Ultraflex UP 56 Manual

PUMPFORHYDRAULIC
STEERINGSYSTEMS
UP56
UP68
ULTRAFLEX
SOCIO
InstallationandMaintenanceManual
R
ITALIANOFRANÇAIS ENGLISH
I
UK F
page 2 pag.25 page. 49
(Dr.No.22825/d08/05/2015)

ULTRAFLEX S.p.A.
ULTRAFLEX
16015 Casella (Genova)Italia-ViaCrose,2
"ULTRAFLEX has over80 yearsofexperienceinthemarineindustryandis aworld leaderintheproduction
ofmechanical,hydraulicandelectronicsteeringsystems,controlboxesandsteeringwheelsforany
kindofpleasure,fishingorcommercialboats.
Thekeyfactorswhichexplaintheincreasingsuccess ofourproductsall overtheworld arethereliability
ofourproductsandthebeforeandaftersaleservice, thequalityofthecompanyorganizationandofthe
humanresourcesandthecontinuousspendinginresearchanddevelopment".
DearCustomer,
Wewouldliketothankyouforchoosingan ULTRAFLEX product.
ULTRAFLEX has beenaleaderinsteeringsystemsforpleasureandprofessionalboatsformanyyears.
ULTRAFLEX productionis sinceeversynonimousofreliabilityandsafety.
All ULTRAFLEX productsaredesignedandmanufacturedtoensurethebestperformance.
Toensureyoursafetyandtomaintainahighqualitylevel, ULTRAFLEX productsareguaranteedonlyif
theyareusedwithoriginalspareparts.
ULTRAFLEX and UFLEX QualityManagementSystemsarecertifiedCISQ-IQNetbytheItalianShipping
Registry(RINA),inconformitywiththeUNIENISO9001:2008rule. ULTRAFLEX certificationNo. 6669/02/S
(former420/96). UFLEX certificationNo. 8875/03/S.
Thequalitymanagementsysteminvolvesallthecompanyresourcesandprocesses startingfromthe
design,inorderto:
- ensureproductqualitytothecustomer;
-maintainandimprovethequalitystandardsconstantly;
-pursueacontinuousprocess improvementtomeetthemarketneedsandtoincrease thecustomer
satisfaction
ULTRAFLEX EnvironmentalManagementSystemiscertifiedCISQ-IQNetbytheItalianShippingRegistry
(RINA),inconformitywiththeUNIENISO14001rule. ULTRAFLEX certificationNo.EMS-1282/S.
Productsforpleasureboatsareconstantlytestedtochecktheirconformitywiththe2013/53/EU.

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SECTION1-PRODUCTDESCRIPTION
1.1 HYDRAULICSTEERINGSYSTEMOPERATION..................................................................................7
1.2 WARNINGSFORTHECORRECTPRODUCTUSE.....................................................................7
1.3 SYSTEMCONFIGURATIONS........................................................................................................................8
1.4 PUMPDESCRIPTION..............................................................................................................9
1.5 PUMPANDPRESSURERELIEFVALVETECHNICALFEATURES............................................................9
TABLEOFCONTENTS
SECTION2-TRANSPORT
2.1 GENERALWARNINGS............................................................................................................................10
2.2 PACKAGINGCONTENTS....................................................................................................................10
SECTION5-MAINTENANCE
5.1 ORDINARYMAINTENANCE................................................................................................................22
5.2 TROUBLESHOOTING.........................................................................................................................22
SECTION3-INSTALLATION
3.1 NECESSARY TOOLSFOR REAR MOUNTINSTALLATION.....................................................................12
3.2 REARMOUNTINSTALLATION(WITHKITKR56)......................................................................12
3.3 NECESSARYTOOLSFOR INTERMEDIATEINSTALLATION.......................................................................14
3.4 INTERMEDIATEINSTALLATION(WITHKITKR56).........................................................................14
3,5 HOSECONNECTIONTO THESYSTEM....................................................................................................16
3,6 TYPEOFINSTALLATION.........................................................................................................................17
3.7 FILLINGANDPURGING.......................................................................................................................18
3,7,1 SINGLESTEERINGSTATION/SINGLE CYLINDER.....................................................................................19
3.7.2 DUALSTEERINGSTATION/SINGLECYLINDER.........................................................................................20
3.8 GENERALRECOMMENDATIONS................................................................................................................20
SECTION4-SAFETYWARNINGS
4.1 SAFETYWARNINGSDURINGUSEANDINSTALLATION.......................................................................21
4.2 CLOTHING....................................................................................................................21
SECTION6-DISMANTLING
6.1 DISMANTLING.......................................................................................................................24
!
DOCUMENTREVISIONS...................................................................................................................................4
MANUALUSEANDSYMBOLSUSED................................................................................................................5
INTRODUCTION.................................................................................................................................6
WARRANTY................................................................................................................................6

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DOCUMENTREVISIONS
Rev. Date Revisiondescription
0
A
B
13/04/2006
24/09/2013
16/07/2014
Firstedition
AdditionofUP68 model, additionofthe rearmount and intermediate
installationdescription
Modificationofchapter"Packagingcontents"

PUMP FORHYDRAULICSYSTEMS -page5 of75
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ENGLISH
Inthis manualthefollowingsymbolsareusedtoensuretheusersafetyandtoguarantee thecorrect
operationoftheproduct:
MANUALUSEANDSYMBOLSUSED
THEINSTALLATIONANDMAINTENANCE MANUALis thedocumentaccompanyingtheproductfromitssale
toitsreplacementanddischarge.Themanualis animportantpartoftheproductitself.
It is necessarytoreadcarefullythemanual,beforeANYACTIVITY involvingtheproduct,handlingand
unloadingincluded.
STERN
BOW
STARBOARD PORT Thepictureasideexplainsthemeaningofsome
nauticalwordscontainedinthismanual.
DANGER ImmediatehazardswhichCAUSEseverepersonalinjuryordeath.
WARNING
CAUTION
Thesymbolasideindicates all theoperationswhichmustbecarriedout
byqualifiedorskilledstaff,inordertoavoidhazards.
Werecommendtrainingthestaff inchargeoftheproductinstallation
andcheckingtheirknowledge.
NOTICE Importantinformationforthecorrectinstallationandformaintenance,that
doesnotcauseanydamage.
Denotes thatahazard existswhichcanresult ininjuryordeathifproper
precautionsarenottaken.
Denotes areminderofsafetypracticesordirectsattentiontounsafe
practices whichcould result inpersonalinjuryordamagetothecraft or
componentsortotheenvironment.

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WARRANTY
ULTRAFLEX guarantees thatitsproductsarewell designedandfree frommanufacturingandmaterialdefects,
foraperiodoftwoyearsfromthedateofmanufacturing.
Fortheproductswhichareinstalledandusedonworkingorcommercialboatsthewarrantyislimitedto
oneyearfromthedateofmanufacturing.
Ifduringthis periodtheproductproves tobedefectiveduetoimpropermaterialsand/ormanufacture, the
manufacturerwill repairorreplacethedefectivepartsfree ofcharge.
Directorindirectdamageis notcoveredbythis warranty.Inparticularthecompanyisnotresponsibleandthis
warrantywillnotcoverthedamageresultingfromincorrectinstallationoruseoftheproduct(exceptfor
replacementorrepairofdefectivepartsaccordingtotheconditionsandtermsabove).
This warrantydoes notcovertheproductsinstalledonraceboatsorboatsusedincompetitions.
Thedescriptionsandillustrationscontainedinthis manualshouldbeusedas generalreferenceonly.
ForanyfurtherinformationpleasecontactourTechnicalAssistanceService.
ULTRAFLEX steeringsystemcomponentsaremarkedaccordingtotheDirective2013/53/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](Italy)
Tel:[phone](abroad)
Fax: [phone]
Email:[e-mail]
www.ultraflexgroup.it
North-South-CentralAmerica:
UFLEX USA
6442 ParklandDrive
Sarasota, FL34243
Ph.:+1.941.351.2628
Fax: [phone]
Email:[e-mail]
www.uflexusa.com
This installationandmaintenancemanualrepresentsanimportantpartoftheproductandmustbeavailable
tothepeopleinchargeofitsuse andmaintenance.
Theusermustknowthecontentofthis manual.
ULTRAFLEX declines allresponsibilityforpossiblemistakes inthismanualduetoprintingerrors.
Apartfromtheessentialfeaturesofthedescribedproduct, ULTRAFLEX reserves therighttomakethose
modifications, suchas descriptions, detailsandillustrations, thatareconsideredtobesuitableforits
improvement,orfordesignorsales requirements, atanymomentandwithoutbeingobligedtoupdatethis
publication.
ALLRIGHTSARERESERVED.Publishingrights,trademarks,partnumbersandphotographsof ULTRAFLEX
productscontainedinthismanualare ULTRAFLEX property.
Greatcarehas beentakenincollectingandcheckingthedocumentationcontainedinthismanualto
makeitas completeandcomprehensibleas possible. Nothingcontainedinthis manualcanbeinterpreted
as warrantyeitherexpressedorimplied-including,notinarestrictedway,thesuitabilitywarrantyforany
specialpurpose. Nothingcontainedinthis manualcanbeinterpretedas amodificationorconfirmationof
thetermsofanypurchase contract.
Toensurethecorrectproductandcomponentoperation,theproductmustbeinstalledbyqualifiedstaff.
Incaseofpartdamageormalfunction,please contactthequalifiedstafforourTechnicalAssistance
Service.
WARNING

PUMP FORHYDRAULICSYSTEMS -page7 of75
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TheUP56-UP68 pumpmustnotbeinstalledonraceboats.
TheUP56-UP68 pumpisprovidedwith(external)pressurereliefvalve(seepictureabove)thatmustbe
placedabsolutelybetweenpumpandcylinderasshownintheparagraph3.5.
All ULTRAFLEX steeringsystemsmustnotbeinstalledonboatsequippedwithengines whosemaximum
horsepowerishigherthanthehorsepowerratingapprovedbyboatmanufacturer.
1.2Warningsfortheproductcorrectuse
Donotmodifythesteeringcylinderinanywaytofitittoyourapplication,otherwise thecylinderwillno
longeroperateinsafetyanditwill endangertheboatandtheoccupants.
WARNING
WARNING
WARNING
DANGER
1PRODUCTDESCRIPTION
1.1Hydraulicsteeringsystemoperation
All ULTRAFLEX hydraulicsteeringsystemsaredesignedinconformitywithUNI-EN-ISO10592 andA.B.Y.C.P21
regulations. All ULTRAFLEX steeringsystemscanoperateattemperatures between-18°C(0°F)and+77°C(+170°F).
Allthecomponentsaremadeforthemarineenvironment,usingmaterialsandworkingprocesses which
offerlonglifeandsafetyunderthemostextremeconditions. Ahydraulicsteeringsystemconsistsofa
steeringpump,acylindertiedtotherudderortotheoutboardor
sterndriveengineandtheconnectinghoses (see picture).Undernormal
operatingconditions, aturnofthesteeringwheelwill pumptheoil,
whichflowsinthroughthehosestothecylinder,accordingtotheturn
direction.Withtheconsequentcylindermovementtheoilwill flowtothe
pumpthroughthehoses andatthesametimemoves theengineorthe
helmwhichareconnectedtothecylinder.Thepumpsareequipped
withavalve, whichpreventsoutgoingfluidfromreturningalongthe
samehose. It also allowstheoperationofthesteeringsystemswithtwo
ormoresteeringstations.Thecylindersaredoubleactingandmaybe
balancedorunbalanced.Intheunbalancedcylindersthetwochambers
havedifferentvolumes andso theyneedadifferentnumberofturnsof
thesteeringwheelandadifferentrotationeffort.Thebalancedcylinders
havesamenumberofsteeringwheelturnsinordertomovethehelm
fromthecentertotheendstrokeinthetwooppositedirections. Awell
balancedsteeringsystemneedsacorrectchoiceofthepumpforthe
cylinder. ULTRAFLEX produces differentpumpmodels,whichhavedifferentcapacity(cm3ofoilmovedeach
steeringwheelturn)andforeachtypeofinstallation.Whilechoosingthepumpitisimportanttoconsider
thecylindervolume. Thenumberofstarboard andportturnsis determinedbytheratio betweenthecylinder
volumeandthepumpcapacity.
Example:ifthepumphas acapacityof28cm3 [1,7cu.in.]andthecylinderhas avolumeof120 cm3 [7,3cu.in.],the
formulalookslikethis: 120/28=4,2.Accordingly,thesteeringwheelwill turn4,2 times beforethecylinderwill
completelyturnfromonesidetotheother.Incase ofinstallationswithdoublecylindersconnectedin
parallelthecylindervolumemustbeadded.Applicationswithless than4turnsarenotrecommended,as
theyneedahighereffort,alsoapplicationswithmorethan8turnsarealsonotrecommended,asthe
response oftheboattosteeris slowly.Themaximumoperatingpressureis 7,0MPa(70 bar)(1000 PSI).
pump
l
l
hydraulichose
l
cylinder
helm
l
l
pressurereliefvalve

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NOTA
Ifitis necessarytousetwoUP56-UP68 pumpsindualstation,please contactourTechnicalAssistance
Service(see page6)inordertohaveanyinformationaboutthenecessarycomponentsandtheinstructions
tobefollowedfortheinstallation.
1.3Systemconfigurations
ThepumpUP56-UP68 modelcanbeinstalledinasingleordualenginesteeringsystemanditcanbeused
withdifferentcylinderconfigurations.Thepossibleconfigurationsare:
STEERINGSTATION
NUMBER
S
I
N
G
L
E
S
T
A
T
I
O
N
HELMNUMBER
With SINGLE CYLINDER
upto300hpmax
MAIN STATION
ADDITIONAL
STATION
D
U
A
L
S
T
A
T
I
O
N
S
I
N
G
L
E
H
E
L
M
NOTICE
With SINGLE CYLINDER and TIEBAR
non-counterrotating
engines upto
300hpmax of
combinedhorsepower
counterrotating
engines upto450hp
max ofcombined
horsepowerandupto
55 m.p.h.
D
U
A
L
H
E
L
M

PUMP FORHYDRAULICSYSTEMS -page9 of75
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1.4Pumpdescription
UP56-UP68 is a pumpwhichhas beendesignedandmanufacturedtobe usedas a componentinthe hydraulic
steeringsystems, as describedinthepreviousparagraph.
Thepumpmustbeinstalledonthebackpartoftheboatdashboard.
Thesteeringwheelismounteddirectlyonthehubofthepump.Inordertoguaranteetheboatsteering
undersafetyconditions,thepumpisprovidedwithacheckvalve.Thefollowingpictureshowsthemain
pumpcomponents:
Pump
Checkvalve
Steeringwheelshaft
Oilfillingcap
Coverglass foroillevelcheck
Systemfitting
Systemfitting
Connectionsforadditionalstations
Washer
Nutforfixingthesteeringwheel
ontheshaft
O-ring*
KR56 bezel*
ScrewsforfixingtheKR56 bezel*
*{KitKR56notincluded-code42558T}
1
2
3
4
5
6
7
8
9
10
11
1.5Pumpandpressurereliefvalvetechnicalfeatures
151 mm [5,94 in.]
151 mm [5,94 in.]
123 mm [4,84 in.]
26 mm
[1,02 in.]
117mm
[6,73 in.]
188mm
[7,40 in.]
25 mm [0,98 in.]
19,05 mm [3/4in.]
5/8 in.-18 UNF
62 mm
[2,44 in.] 70 mm
[2,75 in.]
62,2mm [2,44 in.]
ThepumpmodelUP56-UP68 mustbeusedonlywiththecylindersmodelUC378, UC339-I,UC442-IandUC530-I.
NOTICE
12
13
KIT KR56bezel
-code42558T
(notincluded)
70 mm
[2,75 in.]
55 mm [2,16 in.]
35 mm
[1,37 in.]
2
6
7
8
8
10
9
13
12
11
3
5
4
1
PressurereliefvalveRV70-
code42560D(notincluded)
SPECIFICATION
PUMPUP56
PUMPUP68
Capacity 56cc/rev. -3,4cu.in/rev. 68 cc/rev. -4,15 cu.in/rev.
Max. operating
pressure 70bar(1000 psi) 70 bar(1000 psi)
Piston No. 7 7
Max. steering wheel
diameter 711 mm (28in.) 711 mm (28 in.)
Steering wheelheight 152mm (6in.) 152 mm (6in.)
Weight 8kg 8kg
Oil OL150Ultraflex OL150 Ultraflex

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2.1Generalwarnings
2TRANSPORT
Theproductweightwithitspackagingis 9kg (19,84 pounds)andso itcanbehandledmanually.
2.2Packagingcontents
Beforeusingtheequipmentcheckthattheproducthasnotbeendamagedduringtransport.
Alsomakesurethatallthestandardcomponentsareinthepackaging(seelist).Incaseofdamage,
notifytheclaimtotheforwarderandinformthesupplier.
PUMPS UP56 -UP68:
A)pump;
B)pumpfittingsforpipe/hose Æ12mm;
C)nut,washandkeyfortighteningthesteeringwheelontheshaft;
D)adapter;
WARNING
Thestaff inchargeofhandlingmustoperatewithprotectivegloves andsafetyshoes.
KIT KR56 (NOT INCLUDED -CODE42558T):
E)screws, washes andnutsforfixingthepumptothedashboard;
F)KR56 bezel;
EF
A
C
B
D