Ultraflex UC 68-OBS Manual

HYDRAULICCYLINDERSFOR
SIDEMOUNT APPLICATIONS
InstallationandMaintenanceManual
UC133-IOB
UC68-OBS
UC132-OBS
(Dr.No.23068/e16/07/2019)
PARTNER

ITALIANO
UFLEXUSA
Sarasota,FL34243 -6442 ParklandDrive
"Establishedin1989 UFLEX USAis aleaderinsteeringandcontrolsystemsforthemarineindustry.
Withfull manufacturingcapabilities inSarasota, Florida, UFLEX USAcansupportall sectorsofthemarine
industryregardless ofvolumeand/orproductrequirements. And,asanaffiliateofthe ULTRAFLEX Group,
UFLEX USAhas tremendousresources todrawuponfornewproductdevelopmentinhydraulics, electronics
andmanyothertechnologies.
Innovative productdesignandunparalleleddedicationtoqualitycustomerservice andproductsconti-
nuetobecornerstoneof UFLEX USA's growth.Todayourproductscanbefoundas originally installed
equipmentonmanyofthemostwidelyknownandrespectedboatbrandsintheworld.
Aftermarketpartscanbesourcedfromtrainedandexperienceddistributornetwork throughoutNorth
andSouthAmerica.
Ourdedicationtoprovidingthehighestqualityproductsandservice is onlymatchedbyourcommitment
todevelopingnewproductsemployingthelatestmaterialsandtechnology toenhance ourcustomer's
boatingexperience. Fromsteeringwheelstosophisticatedelectronic controls, UFLEX USAhas everything
youneedtomakesurethatyourboatlooksandperformit's bestformany,manyyears."
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.

HYDRAULIC CYLINDERFORSIDEMOUNTAPPLICATIONS -page 3 of 23
InstallationandMaintenanceManual
SECTION1-PRODUCTDESCRIPTION
1.1 HYDRAULICSTEERINGSYSTEMOPERATION..................................................................................6
1.2 WARNINGSFORTHECORRECT PRODUCTUSE..................................................................................6
1.3 CONFIGURATIONS........................................................................................................................7
1.4 CYLINDERDESCRIPTION..............................................................................................................................8
1.5 TECHNICALFEATURES................................................................................................................................8
TABLEOFCONTENTS
SECTION2-TRANSPORT
2.1 GENERALWARNINGS.............................................................................................................................9
2.2 PACKAGINGCONTENTS.................................................................................................................9
SECTION5-MAINTENANCE
5.1 ORDINARY MAINTENANCE.................................................................................................................20
5.2 TROUBLESHOOTING........................................................................................................................19
SECTION3-INSTALLATION
3.1 DIMENSIONS...............................................................................................10
3.2 NECESSARY TOOLS..................................................................................................................10
3,3 CYLINDERINSTALLATION............................................................................................................11
3,4 HOSEINSTALLATION...................................................................................................................12
3.5 TYPEOFINSTALLATION.............................................................................................................................12
3.6 FILLINGANDPURGING.......................................................................................................................14
3.6.1POSITIONINGOFTHEOILBOTTLE..........................................................................................14
3,6,2SINGLE STEERINGSTATION/SINGLE CYLINDER.......................................................................................17
3.6.3SINGLE STEERINGSTATION/DUAL CYLINDER..............................................................................18
3.6.4DUALSTEERINGSTATION/SINGLECYLINDER.........................................................................................18
3.6.5DUALSTEERINGSTATION/DUALCYLINDER..............................................................................................17
3.7 GENERALRECOMMENDATIONS.........................................................................................................17
SECTION4-SAFETYWARNINGS
4.1 SAFETYWARNINGSDURINGUSEAND INSTALLATION........................................................................19
4..2 CLOTHING.................................................................................................18
SECTION6-DISMALTING
6.1 DISMALTING.......................................................................................................................21
!
MANUALUSEANDSYMBOLSUSED................................................................................................................4
INTRODUCTION.................................................................................................................................5
WARRANTY.............................................................................................5
IMPORTANT:
Theadditionaldocuments"ApplicationGuide"and"SparePartsList" areattachedtothismanual.

InstallationandMaintenanceManual
page 4 of 23-HYDRAULIC CYLINDERFORSIDEMOUNTAPPLICATIONS
STERN
BOW
STARBOARD PORT
THEINSTALLATION AND MAINTENANCE MANUAL is thedocumentaccompanyingtheproductfromitssale
toitsreplacementanddischarge.Themanualis animportantpartoftheproductitself.
It is necessarytoreadcarefully themanual,beforeANY ACTIVITYinvolvingtheproduct,handlingand
unloadingincluded.
Thepictureasideexplainsthemeaningofsome
nauticalwordscontainedinthismanual.
MANUALUSE AND SYMBOLSUSED
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.
LEGEND
m.p.h. =miles perhour
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
er

HYDRAULIC CYLINDERFORSIDEMOUNTAPPLICATIONS -page 5 of 23
InstallationandMaintenanceManual
INTRODUCTION
This installationandmaintenance manualrepresentsanimportantpartoftheproductandmustbeavailable
tothepeopleinchargeofitsuse andmaintenance.
Theusermustknowthecontentofthis manual.
UFLEX USAdeclinesallresponsibilityforpossiblemistakesinthis manualduetoprintingerrors.
Apartfromtheessentialfeaturesofthedescribedproduct, UFLEX USAreservestherighttomakethose
modifications, suchas descriptions, detailsandillustrations, thatareconsideredtobesuitableforits
improvement,orfordesignorsales requirements, atanymomentandwithoutbeingobligedtoupdatethis
publication.
ALLRIGHTSARE RESERVED.Publishingrights,trademarks,partnumbersandphotographsof UFLEX USA
productscontainedinthismanualare UFLEX USAproperty.
Greatcarehas beentakenincollectingandcheckingthedocumentationcontainedinthismanualto
makeitas completeandcomprehensibleaspossible. Nothingcontainedinthis manualcanbeinterpreted
as warrantyeitherexpressedorimplied-including,notinarestrictedway,thesuitabilitywarrantyforany
specialpurpose.Nothingcontainedinthismanualcanbeinterpretedasamodificationorconfirmationof
thetermsofanypurchasecontract.
TECHNICALASSISTANCE SERVICE
UFLEX S.r.l.
ViaMiliteIgnoto,8A
16012 Busalla(GE)-Italy
Tel:[phone](Italy)
Tel:[phone] (abroad)
Fax: [phone]
Email: [e-mail]
www.uflexgroup.it
North-South-CentralAmerica:
UFLEX USA
6442ParklandDrive
Sarasota,FL34243
Tel:[phone]
Fax: [phone]
Email: [e-mail]
www.uflexusa.com
Toensurethecorrectproductandcomponentoperation,theproductmustbeinstalledbyqualifiedstaff.
Incaseofpartdamageormalfunction,please contactthequalifiedstafforourTechnicalAssistance
Service.
WARNING
WARRANTY
1. TwoYearLimitedWarranty. UFLEX USA, Inc.warrantsthatall productsmanufacturedby UFLEX USA,
Inc. or ULTRAFLEX S.p.A. andsold by UFLEX USAtotheretailpurchaser("Purchaser")thatfortwo(2)years
afterthedateofmanufacturetobefreefromdefectsduetomaterialorworkmanship,subjecttothe
exclusionsbelow.ImproperinstallationVOIDSthiswarranty.Installationshouldonlybeattemptedbya
trainedandqualifiedtechnician.
2. Exclusions. This limitedwarrantydoes notcover anddoes notextendtoanyofthefollowing:
(a) Failurecausedbynormalwearandtear,climatic conditions, misuse, neglect,lackofpropermaintenance,
accident,fireorothercasualtydamage, racing,overloading,negligence,modification,beachingor
groundingofvessel,collision,impact,towing,actsofwarorhostilities;
(b) componentsnotmanufacturedby UFLEX USA,Inc.,oritsaffiliates;
(c) costofremovalorreinstallationofanycomponent(includingcomponentsmanufacturedby UFLEX USA,
Inc.)ordisassembly orreassembly oftheunitcontainingthecomponent;
(d) componentsnotmanufacturedby UFLEX USA, Inc. or ULTRAFLEX S.p.A., whetherornotwarrantedbythe
othermanufacturer;
(e) anyproductwhichhasnotbeenproperlyinstalled.

InstallationandMaintenanceManual
page 6 of 23-HYDRAULIC CYLINDERFORSIDEMOUNTAPPLICATIONS
3. Limitations. THEREPAIROR REPLACEMENT OFDEFECTIVE PARTSSHALL BE PURCHASER'SSOLE AND
EXCLUSIVE REMEDYAND UFLEX USA, INC,'SSOLE AND EXCLUSIVE LIABILITY UNDER THISWARRANTY.
LABOR FOR REPLACEMENT IS NOT INCLUDED. UFLEX USA, Inc.'s obligationunderthis warrantyis limited
totherepairorreplacement(at UFLEX USA, Inc.'s soleelection)ofanycovereditemfoundtobedefective,
whendeliveredbyPurchaserpursuanttowrittenauthorizationandinstructionsfrom UFLEX USA,Inc.,
shippingprepaidto UFLEX USA,Inc.'splantorotherdesignatedrepairfacility.Repairedorreplaced
itemsarewarrantedasprovidedhereinfortheunexpiredportionoftheapplicablewarrantyperiod.
THISWARRANTY, AND THERIGHTSAND REMEDIESUNDER IT, IS EXCLUSIVE AND IS GIVEN INPLACE OF
ALL OTHER WARRANTIES,WHETHER EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WHETHER ARISING BY LAW,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
OR LOSSESRESULTING FROMDEFECTS.THERETAILSELLER IS NOT ACO-WARRANTOR AND IS NOT
AUTHORIZED BY UFLEX USA, INC. TO AMEND OR MODIFYTHISLIMITED WARRANTY INANY MANNER.
4.TransferabilityofWarranty. Thislimitedwarrantymay notbetransferredtosubsequentpurchasers.
5. Miscellaneous. UFLEX USA, Inc.is anaffiliateof ULTRAFLEX S.p.A. UFLEX,USA, Inc., reserves therightto
makechanges inthedesignandconstructionofitsproductsatanytime, withoutnotice andwithoutany
obligationtoincorporatesuchchanges intoproductsofpriormanufacture. Thislimitedwarrantyapplies
tonewcomponentssold by UFLEX USA, Inc.. This limitedwarrantycontainstheentireagreementsbetween
UFLEX USA, Inc.andPurchaserandsupersedesallprioragreements,discussions, negotiations,
commitmentsandrepresentations, whetheroralorwritten,betweenthemregarding UFLEX USA, Inc's
warranty.If anyprovisionofthislimitedwarranty, ortheapplicationofit,isdeterminedtobeinvalidof
unenforceableforanyreason,theremainderofthislimitedwarrantyandtheapplicationofitshallnot
beaffected.
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.

HYDRAULIC CYLINDERFORSIDEMOUNTAPPLICATIONS -page 7 of 23
InstallationandMaintenanceManual
TheUC 68-OBS,UC 132-OBSandUC 133-IOB sidemountcylindersmustnotbeinstalledonrace boats.
Dualengineapplicationsrequiretwosteeringcylindersandtie bar,whenthecombinedenginehorsepower
exceeds450hp,and/orwhentheboatspeedexceeds55 m.p.h.
All ULTRAFLEX steeringsystemsmustnotbeinstalledonboatsequippedwithengines whosemaximum
horsepoweris higherthanthehorsepowerratingapprovedby boatmanufacturer.
1.2 Warningsfortheproductcorrectuse
Beforebeginningtheinstallation,checkthemountingcompatibilityoftheUC 68-OBS,UC 132-OBSandUC
133-IOB cylinderstotheenginebyconsultingtheattacheddocument"ApplicationGuide"containedinthe
packaging.
WARNING
WARNING
WARNING
WARNING
DANGER
1PRODUCTDESCRIPTION
1.1Hydraulicsteeringsystemoperation
l
engine
l
hydraulic
hose
l
cylinder
l
pump
All UFLEX hydraulicsteeringsystemsaredesignedinconformitywithUNI-EN-ISO10592andA.B.Y.C.P21
regulations. All UFLEXsteeringsystemscanoperateattemperatures between-18°C(0°F)and+77°C(+170°F).
Allthecomponentsaremadeforthemarineenvironment,usingmaterialsandworkingprocesseswhich
offerlonglifeandsafetyunderthemostextremeconditions. Ahydraulicsteeringsystemconsistsofa
steeringpump,acylindertiedtotherudderortotheoutboard or
sterndrive engineandtheconnectinghoses (see picture).Under
normaloperatingconditions, aturnofthesteeringwheelwill pump
theoil,whichflowsinthroughthehoses tothecylinder,according
totheturndirection.Withtheconsequentcylindermovementthe
oilwillflowtothepumpthroughthehoses andatthesametime
moves theengineorthehelmwhichareconnectedtothecylinder.
Thepumpsareequippedwithavalve,whichpreventsoutgoing
fluidfromreturningalongthe samehose. It also allows the operation
ofthesteeringsystemswithtwoormoresteeringstations. The
cylindersaredoubleactingandmaybebalancedorunbalanced.
Intheunbalancedcylindersthetwochambershavedifferent
volumes andso they needadifferentnumberofturnsofthesteering
wheelandadifferentrotationeffort.Thebalanced cylindershave
samenumberofsteeringwheelturnsinordertomove thehelmfromthecentertotheendstrokeinthetwo
oppositedirections. Awellbalancedsteeringsystemneedsacorrectchoice ofthepumpforthecylinder.
UFLEX produces differentpumpmodels,whichhave differentcapacity(cm3ofoilmovedeachsteeringwheel
turn)andforeachtypeofinstallation.Whilechoosingthepumpitisimportanttoconsiderthecylinder
volume. Thenumberofstarboard andportturnsis determinedby theratiobetweenthecylindervolume
andthepumpcapacity.
Example:ifthepumphas acapacityof28 cm3 [1,7cu.in.]andthecylinderhas avolumeof132cm3 [7,3cu.in.],the
formulalookslikethis: 132/28=4,7.Accordingly, thesteeringwheelwill turn4times andanhalf beforethe
cylinderwill completelyturnfromonesidetotheother.Incaseofinstallationswithdoublecylinders
connectedinparallelthecylindervolumemustbeadded.Applicationswithlessthan4turnsarenot
recommended,astheyneedahighereffort,alsoapplicationswithmorethan8turnsarealsonot
recommended,astheresponse oftheboattosteerisslowly.Themaximumoperatingpressureis7,0MPa
(70bar)(1000 PSI).
Do notmodifythesteeringcylinderinanyway tofitittoyourengineapplication,otherwise thecylinderwill
nolongeroperateinsafetyanditwillendangertheboatandtheoccupants.

InstallationandMaintenanceManual
page 8 of 23-HYDRAULIC CYLINDERFORSIDEMOUNTAPPLICATIONS
1.3Configurations
ThehydrauliccylindersforsidemountinstallationsUC68-OBS,UC132-OBS,UC133-IOBmodelcanbe
installedwithdifferentconfigurationsaccordingtothenumberandthetypeofengines usedwithasingleor
dualenginesteeringsystem.
Thepossibleconfigurationsare:
S
I
N
G
L
E
S
T
A
T
I
O
N
ENGINE NUMBER
With SINGLECYLINDER
With SINGLECYLINDER
and TIEBAR
With DUALCYLINDER
and TIEBAR
up to250hpmax
andupto55 m.p.h.
MAIN
STATION
ADDITIONAL
STATION
D
U
A
L
S
T
A
T
I
O
N
S
I
N
G
L
E
E
N
G
I
N
E
D
U
A
L
E
N
G
I
N
E
DANGER
Dualengineinstallationsrequiretheuse ofatiebar.
upto150hpmaxandup
to55m.p.h.
UC 68-OBS UC 132-OBSUC 133-IOB
counterandnon-counterrotatingengines
upto300hpmaxof combinedhorsepower
andupto60 m.p.h.
non-counterrotatingenginesupto
250hpmax ofcombined horsepowerandup
to55m.p.h.;
counterrotatingenginesupto300hpmax
ofcombinedhorsepowerandupto
55m.p.h.
enginesupto150hpmaxofcombined
horsepower and up to
55m.p.h.
With SINGLECYLINDER
STEERINGSTATION
NUMBER
With SINGLECYLINDER
and TIEBAR
NOTICE
Thepictures above areindicati-
ve,forfurtherinformationabout
installationseeparagraph3.5,
NOTICE
Incase ofusewithpower-assistedsterndrives,please contactourTechnicalAssistance Service.

HYDRAULIC CYLINDERFORSIDEMOUNTAPPLICATIONS -page 9 of 23
InstallationandMaintenanceManual
1.4Cylinderdescription
UC 68-OBS,UC 132-OBSandUC133-IOB arehydraulic sidemountcylinderswhichhave beendesignedand
manufacturedtobeusedasacomponentinthehydraulicsteeringsystems, asdescribedintheprevious
paragraph.
Thecylindersareinstalledontherightsideofthetilt tubeoftheavailableoutboard engines onthemarket,
and,accordingtothesameinstructionsdescribedinthis manual,they arealso installedonthetilt tubes of
theinboard-outboard applications. It is possibletoadjustthecylindertoall thedifferentengineapplications
thankstoalinkarmsuppliedwiththeengine. Thefollowingpictures showthemaincylindercomponents:
Cylinderbody
Bleeders
Pin
Extension
1
2
3
4
1.5Technicalfeatures
SPECIFICATIONS UC68-OBS UC132-OBS UC133-IOB
Volume 68/100cc-4.1/6.1cu.in 132/163cc-8/9.95cu.in 132cc-8cu.in
Outoutforce 185/270kg-408/595Ibs 455/563 kg-1003/1240lbs 455kg-1003lbs
Insidediameter 25mm -0.98" 32mm-1.25" 32 mm-1.25"
Stroke 203mm -8" 203mm-8" 203mm-8"
Oil incompliancewithISOVG15incompliancewithISOVG15incompliancewithISOVG15
UC68-OBS(unbalanced)
2
3
4
UC133-IOB (balanced)
UC132-OBS(unbalanced)
1
1
1
2
2
3
3
4
4
WARNING
Theunbalancedcylinderscanbeusedonlywith ULTRAFLEX pumps.
OIL15 OIL15 OIL15

InstallationandMaintenanceManual
page 10 of 23-HYDRAULIC CYLINDERFORSIDEMOUNTAPPLICATIONS
CONTENTSOFTHESTANDARDPACKAGING:
A)No.1cylinderbody:
B)No.1extention;
C)pin;
D)No.1plastichoseforthehydrauliccircuitbleeding;
2.1 Generalwarnings
2TRANSPORT
Theproductweightwithitspackagingis 3kg (7pounds)andso itcanbehandledmanually.
2.2 Packagingcontents
Beforeusingtheequipmentcheckthattheproducthasnotbeendamagedduringtransport.
Alsomakesurethatallthestandardcomponentsareinthepackaging(seelist).Incaseofdamage,
notifytheclaimtotheforwarderandinformthesupplier.
WARNING
Thestaffinchargeofhandlingmustoperatewithprotectivegloves andsafetyshoes.
UC132-OBS
UC68-OBS
UC133-IOB
ll
l
B
A
l
D
l
A
A
l
l
D
l
l
B
l
l
B
D
l
CC
C
Thepackagingmustbedisposedofaccordingto theexistinglaws.
CAUTION