Ultraflex UC 128-TS Manual

HYDRAULICCYLINDERFOR
OUTBOARDENGINES
UC128-TS
(Dr.No.22635/p27/07/2018)
InstallationandMaintenanceManual
ENGLISH
PARTNER
(REV.1)

UFLEXUSA
Sarasota,FL34243 -6442 ParklandDrive
DearCustomer,
Wewould liketothankyouforchoosingan ULTRAFLEX SpAproduct.
ULTRAFLEX SpAhasbeenaleaderinsteeringsystemsforpleasureandprofessionalboatsformany
years.
All ULTRAFLEX SpAproductsaredesignedandmanufacturedtoensurethebestperformance.
To ensureyoursafetyandtomaintainahighqualitylevel, ULTRAFLEX SpAproductsareguaranteedonly
iftheyareusedwithoriginalspareparts(see attacheddocument"ApplicationSpareParts").
Thequalitymanagementsysteminvolvesallthecompanyresourcesandprocesses startingfromthe
design,inorderto:
- ensureproductqualitytothecustomer;
-maintainandimprove thequalitystandardsconstantly;
-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.
Innovative productdesignandunparalleleddedicationtoqualitycustomerservice andproductsconti-
nuetobecornerstoneof UFLEX USA's growth.Todayourproductscanbefoundas originally installed
equipmentonmanyofthemostwidelyknownandrespectedboatbrandsintheworld.
Aftermarketpartscanbesourced fromtrainedandexperienceddistributornetwork troughoutNorth
andSouthAmerica.
Ourdedicationtoprovidingthehighestqualityproductsandservice is onlymatchedbyourcommitment
todevelopingnewproductsemployingthelastestmaterialsandtechnologytoenhanceourcustomer's
boatingexperience. Fromsteeringwheelstosophisticatedelectronic controls, UFLEX USAhas everything
youneedtomakesurethatyourboatlooksandperformit's bestformany,manyyears."

HYDRAULIC CYLINDERFOROUTBOARD ENGINE -page 3 of 26
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InstallationandMaintenanceManual
SECTION1-PRODUCTDESCRIPTION
1.1 HYDRAULICSTEERINGSYSTEMOPERATION.................................................................................8
1.2 WARNINGSFOR THECORRECTPRODUCTUSE......................................................................8
1.3 CONFIGURATIONS.........................................................................................................................9
1.4 UC128-TSCYLINDERDESCRIPTION......................................................................................................10
1.5 TECHNICALFEATURES..........................................................................................................................10
TABLEOFCONTENTS
SECTION2-TRANSPORT
2.1 GENERALWARNINGS.............................................................................................................................11
2.2 PACKAGINGCONTENTS....................................................................................................................11
SECTION5-MAINTENANCE
5.1 ORDINARY MAINTENANCE................................................................................................................23
5.2 HEADREPLACEMENT.........................................................................................................................23
5.3 TROUBLESHOOTING.........................................................................................................................24
SECTION3-INSTALLATION
3.1 MINIMUMTRANSOMREQUIREMENTS.........................................................................................12
3.2 NECESSARYTOOLS.......................................................................................................................12
3,3 STANDARD (STARBOARD)CYLINDERINSTALLATION................................................................13
3,4 HOSEINSTALLATION................................................................................................................................16
3.5 TYPEOFINSTALLATION...........................................................................................................................17
3.6 FILLINGAND PURGING.......................................................................................................................18
3.6.1 POSITIONINGOFTHEOILBOTTLE...................................................................................19
3,6,2 SINGLESTEERINGSTATION/SINGLECYLINDER......................................................................................19
3.6.3 SINGLE STEERINGSTATION/DUALCYLINDER..............................................................................20
3.6.4 DUALSTEERINGSTATION/SINGLECYLINDER.........................................................................................20
3.6.5 DUAL STEERINGSTATION/DUAL CYLINDER............................................................................................21
3.7 GENERAL RECOMMENDATIONS................................................................................................................21
SECTION4-SAFETYWARNINGS
4.1 SAFETY WARNINGSDURINGUSEAND INSTALLATION.......................................................................22
4..2 CLOTHING................................................................................................................................22
SECTION6-DISMANTLING
6.1 DISMANTLING...............................................................................................................................26
!
DOCUMENTREVISIONS...................................................................................................................................4
MANUALUSEANDSYMBOLSUSED................................................................................................................5
INTRODUCTION.................................................................................................................................6
WARRANTY................................................................................................................................6
IMPORTANT:
Theadditionaldocuments"ApplicationGuide"and"SparePartsList" areattachedtothismanual.

page 4 of 26 -HYDRAULIC CYLINDERFOROUTBOARD ENGINE
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InstallationandMaintenanceManual
DOCUMENTREVISIONS
Rev. Date Revisiondescription
0
1
20/02/2006
27/07/2018
Firstedition
Newversionwith removableheads

HYDRAULIC CYLINDERFOROUTBOARD ENGINE -page 5 of 26
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InstallationandMaintenanceManual
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.

page 6 of 26 -HYDRAULIC CYLINDERFOROUTBOARD ENGINE
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InstallationandMaintenanceManual
INTRODUCTION
This installationandmaintenance manualrepresentsanimportantpartoftheproductandmustbeavailable
tothepeopleinchargeofitsuse andmaintenance.
Theusermustknowthecontentofthis manual.
UFLEX declinesallresponsibilityforpossiblemistakesinthis manualduetoprintingerrors.
Apartfromtheessentialfeaturesofthedescribedproduct, UFLEX reservestherighttomakethose
modifications, suchas descriptions, detailsandillustrations, thatareconsideredtobesuitableforits
improvement,orfordesignorsales requirements, atanymomentandwithoutbeingobligedtoupdatethis
publication.
ALL RIGHTSARE RESERVED.Publishingrights, trademarks, partnumbersandphotographs of UFLEX products
containedinthismanualare UFLEX property.
Greatcarehas beentakenincollectingandcheckingthedocumentationcontainedinthismanualto
makeitas completeandcomprehensibleaspossible. Nothingcontainedinthis manualcanbeinterpreted
as warrantyeitherexpressedorimplied-including,notinarestrictedway,thesuitabilitywarrantyforany
specialpurpose.Nothingcontainedinthismanualcanbeinterpretedasamodificationorconfirmationof
thetermsofanypurchasecontract.
Toensurethecorrectproductandcomponentoperation,theproductmustbeinstalledbyqualifiedstaff.
Incaseofpartdamageormalfunction,please contactthequalifiedstafforourTechnicalAssistance
Service.
WARNING
WARRANTY
1.TwoYearLimitedWarranty. UFLEX USA, Inc.warrantsthatall productsmanufacturedby UFLEX USA,
Inc. or UFLEX S.p.A. andsold by UFLEX USAtotheretailpurchaser("Purchaser")thatfortwo(2)yearsafter
thedateofmanufacturetobefree fromdefectsduetomaterialorworkmanship,subjecttotheexclusions
below.ImproperinstallationAVOIDSthiswarranty.Installationshould onlybeattempetedbyatrained
andqualifiedtechnician.
2. Exclusions. This limitedwarrantydoes notcover anddoes notextendtoanyofthefollowing:
(a) Failurecausedby normalwearandtear,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 UFLEX S.p.A., whetherornotwarrantedbythe
othermanufacturer;
(e) anyproductwhichhasnotbeenproperlyinstalled.
TECHNICALASSISTANCE SERVICE
North-South-CentralAmerica:
UFLEX USA
6442ParklandDrive
Sarasota,FL34243
Tel:[phone]
Fax: [phone]
Email: [e-mail]
www.uflexusa.com
UFLEX S.r.l.
ViaMiliteIgnoto,8A
16012 Busalla(GE)-Italy
Tel:[phone]
Fax: [phone]
Email: [e-mail]
www.ultraflexgroup.it

HYDRAULIC CYLINDERFOROUTBOARD ENGINE -page 7 of 26
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InstallationandMaintenanceManual
3. Limitations. THEREPAIROR REPLACEMENT OFDEFECTIVE PARTSSHALL BE PURCHASER'SSOLE AND
EXCLUSIVEREMEDY AND UFLEX USA,INC,'SSOLEANDEXCLUSIVE LIABILITYUNDER THISWARRANTY.
LABOR FOR REPLACEMENT IS NOT INCLUDED. UFLEX USA, Inc.'s obligationunderthis warrantyis limited
totherepairorreplacement(at UFLEX USA, Inc.'s soleelection)ofanycovereditemfoundtobedefective,
whendeliveredby Purchaserpursuanttowrittenauthorizationandinstructionsfrom UFLEX USA, Inc.,
shippingprepaidto UFLEX USA,Inc.'s plantorotherdesignatedrepairfacility.Repairedorreplaced
itemsarewarrantedasprovidedhereinfortheunexpiredportionoftheapplicablewarrantyperiod.
THISWARRANTY, AND THERIGHTSAND REMEDIESUNDER IT, IS EXCLUSIVE AND IS GIVEN INPLACE OF
ALLOTHERWARRANTIES,WHETHEREXPRESSORIMPLIED,INCLUDINGANYIMPLIEDWARRANTYOF
MERCHANTABILITYOR FITNESSFORPARTICULARPURPOSE, WHETHERARISINGBYLAW,CUSTOM,
CONDUCT OR USAGE OFTRADE, PURCHASER'SREMEDIESSHALL BE LIMITED ASSTATED HEREINAND
UFLEX USA, INC. SHALL NOT BE LIABLE FOR ANY INCIDENTAL, CONSEQUENTIAL OR INDIRECT DAMAGES
ORLOSSESRESULTINGFROMDEFECTS.THERETAILSELLERIS NOTACO-WARRANTORAND ISNOT
AUTHORIZED BY UFLEX USA, INC. TO AMEND OR MODIFYTHISLIMITED WARRANTY INANY MANNER.
4.TransferabilityofWarranty. Thislimitedwarrantymay notbetransferredtosubsequentpurchasers.
5.Miscellaneous. UFLEX USA,Inc. is anaffiliateof UFLEX S.p.A. UFLEX,USA,Inc.,reservestherighttomake
changes inthedesignandconstructionofitsproducts atanytime, withoutnotice andwithoutanyobligation
toincorporatesuchchanges intoproductsofpriormanufacture. Thislimitedwarrantyapplies tonew
componentssold by UFLEX USA,Inc.. This limitedwarrantycontainstheentireagreementsbetween
UFLEX USA, Inc.andPurchaserandsuspersedes allprioragreements,discussions, negotiations,
commitmentsandrepresentations, whetheroralorwritten,betweenthemregarding UFLEX USA, Inc's
warranty.If anyprovisionofthislimitedwarranty, ortheapplicationofit,isdeterminedtobeinvalidof
unenforceableforanyreason,theremainderofthislimitedwarrantyandtheapplicationofitshallnot
beaffected.
6. Ultron3000 andPowerC. TheUltron3000and"PowerC-UserandInstallationManual" describes
activities,operations,technical specificationswhichmustbefollowedduringtheinstallationand/or
usageoftheproduct,inordertokeepavalidwarranty.Descriptionsanddrawingsinthatmanualare
suitabletoallowinstallationanduse oftheproducttoskilledpersons. Incaseofdoubtand/orforany
information,pleasecontactourTechnicalService.
All communicationsandnoticesfromPurchaserregardingthis limitedwarrantyshould besentto: UFLEX
USA, INC., 6442 ParklandDrive, Sarasota, FL34243; [phone].
Return policy
Anyproductthatis presumeddefective shouldbereportedto UFLEX USAwithin48 hoursofreceiptor
discoveryinthefield.Uponnotification UFLEX USAwill attempttotroubleshoottheproblemwithourcustomer
overthephone.If weareunabletoresolvetheproblem UFLEX willissueaReturnGoodsAuthorization
numberandwerequirethattheproductinquestionbereturnedto UFLEX withallitspartsinitsoriginal
packaging.Theproductshouldbereturnedfreightprepaidto:
UFLEXUSA
RGA Department-RGA #
6442ParklandDrive
Sarasota, Florida34243
Uponreceipt UFLEX will examinetheproducttodeterminethecause ofthedefect.If theproductis determined
tohaveadefectinworkmanshipormaterial,itwillberepairedatourdiscretion.
Ourwarrantydoes notcoverlabor,towingorotherexpenses. Further,itdoes notcoverproductsthathave
beenimproperly installed,damagedininstallation,misapplied,ormisused.
Ourproductsarenotintendedforuseinracingapplications.

page 8 of 26 -HYDRAULIC CYLINDERFOROUTBOARD ENGINE
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InstallationandMaintenanceManual
ULTRAFLEX hydraulicsteeringsystemsshouldnotbeusedinracingapplications.
To avoidproductdamage,donotdisassemblepre-assembledcomponents.
All UFLEX steeringsystems mustnotbe installedonboatsequippedwithengines whose maximum horsepower
ishigherthanthehorsepowerratingapprovedby 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 ULEX hydraulic steeringsystemsaredesignedinconformitywithUNI-EN-ISO10592andA.B.Y.C. P21 regulations.
AllUFLEXsteeringsystemscanoperateattemperatures between-18°C(0°F)and+77°C(+170°F).All the
componentsaremadeforthemarineenvironment,usingmaterialsandworkingprocesseswhichoffer
longlifeandsafetyunderthemostextremeconditions.Ahydraulicsteeringsystemconsistsofasteering
pump,acylindertiedtotherudderortotheoutboard orsterndrive
engineandtheconnectinghoses(see picture).Undernormal
operatingconditions, aturnofthesteeringwheelwillpumptheoil,
whichflowsinthroughthehosestothecylinder,accordingtothe
turndirection.Withtheconsequentcylindermovementtheoilwill
flowtothepumpthroughthehoses andatthesametimemoves the
engineorthehelmwhichareconnectedtothecylinder.Thepumps
areequippedwithavalve,whichpreventsoutgoingfluidfrom
returningalongthesamehose.It also allowstheoperationofthe
steeringsystemswithtwoormoresteeringstations.Thecylinders
aredoubleactingandmaybebalancedorunbalanced.Inthe
unbalancedcylindersthetwochambershave differentvolumes and
so they needadifferentnumberofturnsofthesteeringwheelanda
differentrotationeffort.Thebalancedcylindershavesamenumber
ofsteeringwheelturnsinordertomove thehelmfromthecenterto
theendstrokeinthetwooppositedirections. Awell balancedsteeringsystemneedsacorrectchoice ofthe
pumpforthecylinder. UFLEX produces differentpumpmodels,whichhave differentcapacity(cm3ofoilmoved
eachsteeringwheelturn)andforeachtype ofinstallation.Whilechoosingthepumpitis importantto
considerthecylindervolume. Thenumberofstarboardandportturnsisdeterminedbytheratiobetween
thecylindervolumeandthepumpcapacity.
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
l
l
l
pump

HYDRAULIC CYLINDERFOROUTBOARD ENGINE -page 9 of 26
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InstallationandMaintenanceManual
1.3Configurations
Thehydrauliccylinderforoutboard engineUC128-TSmodelcanbeinstalledwithdifferentconfigurations
accordingtothenumberandthetypeofengines usedwithasingleordualenginesteeringsystem.
Thepossibleconfigurationsare:
Onrequest,tripleoutboardengineapplicationsareavailable.Fordetailedinformation,pleasecontact
UFLEX 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 120cc -7.8 cu. in
Outputforce 450 Kg-992 lbs (@70 bar)
Insidediameter 35mm -1.37"
Stroke 198 mm -7.79"
Oil
OL150 Ultraflex
*Thecylinderoutputforceisatheoreticalforcewithasystempressureof105bar.Thisforce doesnot
correspondtotheonenormallyusedbythesystembutitrepresentsthelimitingconditionsofuse.
CAUTION