVED. Rightstopublication,trademarks, logosandphotographsof ULTRAFLEX productspresent
inthis manualarethepropertyof ULTRAFLEXandmay notbereproduced infullorinpart.Greatcarehas been
takentocollectandverifydocumentationtomakethis manualas completeandeasytounderstandaspossible.
Noneoftheinformationobtainedinthis publicationmay beinterpretedas aguarantee oranexpress orimplicit
condition-includingbutnotlimitedto, theguaranteeofsuitabilityforaparticularpurpose. Noneoftheinformation
containedinthis publicationmay beinterpretedas achangetoorassertionofthetermsofanycontractof
purchase.
Theproductmustbeinstalledbyexperiencedpersonneltoensurecorrectfunctioningoftheproductandits
components.Intheeventofbreakageofthecomponentsormalfunctioning,contactspecializedpersonnel
orourTechnicalAssistanceService.
WARNING
TECHNICALASSISTANCE SERVICE
UFLEX S.r.l.
ViaMiliteIgnoto,8A
16012Busalla(GE)-Italia
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

Installationandmaintenancemanual
ULTRAFLEX
page 6 of 47-SINGLELEVERCONTROL B301 AND B302
ENGLISH
1.2 Dimensions
1PRODUCTDESCRIPTION
1.1 Productdescriptionandrecommendations foruse
TheB301 singleengineandtheB302 dualenginecontrolsaredesignedas asingleleverdualfunctionper
engine. They arespecifically designedtooperatewithoutboard,sterndrive (I/O)andinbord marine
propulsionengines. ThecontrolscanoperatewithallUltraflex cables excepttheC4; K59kitis included
withboththecontrols,necessary toinstallUltraflex C2, C8,C0, andMach0cables.
Foralltheothercablesthefollowingkitsareavailableondemand:
-K60 forcables Ultraflex C5 -C16 -MACH5;
- K 61 forcables Ultraflex C22;
- K 62 forcables Ultraflex C36 -MACH36.
- Thecables C14 andMACH14 requirenoinstallationkit.
Fig1
Distanza minimaper la corretta installazionedeicavi
Thepictures belowshowthelevercontrolB301andB302dimensions.
B301 B302
Distanzaminimaper lacorretta installazionedeicavi
Minimumdistance toallowthe cableinstallation
Minimumdistance toallowthe cableinstallation

SINGLELEVERCONTROL B301 AND B302 -page 7 of 47
Installationandmaintenancemanual
ULTRAFLEX
ENGLISH
Disposeofpackaginginaccordance withthelaw.
2.1 Generalwarnings
2TRANSPORTATION
Theproductanditspackagingweighabout2.5kg (5.5pounds)andcanthereforebemovedbyhand.
2.2 Package contents
Beforeusingthedevice,checkthatithas notsuffereddamageduringtransportationorstorage.Also
checkthatall thecomponentssuppliedwithitarecontainedinthepackage(refertolist).Ifyou
identifyanydamage, notifythecarrierandyoursupplier.
WARNING
Personnelhandlingtheloadmustworkwithsafetyglovesandfootwear.
WARNING
Contentsofthelever controlpackaging:
A
B
F
B301
B302
A
D
C
EG
I
H
REF B301 B302
A 1levercontrol 1lever control
B 4screwsM5x35 4screwsM5x35
C 4nutsM5 4nutsM5
D 4washers 4washers
E 3snaprings 6snaprings
F 1kitK59for cableinstallation 2kitsK59forcableinstallation
G 1screwM5x12 2 screwsM5x12
H 1plate 2plates
I 1pin 2pins

Installationandmaintenancemanual
ULTRAFLEX
page 8 of 47-SINGLELEVERCONTROL B301 AND B302
ENGLISH
3INSTALLATION
3.1Toolsrequired
Phillips
screwdriver
Pliers Openend
wrench
8mm [0,31”]
Socket wrench
17mm [0,66”]
1Remove therubber
coverfromthelever
hub(1).
3.3Adjustmentoftheleverinclination
Theleverangularpositioncanbeadjustedbothforward andbackward accordingtothecontrolposition.
Followtheinstructionsbelow:
1
2Extracttheplastic
pin(2).
4Extractthelever
andturnittothe
desiredposition,then
reinsertitbyputting
intogearwiththe
shaftofthecontrol
box.
2
3Takeoutthe
hexagonalheadscrew
(3)witha17socket
wrench.
3
3.2Controlboxinstallation
1Install thecontrolinapositionthatallowsthelevertorotatefree andtakecarethatitcanreachthe
fullforwardandfullreversestroke.
2Refertotheoverall dimensionsgiveninparagraph1.2 tocheckthatthebox caneffectively be
installedinthedesiredposition.
3Afterdeterminingtheappropriatelocation,drill theholes requiredtoassemblethecontrolbox
usingthetemplateprovidedforsingleordualcontrol.
Whenthecableisinstalledavoidtoonarrowbends.
WARNING
NOTICE
Forthesingleanddualcontrolinstallationrefertothedrillingtemplatesenclosed.
Connectthecablestotheleverbeforethelevercontroltothedashboard.
CAUTION
Theuse ofaproperkillingswitchsystemis recommendedforeachULTRAFLEXcontrolsysteminstallation.

SINGLELEVERCONTROL B301 AND B302 -page 9 of 47
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ENGLISH
3.4Connectingcontrolcable
1Selectadirectpathwithaminimumnumberofbendsandwithoutanyobstacles.
Avoidtoonarrowbends(theminimum bendradiusis 203 mm(8")).
WARNING
NOTICE
Outboard engineinstallationsrequireanadditionallengthofabout120cm(47")ofthecables toallow
engineswing.
Thecablescanbefixedwithsuitablecable hangers(suppliedseparately)orroutedthroughsegmentsof
conduit(suppliedseparatelytoo)forlongstraightruns.
WARNING
2CONTROLB301:
Removetherear
cover (4) ofthecontrol
by(unscrewing)the
screws (5) soas to
reacheasilythe
elementswherethe
cables aretobefixed.
45
5
CONTROL B302:
Spilt thetwoboxes
(6),byremoving
thescrews (5).
5
5
6 6
3Aspecificfittingkitisavailableforeachcabletype,K59kitisalso includedwithbothsinglelevers
B301 andB302.
Toinstallthecablesonthecontrol/controlsfollowtheinstructionsprovidedwitheachkit.
To installthecables C14 andMACH14 followtheinstructionsgivenbelow.
B301 B302
5Applythreadlocking lowstrength (Loctite222)onthescrew(3)andfastenitcompletely.
Insertthepinonthescrew(2).Inserttherubbercover(1).
Makesurethechosenangularpositionallowsthecorrectstrokeofthecable.
WARNING
3.5InstallationofcablesC14andMach14
3.5.1 Shift cableconnection
1Positionthe
controlbox onaplane
surfaceasinthe
picture(theUltraflex
logoonthelevermust
bevisible).
Removethecable
fastener(7)fromthe
plate(8)throughthe
screws(9).
2Mountthecable
makingsurethe
cablecylinder(10)is
placedinsidethe
platehole(11).
7
8
910
11
Toavoidthecontrolstiffening,donotfixthecablesnearthecontroloutlet(theminimumfixing
distance is500mm)andinanycase donotuse fixingsystemsthatcandeformthecableconduit.

Installationandmaintenancemanual
ULTRAFLEX
page 10 of 47-SINGLELEVERCONTROL B301 AND B302
ENGLISH
3Remountthe
cablefastener(7)on
theplate(8)aligning
thecylinderofthe
connector(10)withthe
holeofthecable
fastener.
4Fixthecable
fastener(7)totheplate
(8)withthescrews(9).
7
8
10
9
8
6Turnthecontrol
boxupsidedown
(internalmechanism
lookingupward).
Putthepin(I)inoneof
thethree holes (a),(b),
or(c)ofthelever(12).
NOTICE
Theholeischosenaccordingtothestrokeofthecable(seethetablebelow).
7
I
12
5Measuretheengineshiftleverstrokefromthe
forwardgeartothereversegear.Seethepossible
strokes onthecontroldevice andselectthenearestone;
forinstance,ifthestrokeontheengine(fromoneend
ofstroketotheother)is67 mm,thecablemustbe
connectedtothemoreinternalhole(68 mm stroke).If a
strokeof70 mm is detected,checkifthe68 mm stroke
is sufficientotherwiseconnectthecabletothecentral
hole(76 mm stroke);somemillimeters(5-6)ofsurplus
strokeonthecontroldevicearecounterbalancedby
thecableplay.
b
HOLE a b c
STROKE [mm ] 68 76 82
a
b
c
c
a
Adjusttheshift cablestrokeinordertonotforce thetopandthebottomoftheenginestroke.
Thenon-compliance withthisrecommendationcausesthecontrolsystemmalfunctionsuchas:
-Highresistancetotheleveroperation
-Earlywearofthemechanismthatcancause itslocking.
WARNING