Installation and Maintenance Manual HYDRAULIC CYLINDER FOR INBOARD ENGINES UC 378 ITA LIANO F R A NÇ A IS SOCIO. pag. 21. (Dr. No /b 18/02/2015)

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1 HYDRAULIC CYLINDER FOR INBOARD ENGINE F R A NÇ A I ITA LIANO UC 378 Instaation and Maintenance Manua R OCIO UK I F page. 2 pag. 2 page. 4 (Dr. No. 2349/b 8/02/205)

2 Dear Customer, We woud ike to thank you for choosing an ULTRAFLEX product. ULTRAFLEX has been a eader in steering systems for peasure and professiona boats for many years. ULTRAFLEX production is since ever synonimous of reiabiity and safety. A ULTRAFLEX products are designed and manufactured to ensure the best performance. To ensure your safety and to maintain a high quaity eve, ULTRAFLEX products are guaranteed ony if they are used with origina spare parts. ULTRAFLEX and UFLEX Quaity Management ystems are certified CIQ-IQNet by the Itaian hipping Registry (RINA), in conformity with the UNI EN IO 900:2008 rue. ULTRAFLEX certification No. 6669/02/ (former 420/96). UFLEX certification No. 8875/03/. The quaity management system invoves a the company resources and processes starting from the design, in order to: - ensure product quaity to the customer; - maintain and improve the quaity standards constanty; - pursue a continuous process improvement to meet the market needs and to increase the customer satisfaction ULTRAFLEX Environmenta Management ystem is certified CIQ-IQNet by the Itaian hipping Registry (RINA), in conformity with the UNI EN IO 400 rue. ULTRAFLEX certification No. EM-282/. Products for peasure boats are constanty tested to check their conformity with the 203/53/EU. "ULTRAFLEX has over 80 years of experience in the marine industry and is a word eader in the production of mechanica, hydrauic and eectronic steering systems, contro boxes and steering whees for any kind of peasure, fishing or commercia boats. The key factors which expain the increasing success of our products a over the word are the reiabiity of our products and the before and after sae service, the quaity of the company organization and of the human resources and the continuous spending in research and deveopment". ULTRAFLEX.p.A. 605 Casea (Genova) Itaia - Via Crose, 2

3 Instaation and Maintenance Manua TABLE OF CONTENT MANUAL UE AND YMBOL UED...4 INTRODUCTION...5 WARRANTY...5 ECTION - PRODUCT DECRIPTION. HYDRAULIC TEERING YTEM OPERATION FOR THE CORRECT PRODUCT UE YTEM CONFIGURATION CYLINDER DECRIPTION TECHNICAL FEATURE...8 ECTION 2 - TRANPORT 2. GENERAL PACKAGING CONTENT...9 ECTION 3 - INTALLATION 3. NECEARY TOOL CYLINDER INTALLATION...0 3,3 HOE INTALLATION...2 3,4 TYPE OF INTALLATION FILLING AND PURGING...4 3,5, INGLE TEERING TATION/ INGLE CYLINDER DUAL TEERING TATION/INGLE CYLINDER GENERAL RECOMMENDATION...6 ECTION 4 - AFETY 4. AFETY DURING UE AND INTALLATION CLOTHING...7 ECTION 5 - MAINTENANCE 5. ORDINARY MAINTENANCE TROUBLEHOOTING...8 ECTION 6 - DIMANTLING 6. DIMANTLING...20! HYDRAULIC CYLINDER FOR INBOARD ENGINE - page 3 of 64

4 Instaation and Maintenance Manua MANUAL UE AND YMBOL UED THE INTALLATION AND MAINTENANCE MANUAL is the document accompanying the product from its sae to its repacement and discharge. The manua is an important part of the product itsef. It is necessary to read carefuy the manua, before ANY ACTIVITY invoving the product, handing and unoading incuded. DANGER Immediate hazards which CAUE severe persona injury or death. Denotes that a hazard exists which can resut in injury or death if proper precautions are not taken. CAUTION NOTICE Denotes a reminder of safety practices or directs attention to unsafe practices which coud resut in persona injury or damage to the craft or components or to the environment. Important information for the correct instaation and for maintenance, that does not cause any damage. The symbo aside indicates a the operations which must be carried out by quaified or skied staff, in order to avoid hazards. We recommend training the staff in charge of the product instaation and checking their knowedge. TERN TARBOARD PORT The picture aside expains the meaning of some nautica words contained in this manua. BOW page 4 of 64 - HYDRAULIC CYLINDER FOR INBOARD ENGINE

5 Instaation and Maintenance Manua INTRODUCTION This instaation and maintenance manua represents an important part of the product and must be avaiabe to the peope in charge of its use and maintenance. The user must know the content of this manua. ULTRAFLEX decines a responsibiity for possibe mistakes in this manua due to printing errors. Apart from the essentia features of the described product, ULTRAFLEX reserves the right to make those modifications, such as descriptions, detais and iustrations, that are considered to be suitabe for its improvement, or for design or saes requirements, at any moment and without being obiged to update this pubication. ALL RIGHT ARE REERVED. Pubishing rights, trademarks, part numbers and photographs of ULTRAFLEX products contained in this manua are ULTRAFLEX property. Great care has been taken in coecting and checking the documentation contained in this manua to make it as compete and comprehensibe as possibe. Nothing contained in this manua can be interpreted as warranty either expressed or impied - incuding, not in a restricted way, the suitabiity warranty for any specia purpose. Nothing contained in this manua can be interpreted as a modification or confirmation of the terms of any purchase contract. To ensure the correct product and component operation, the product must be instaed by quaified staff. In case of part damage or mafunction, pease contact the quaified staff or our Technica Assistance ervice. UFLEX.r.. Via Miite Ignoto,8A 602 Busaa (GE)-Itay Ph.: (Itay) Ph.: (abroad) Fax: Emai: ut@utrafexgroup.it TECHNICAL AITANCE ERVICE North - outh - Centra America: UFLEX UA 6442 Parkand Drive arasota, FL Ph.: Fax: Emai: ufex@ufexusa.com WARRANTY ULTRAFLEX guarantees that its products are we designed and free from manufacturing and materia defects, for a period of two years from the date of manufacturing. For the products which are instaed and used on working or commercia boats the warranty is imited to one year from the date of manufacturing. If during this period the product proves to be defective due to improper materias and/or manufacture, the manufacturer wi repair or repace the defective parts free of charge. Direct or indirect damage is not covered by this warranty. In particuar the company is not responsibe and this warranty wi not cover the damage resuting from incorrect instaation or use of the product (except for repacement or repair of defective parts according to the conditions and terms above). This warranty does not cover the products instaed on race boats or boats used in competitions. The descriptions and iustrations contained in this manua shoud be used as genera reference ony. For any further information pease contact our Technica Assistance ervice. ULTRAFLEX steering system components are marked according to the Directive 203/53/EU. We remind you that ony marked steering systems must be used on the boats marked. We inform you that the ULTRAFLEX warranty is nu if some ULTRAFLEX components are instaed on a steering system together with products of other brands. HYDRAULIC CYLINDER FOR INBOARD ENGINE - page 5 of 64

6 ULTRAFLEX PRODUCT DECRIPTION. Hydrauic steering system operation.2 Warnings for the product correct use Instaation and Maintenance Manua A ULTRAFLEX hydrauic steering systems are designed in conformity with UNI-EN-IO 0592 and A.B.Y.C. P2 reguations. A ULTRAFLEX steering systems can operate at temperatures between -8 C (0 F) and +77 C (+70 F). A the components are made for the marine environment, using materias and working processes which offer ong ife and safety under the most extreme conditions. A hydrauic steering system consists of a steering pump, a cyinder tied to the rudder or to the outboard or sterndrive engine and the connecting hoses (see picture). Under norma operating conditions, a turn of the steering whee wi pump the oi, which fows in through the hoses to the cyinder, according to the turn direction. With the consequent cyinder movement the oi wi fow to the pump through the hoses and at the same time moves the engine or the hem which are connected to the cyinder. The pumps equipped with a vave which prevents outgoing fuid from returning aong the same hose, aow the operation of the steering systems with two or more steering stations. The cyinders are doube acting and may be baanced or unbaanced. In the unbaanced cyinders the two chambers have different voumes and so they need a different number of turns of the steering whee and a different rotation effort. The baanced cyinders have same number of steering whee turns in order to move the hem from the center to the end stroke in the two opposite directions. A we baanced steering system needs a correct choice of the pump for the cyinder. ULTRAFLEX produces pump hydrauic hose cyinder different pump modes, which have different capacity (cm 3 of oi moved each steering whee turn) and for each type of instaation. Whie choosing the pump it is important to consider the cyinder voume. The number of starboard and port turns is determined by the ratio between the cyinder voume and the pump capacity. Exampe: if the pump has a capacity of 28 cm 3 [,7cu.in.] and the cyinder has a voume of 20 cm 3 [7,3cu.in.], the formua ooks ike this: 20/28=4,2. Accordingy, the steering whee wi turn 4,2 times before the cyinder wi competey turn from one side to the other. In case of instaations with doube cyinders connected in parae the cyinder voume must be added. Appications with ess than 4 turns are not recommended, as they need a higher effort, aso appications with more than 8 turns are aso not recommended, as the response of the boat to steer is sowy. hem DANGER Do not modify the steering cyinder in any way to fit it to your appication, otherwise the cyinder wi no onger operate in safety and it wi endanger the boat and the occupants. A ULTRAFLEX steering systems must not be instaed on boats equipped with engines whose maximum horsepower is higher than the horsepower rating approved by boat manufacturer. The UC 378 cyinder must not be instaed on race boats. In dua hem appications horsepower must not exceed 450hp and boat speed must not exceed 55 m.p.h. page 6 of 64 - HYDRAULIC CYLINDER FOR INBOARD ENGINE

7 Instaation and Maintenance Manua.3 ystem configurations The hydrauic cyinder for inboard engine UC 378 mode can be instaed with different configurations according to the number and the type of engines used with a singe or dua engine steering system. The possibe configurations are: I N TEERING TATION NUMBER G LE I N HELM NUMBER G LE up to 300hp max T A H EL T I O N M With INGLE CYLINDER D U A L T A T I O N ADDITIONAL TATION MAIN TATION D U A L H EL M non-counter rotating engines up to 300 hp max of combined horsepower counter rotating engines up to 450 hp max of combined horsepower and up to 55 m.p.h. With INGLE CYLINDER and TIE BAR NOTICE Dua engine instaations require the use of a tie bar. Dua station instaations require the use of 2 hems with non-return vave. HYDRAULIC CYLINDER FOR INBOARD ENGINE - page 7 of 64

8 Instaation and Maintenance Manua.4 Cyinder description UC 378 is a hydrauic inboard cyinder which has been designed and manufactured to be used as a component in the hydrauic steering systems, as described in the previous paragraph. The cyinder with mobie rod is instaed directy to the arm of the hem through the proper ba joint on the end part of the cyinder. On the opposite side it is fixed directy to the boat through a support with pate (see par. 3.2). For the dua hem appication, the singe cyinder must be mounted with a tie bar (see par..3). The foowing picture shows the main cyinder components: 2 Cyinder body Beeders Ba joint upport with mounting brackets 3 5 Rod Technica features Overa dimensions: PECIFICATION UC 378 Voume 376 cc - 23 cu. in Output force 77 kg Ibs (@70 bar) Torque 87.6 Kg/m bs/in. (@70 bar) Inside diameter 50 mm -.96" troke 228 mm " Oi In compiance with IO VG 5 5,875 mm [5/8 in.] 9,05 mm [3/4 in.] 77 mm [28,22 in.] 45 mm [,77 in.] 00 mm [3,93 in.] 9,05 mm [3/4 in.] 45 mm [5,70 in.] 60 mm [2,3 in.] page 8 of 64 - HYDRAULIC CYLINDER FOR INBOARD ENGINE

9 ULTRAFLEX Instaation and Maintenance Manua 2 TRANPORT 2. Genera warnings The product weight with its packaging is 9kg (9 pounds) and so it can be handed manuay. The staff in charge of handing must operate with protective goves and safety shoes. 2.2 Packaging contents Before using the equipment check that the product has not been damaged during transport. Aso make sure that a the standard components are in the packaging (see ist). In case of damage, notify the caim to the forwarder and inform the suppier. A B C A) Cyinder B) 2 fexibe hoses for cyinder-system connection C) 2 fittings for fexibe hose-system connection with a 2mm (0,5") hose. CAUTION The packaging must be disposed of according to the existing aws. HYDRAULIC CYLINDER FOR INBOARD ENGINE - page 9 of 64

10 3 INTALLATION 3. Necessary toos Instaation and Maintenance Manua Open end wrench 22 mm (0,86") Open end wrench 24 mm (0,94") Torque wrench 3.2 Cyinder instaation DANGER An arm () shorter than the one indicated coud move the hem instead of the cyinder up to the end stroke by causing the breaking of the steering guide and the foowing oss of boat contro. A onger arm () reduces the steering ange. NOTICE If the arm is not aready mounted, see the mounting instructions of the arm manufacturer. NOTICE If the arm corresponds to the dimensions shown in the picture, foow the assemby drawing beow, otherwise foow the indications on the foowing page. y 696,5 mm [27,42 in.] 580 mm [22,83 in.] 6,5 mm [4,58 in.] 228 mm [8,97 in.] A B 228 mm [8,97 in.] 97,5 mm [7,77 in.] page 0 of 64 - HYDRAULIC CYLINDER FOR INBOARD ENGINE

11 Instaation and Maintenance Manua Check if the arm () and the hem bade (2) are aigned, then center them to the ongitudina axis. 2 2 Mount it by ooking for the "x" imaginary ine parae to the transom. It joins the arm hoe in the two "A" and "B" end stroke positions of the cyinder when the anges between the two "A" and "B" positions and the "y" ongitudina axis are the same ones. This ine wi be the mounting axis of the cyinder. A y = = B x 3 Check if the "z" axis of the bracket (3) is perpendicuar to the"x" axis of the cyinder. Fix the bracket (3) on a proper support with 4 screws diam. 8 mm (5/6") and 4 stainess stee sefocking nuts fit to bear the forces at stake (screws and nuts are not suppied). NOTICE The oi fittings must be aways in high position. 3 z 60 mm [2,36 in.] 45 mm [5,70 in.] x 4 Connect the joint (4) to the arm (); the arm must be under the joint; (foow the instructions of the arm manufacturer). The ba joint (4) must be ocked by means of the safety ock nut (5) with a torque of 00±0Nm (73.8±7.38 b-ft) (22mm -0.86" wrenches and 24mm -0.94" wrenches). Fine adjustment must not exceed the vaue shown in the picture mm [0.86"] max. 5 CAUTION Check if the cyinder in the two "A" and "B" end stroke positions is aigned in horizonta position (parae to the transom). Move the hem forward and backward in order to check the free movement of the cyinder and if these positions are perfecty symmetrica to the "y" axis as shown in picture 2. Be sure the movement of the ba joints is not hindered. DANGER Check if the cyinder and not the hem moves up to the end stroke. In case of connection of the two hems with tie bar, the cyinder can be connected directy to the tie bar or to one of the hem arms; foow the instructions given with the arms and/or with the tie bar. HYDRAULIC CYLINDER FOR INBOARD ENGINE - page of 64

12 Instaation and Maintenance Manua 3.3 Hose instaation The two fittings mounted on the cyinder body are aready oriented and are ready to be used. DANGER The fittings mounted on the cyinder cannot be oriented. If they are unscrewed, they coud be broken and the cyinder is no more usabe. An excessive hose bend coud resut in its interna breaking which wi cause a bad operation of the system. In this case it is necessary to repace the damaged hose. YE NO Connect the fexibe hoses suppied () to the cyinder and to the fittings suppied (2) by tightening the nuts with ogive (3) by means of an open end wrench 22 mm (0.86") with a torque of Nm ( b-ft). Connect the rigid tubes (4) to the pump (2) and to the fittings (2) in the same way NOTICE The instaation of the rigid tubes (4) (cutting, bending and routing) must be carried out by speciaized staff by foowing the instructions of the manufacturer. If copper or stee tubes are used, rinsing is required. page 2 of 64 - HYDRAULIC CYLINDER FOR INBOARD ENGINE

13 ULTRAFLEX Instaation and Maintenance Manua 3.4 Type of instaation With reference to the boat, the hose which is connected to the port side (P) of the pump must be aways connected to the fitting of the side port (P), whie the hose which is connected to the starboard side () of the pump must be connected to the fitting of the starboard side (), CAUTION Connect hoses as shown in the foowing pictures: The UC 378 hydrauic cyinder for inboard engines can be instaed with different configurations according to the number and the type of engines used with a singe or dua steering system. The possibe configurations are: INGLE TATION / INGLE CYLINDER: 3 6 P 3 P 2 P steering station cyinder T" fittings with beed vaves fittings suppied fexibe hoses suupied tie bar DUAL TATION / INGLE CYLINDER WITH DUAL HELM: DUAL TATION / INGLE CYLINDER: steering station cyinder T" fittings with beed vaves fittings suppied fexibe hoses suupied 5 4 P 2 ULTRAFLEX PUMP INGLE TATION / INGLE CYLINDER WITH DUAL HELM: 8 P P 7. main steering station 2. additiona steering station 3. cyinder 4. "T" fittings with beed vaves P P 2 P P fittings suppied 6. fexibe hoses suppied 7. kit 20U-2. main steering station 2. additiona steering station 3. cyinder 4. "T" fittings with beed vaves 5. fittings suppied 6. fexibe hoses suppied 7. kit 20U-2 8. tie bar HYDRAULIC CYLINDER FOR INBOARD ENGINE - page 3 of 64 NOTICE

14 Instaation and Maintenance Manua 3.5 Fiing and purging After the first instaation and after maintenance operations it is necessary to fi the system with hydrauic oi. This operation must avoid the air in the system, to ensure the good system operation. The hydrauic system must be fied from the highest point of the system, which means from the upper steering station. CAUTION To avoid air bubbes in the oi, it is necessary to fi the tank sowy. The fiing and beeding operations must be carried out at east by two operators. DANGER Use ULTRAFLEX oi or other compatibe ois. Hydrauic oi OL50 has been specificay formuated for ULTRAFLEX to ensure high quaity performance eve of ULTRAFLEX products throughout time. Its specia "Zinc Free" formua enhances protection against marine oxidation. The specia mix of anti-wear and stabiizing components of OL50 aow ensuring great resuts as far as the product duration and performances are concerned in severa environmenta conditions. ULTRAFLEX hydrauic oi compies with standard IO 0592 concerning hydrauic steering systems. ULTRAFLEX is not to be hed responsibe for any damages or performance deterioration if ois different from OL50 are used. DANGER Do NOT use ATF Dexron II transmission ois or brake ois which coud cause the steering system seizing. Ois which are compatibe with OL50 ULTRAFLEX are: - he Teus T5 and he Teus T22 - Mobi DTE M NOTICE ULTRAFLEX wi not be abe to ensure the compatibiity of the above mentioned ois with OL50 if the oi manufacturers vary their formuation; in particuar, it wi not be abe to ensure its compiance with standard IO 0592 concerning hydrauic steering systems. Under no circumstances ULTRAFLEX is to be hed responsibe for any damages or performance deterioration. In the days after the fiing, check the oi eve; if necessary top off the system. At the beginning the oi eve can ower, as sma amounts of air can be reeased in a homogeneous way. According to the types of instaation, it is necessary to carry out the different beeding procedures, as it foows. page 4 of 64 - HYDRAULIC CYLINDER FOR INBOARD ENGINE

15 Instaation and Maintenance Manua 3.5. inge steering station/ singe cyinder - Unscrew the two beed vaves and manuay push the cyinder body to one side unti it stops as shown in picture. - Position the oi botte as expained in the picture. - Cose the beed vave on the cyinder end stroke side and put a purged oi tank near the other beed vave (as shown in picture 2). 2 - Turn the steering whee sowy (as shown in picture 2) so that the oi can come out of hoses, NOTICE NOTA Hod the cyinder body with the hand to prevent movements caused by the air present in the cyinder chamber (picture 2). - When the oi comes out of the beed vave (without air bubbes), cose the beed vave and continue to turn the steering whee in the same direction to fi the cyinder chamber (picture 3). During this phase the cyinder body wi move to the opposite direction up to the end stroke. 3 - Open the other beed vave and move purged oi tank to the other side. Hoding the cyinder body in this position, turn the steering whee as shown in picture 4, unti oi without air bubbes comes out of the beed vave. Then cose the beed vave. 4 - Repeat the entire procedure to ensure the absence of air in the system. NOTA HYDRAULIC CYLINDER FOR INBOARD ENGINE - page 5 of 64

16 Instaation and Maintenance Manua Dua steering station/ singe cyinder - Manuay unscrew the two beed vaves onthe cyinder "T" fittings and push the cyinder up to the end stroke. - Position the oi botte near the (upper) main steering station according to what is previousy described. vent pug beed vaves Wait unti the oi reaches the ower tank and both tanks are fied. - Foow the same beeding procedure described in paragraph 3.5 starting from the ower station and repeat it for the upper station. non-vent pug For the (ower) additiona steering station tank use ony the non-vent pug (suppied with the "kit 20U-2"). For the (upper) main steering station tank use ony the vent pug. - Repeat the procedure at east 3 times to ensure the absence of air in the system. 3.6 Genera recommendation It is very important to check the absence of air in the system before using the boat! We recommend trying to manuay move the engine towards port and starboard, making sure that there is no movement of the cyinder body on the main cyinder shaft. If the cyinder body moves more than /6 inches (5mm), there is sti air in the system. The air presence in the system can cause bad responses to the contros and so it can cause damage, injuries or death. page 6 of 64 - HYDRAULIC CYLINDER FOR INBOARD ENGINE

17 4 AFETY Instaation and Maintenance Manua This section shows the safety rues which must be foowed for the correct equipment operation. We recommend reading carefuy this section and aso the other manuas suppied with the steering system components. 4. afety warnings during use and instaation REPECT TRICTLY the foowing safety rues: ULTRAFLEX decines a responsibiity in case the user does not foow these rues and it is not responsibe for negigence during the use of the system. DANGER - DO NOT PUT HAND BETWEEN THE MOVING PART. - Do not disabe the safety devices. - Do not modify or add devices to the system, without ULTRAFLEX written authorisation or technica intervention which wi prove the modification. - Do not use the equipment for a purpose different from the one it has been designed for, which is specified in the instaation and maintenance manua. - Do not et non-speciaized staff perform the instaation. - Do not disassembe the hydrauic connections before beeding the oi in the system competey. The hoses can contain high pressure oi. - Do not put the feet on the cyinder. - Check the system after the instaation and the purging but before operating the vesse. Turn the steering whee unti the cyinder/s reaches/reach the end stroke. Turn the steering whee to the opposite direction. Repeat on each instaed hem to verify the correct instaation and the system operation. - Carefuy use seaing fuid (such as Loctite). If it reaches the hydrauic system, it may cause damage and mechanica faiure. - Do not use tefon tape or adhesive tape to sea the fittings, as this materia may be injested, by causing the system fai. - During the system instaation, prevent foreign matters from entering the system. Even a itte object may cause asting damage that are not detected immediatey. - Avoid too narrow bend radius of hoses. - Avoid the hose contact with edges or sharp corners. - Avoid the hose contact with heat sources. 4.2 Cothing During instaation, inspection or maintenance, IT I ATTENZIONE TRICTLY FORBIDDEN to wear neckaces, braceets or cothes which coud get caught in the moving parts.! HYDRAULIC CYLINDER FOR INBOARD ENGINE - page 7 of 64

18 5 MAINTENANCE 5. Ordinary maintenance Instaation and Maintenance Manua Poor instaation and maintenance may resut in oss of steering and cause property damage and/or persona injury. Maintenance requirements change according to cimate, frequency and the use. Inspections are necessary at east every year and must be carried out by speciaized marine mechanics. Check the cyinder fittings and the seas and the hem gaskets to prevent eaks. Repace them if necessary. To keep a suitabe oi eve in the tank, fi and beed the system as described in this manua in paragraph 3.5. Check the hose and the entire system wear, the nut and bot tightening every six months and make sure that they are not damaged. Cean the system using water and non-abrasive soap. Use ony compatibe hydrauic ois, indicated in the paragraph "technica features" and "fiing and beeding". Do not use brake ois or automatic transmission fuid (ATF) in any case. 5.2 Troubeshooting Whenever the foowing checks need the remova and/or disassemby of the steering system components, such work must be carried by speciaized staff. ULTRAFLEX offers genera information ony and is not responsibe for any consequences resuting from incorrect disassemby. PROBLEM CAUE OLUTION During the fiing, the steering system becomes competey jammed. The system is very difficut to fi. Air keeps bubbing at the top of the steering system tank even after fiing the system competey. Bockage in the hoses between steering system and cyinder. Air in the system. Leaks from the cyinder beeder. Repace hoses. The damaged hose must be repaced, otherwise it may cause oss of steering and severe persona injury or property damage. Repeat the fiing and the beeding procedure of the system. Insta horizontay the hoses and in any case with a maximum incination of 3cm each meter. Tighten the beeder on the cyinder. The steering system is stiff and hard to turn, even when the boat is not moving. Coied hose. Hem has been mounted upside down. Restrictions in hoses or fittings. Air in oi Uncoi and straighten the hose. Mount the hem with the fiing hoe in upposition. Look for and remove the restriction. Repeat the fiing and the beeding procedure of the system. page 8 of 64 - HYDRAULIC CYLINDER FOR INBOARD ENGINE

19 The steering system is stiff and hard to turn, even when the boat is not moving. The steering system is stiff and hard to turn, even when the boat is not moving, if unbaanced cyinders are used. Wrong oi has been used. Dirt in the vave. Instaation and Maintenance Manua Drain the fiing and beeding system. ULTRAFLEX is not responsibe for damage caused by fuids that are not recommended in this manua and so the warranty is canceed. Do not use the boat and contact a speciaized technician for the vave ceaning. The steering system is easy to turn at the dock but becomes hard to turn when the boat is in motion. When the steering whee is turned, the rod (movabe rod cyinders) or the body (fixed cyinder rod) of the cyinder do not move. Leaks from steering system fittings. Leaks from the tank pug. The steering whee is too sma. Incorrect setting of the torque tab. Air in oi. Air in the system. Oi eak. Hem mounted upside down. Bad tightening or ow torque of the fittings. Lack of fitting seaant. Never use tefon tape or adhesive tape on any fitting. Bad tightening of the pug. The vent pug (back) on the additiona hem is in the ower position. Worn and damaged sea. Too high oi eve. Repace the steering whee with a bigger one. Ony within the maximum dimensions aowed by the hem. Adjust the torque tab. Check the oi eve and repeat the beeding procedure as expained in this manua. Repeat the fiing and beeding procedure of the system. Look for the eak and contact speciaized staff. Mount the hem with the fiing hoe in upposition. Tighten the fittings with a maximum torque of 20Nm (5 in.ibs). Drain and disassembe the steering system. Remove the fittings and remove the oi from threads. Put the seaant on the fittings and tighten them, insta the hem. After this operation it is necessary to carry out another beeding. Tighten the pug. Repace the vent pug (back) with the pug for the additiona hem kit (siver). Repace the pug. Foow the procedure to maintain the suitabe oi eve, which is described in the pump manua. HYDRAULIC CYLINDER FOR INBOARD ENGINE - page 9 of 64

20 6 DIMANTLING 6. Dismanting Instaation and Maintenance Manua When for any reason, the steering system is put out of service, it is necessary to foow some rues in order to respect the environment. heaths, pipeines, pastic or non-metaic components must be disassembed and disposed of separatey. The steering system CONTAIN POLLUTING OIL which must be disposed of according to the rues in force in the country. page 20 of 64 - HYDRAULIC CYLINDER FOR INBOARD ENGINE

21 .p.a. 605 Casea (Genova) Itaia - Via Crose, 2