ULTRAFLEX UC 94-OBF. Installation and Maintenance Manual HYDRAULIC CYLINDER FOR OUTBOARD ENGINES PARTNER. page. 2 pag. 23 page. 45

Transcription

1 Instaation and Maintenance Manua HYDRAULIC CYLINDER FOR OUTBOARD ENGINES UC 94-OBF FRANÇAIS ITALIANO ENGLISH R ULTRAFLEX PARTNER UK I F page. 2 pag. 23 page. 45 (Dr. No /02/2015)

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 Systems are certified CISQ-IQNet by the Itaian Shipping Registry (RINA), in conformity with the UNI EN ISO 9001:2008 rue. ULTRAFLEX certification No. 6669/02/S (former 420/96). UFLEX certification No. 8875/03/S. ENGLISH 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 System is certified CISQ-IQNet by the Itaian Shipping Registry (RINA), in conformity with the UNI EN ISO rue. ULTRAFLEX certification No. EMS-1282/S. Products for peasure boats are constanty tested to check their conformity with the 2013/53/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 S.p.A Casea (Genova) Itaia - Via Crose, 2

3 TABLE OF CONTENTS Instaation and Maintenance Manua MANUAL USE AND SYMBOLS USED...4 INTRODUCTION...5 WARRANTY...5 SECTION 1 - PRODUCT DESCRIPTION ENGLISH 1.1 HYDRAULIC STEERING SYSTEM OPERATION S FOR THE CORRECT PRODUCT USE CONFIGURATIONS UC94-OBF CYLINDER DESCRIPTION TECHNICAL FEATURES...8 SECTION 2 - TRANSPORT 2.1 GENERAL S PACKAGING CONTENTS...9 SECTION 3 - INSTALLATION 3.1 MINIMUM TRANSOM REQUIREMENTS NECESSARY TOOLS ,3 STANDARD (STARBOARD)CYLINDER INSTALLATION ,4 HOSE INSTALLATION TYPE OF INSTALLATION FILLING AND PURGING POSITIONING OF THE OIL BOTTLE ,6,2 SINGLE STEERING STATION DUAL STEERING STATION GENERAL RECOMMENDATIONS...18 SECTION 4 - SAFETY S! 4.1 SAFETY S DURING USE AND INSTALLATION CLOTHING...19 SECTION 5 - MAINTENANCE 5.1 ORDINARY MAINTENANCE TROUBLESHOOTING...20 SECTION 6 - DISMANTLING 6.1 DISMANTLING...22 IMPORTANT: The additiona documents "Appication Guide" and "Spare Parts List" are attached to this manua. HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 3 of 67

4 Instaation and Maintenance Manua ITALIANO ENGLISH MANUAL USE AND SYMBOLS USED THE INSTALLATION 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. In this manua the foowing symbos are used to ensure the user safety and to guarantee the correct operation of the product: DANGER CAUTION NOTICE Denotes that an extreme intrinsic hazard exists which woud resut in high probabiity of death or irreparabe injury if proper precautions are not taken. Denotes that a hazard exists which can resut in injury or death if proper precautions are not taken. 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. STERN STARBOARD PORT The picture aside expains the meaning of some nautica words contained in this manua. LEGEND m.p.h. = mies per hour km/h = kiometres per hour BOW 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 page 4 of 67 - HYDRAULIC CYLINDER FOR OUTBOARD 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 RIGHTS ARE RESERVED. 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. ENGLISH 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 Service. UFLEX S.r.. Via Miite Ignoto,8A Busaa (GE)-Itay Ph: Fax: Emai: ut@utrafexgroup.it TECHNICAL ASSISTANCE SERVICE North - South - Centra America: UFLEX USA 6442 Parkand Drive Sarasota, 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 Service. ULTRAFLEX steering system components are marked according to the Directive 2013/53/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 OUTBOARD ENGINE - page 5 of 67

6 1 PRODUCT DESCRIPTION 1.1 Hydrauic steering system operation Instaation and Maintenance Manua ITALIANO ENGLISH A ULTRAFLEX hydrauic steering systems are designed in conformity with UNI-EN-ISO and A.B.Y.C. P21 reguations. A ULTRAFLEX steering systems can operate at temperatures between -18 C (0 F) and +77 C (+170 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 are equipped with a nonreturn vave, which prevents outgoing fuid from returning aong the same hose. It aso aows 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 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 20 cm 3 [1,2cu.in.] and the cyinder has a voume of 94cm 3 [5,7cu.in.], the formua ooks ike this: 94/20=4,7. Accordingy, the steering whee wi turn 4 times and an haf 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. The maximum operating pressure is 7,0MPa (70 bar) (1000 PSI). 1.2 Warnings for the correct product use pump engine cyinder hydrauic hose Before beginning the instaation, check the mounting compatibiity of the UC94-OBF cyinder to the engine by consuting the attachted document "Appication Guide" contained in the packaging. DANGER Do not modify the steering cyinder in any way to fit it to your engine 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. ULTRAFLEX hydrauic steering systems must not be instaed on race boats. DANGER It is forbidden to disassembe the components which are suppied preassembed to avoid compromising the product integrity. page 6 of 67 - HYDRAULIC CYLINDER FOR OUTBOARD ENGINE

7 Instaation and Maintenance Manua 1.3 Configurations The hydrauic cyinder for outboard engine UC94-OBF mode can be instaed on boats a singe engine used with a singe or dua steering system. S I N STEERING STATION NUMBER ENGLISH G LE S T A T I O N ENGINE NUMBER S I N G LE up to 150hp max D U A L ADDITIONAL STATION MAIN STATION E N GI N E With SINGLE CYLINDER S T A T I O N CAUTION NOTA In case of singe engine appications with a horsepower which exceeds 150hp, it is necessary to assembe the Utrafex UC 128-OBF or UC128-SVS cyinder. HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 7 of 67

8 Instaation and Maintenance Manua ITALIANO ENGLISH 1.4 UC94-OBF cyinder description UC94-OBF is a hydrauic outboard front mount 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 is instaed to the tit tube rod of the avaiabe engines on the market as shown in the attached document "Appication guide". It is possibe to meet a the different cyinder appications due to the two different ink arms and a proper spacer kit. The foowing picture shows the main cyinder components: a 7b Cyinder body Fittings and beed vaves Bu horns Tit tube rod Spacers Adjustment coar Straight ink arm (UC94-OBF/1) Curved ink arm (UC94-OBF/3) 6 2 7a 1 7b Technica features SPECIFICATIONS UC94-OBF/1 -/3 Voume 94 cc cu. in Max. cyinder outout force* thrust* 354 kg bs (@ 70 bar) Inside diameter 30 mm " Stroke 186 mm - 7.3" Oi OL150 Utrafex 78 mm (3.08") 546 mm (21.5") UC94-OBF/1 UC94-OBF/3 CAUTION * The cyinder thrust shown above is a theoretica vaue cacuated considering a pressure system of 70 bar (1000 psi). This vaue is not the one considered for the system norma use but for the system use in extreme conditions. page 8 of 67 - HYDRAULIC CYLINDER FOR OUTBOARD ENGINE

9 ULTRAFLEX Instaation and Maintenance Manua 2 TRANSPORT The product weight with its packaging is 8kg (18 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. B D A C CONTENTS OF THE STANDARD PACKAGING: E A ) No.1 cyinder body with rod, fittings and bu horns; B ) No.1 ink arm kit composed of: - tit tube rod (2 pieces) + No.1 ockpin - No.2 ocknuts + No.2 washers; C ) No. 1 spacer kit composed of: - No.8 pastic spacers; - No.2 stee spacers; - No.1 ring nut for adjustement coar; D) No.1 kit composed of: No.2+1 ocknuts; No.2 ock washers; No.1 short hexagon headed screw No.1 ong hexagon headed screw (code 73584U); E ) No.1 pastic hose for the hydrauic circuit beeding; CAUTION The packaging must be disposed of according to the existing aws. HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 9 of 67 E N G L IS H 2.1 Genera warnings

10 Instaation and Maintenance Manua 3 INSTALLATION 3.1 Minimum transom requirements ITALIANO ENGLISH The foowing picture shows the minimum spash we dimensions. These dimensions must be respected in order to prevent the cyinder from being damaged when the outboard engine is competey tited upwards. The picture shows aso the minimum transom dimensions, needed for the instaation and the correct operation of the engine steering cyinder. B 90 C A MINIMUM SPLASH WELL DIMENSION REQUIREMENTS Engine No. A B C mm " 152 mm " 152 mm " mm " 152 mm " 152 mm " ENGINE JACK PLATE APPLICATION TO THE TRANSOM. A jack pate instaation wi change a the appication cearances. A new cearance check must be competed with the titing of the engine in conjunction with the vertica movement of the jack pate in a the possibe positions. If the steering cyinder comes into contact with the spash we, transom and/or jack pate, stop the instaation immediatey! Use the jack pate manufacturer's instructions to imit the upper or ower direction in which the interference occurs. If this is not possibe pease contact speciaized staff. 3.2 Necessary toos Aen wrench 4 mm [5/32 ] Open end wrench 3/4'' Open end wrench 14mm Open end wrench 11/16 Open end wrench 5/8 Piers Torque wrench MOLYKOTE 1000 CAUTION During instaation use ony stainess stee toos to prevent the corrosion of the meta parts. page 10 of 67 - HYDRAULIC CYLINDER FOR OUTBOARD ENGINE

11 ULTRAFLEX Instaation and Maintenance Manua 3.3 Cyinder instaation 2 Position the engine straight so that its arm is perpendicuar to the transom CAUTION During this phase an oi eak from the fittings can occur. This oi must not be discharged into the sea in any case. 4 Grease the two parts of which the tit tube rod is made up (5) and (6), by using marine grease to prevent the corrosion of the meta parts. 5 Insert the first part of the tit tube rod (5) into the tit tube. 5 3 With reference to the appication instructions contained in the Appication Guide, position the screw (3) contained in the D2 bag (see par. 2.2) and connect the ink arm to the tier arm. Tighten the screw with a torque of 40[Nm] (29.5 [b ft]). Thread on the ocknut (4) and tighten it with a torque of 25[Nm] (18.5 [b ft]). After tightening the ocknut (4), check for the right torque 40[Nm] (29.5 [b ft]) of the screw (3). To tighten the screw (3) and the ocknut (4) on the tier arm ask your mechanic for the maximum torque aowed. If it is ower than the one indicated in this manua, tighten with the torque indicated by the mechanic. It is important to check periodicay, at east every 3 months (or every month for professiona uses), the right torque of this screw (3) and of the ocknut (4). 6 Insert the secord part of the tit tube rob (6) by ocking it by means of the pin (7), then hoding the pin with your hand continue to insert the tit tube rod into the tit tube. 7 Position the bot (8) and the nut (9) on the adjustment coar (10) and screw it to the right side of the tit tube unti it comes into contact with the tit tube stop nut HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 11 of 67 E N G L IS H 1 After removing the protective caps of the fittings, manuay center the rod (1) on the cyinder body (2).

12 Instaation and Maintenance Manua 8 With reference to the' "Appication Guide" choose the spacers for the tit tube rod. 9 Insert the right and eft bu horns (11) by connecting the rod and the tit tube rod as shown in the picture. ITALIANO ENGLISH 8,1 mm / 3,1" LARGE MEDIUM SMALL The number and position of the spacers shown in the Appication Guide is ony indicative. NOTICE In this phase ensure that the cyinder body is centered on the rod and that the engine is perpendicuar to the transom. 10 Choose the spacers to fi the gap between ring nut and buhorn d and d 2 between tit tube and buhorn considering the thickness of the stainess washer. 3,2 mm / 0,12" 1,6 mm /0,06" Once the correct spacers have been chosen, remove the bu horns. 12 Insert the pastic and stainess stee spacers and the two stainess washer on the tit tube rod.. NOTICE 11 Both the stainess stee spacers must be positioned towards the tit tube on the opposite side of the bu horns to avoid their wear during engine ifting and owering. 13 Insert the right and eft bu horns (11) by connecting rod and tit tube rod as shown in the picture. Aways eave a minimum cearance between spacers and buhorn in order to aow the rod titing in the tit tube Insert the washers (12) on the two ends of the tit tube rod and tighten the nuts (13), with a torque of 70[Nm] (52[b ft]). after greasing them with marine grease. 15 Position washers(14) and tighten both ocking nuts (15) with a torque of 60[Nm] (22 [b ft]). NOTICE The ock washer tabs must be bent afterwards (see point 20) Check the correct torque of both nuts. 16 Check the correct titing of the engine. If whie titing the engine is bocked, reduce the overa dimensions of the spacers. page 12 of 67 - HYDRAULIC CYLINDER FOR OUTBOARD ENGINE

13 Instaation and Maintenance Manua 17 Unscrew the adjustment coar (10) and bring it into contact with the stainess washer, unti the cearance is eiminated, 19 Tighten the set screw (8) on the adjustment coar (10) with a torque of 3[Nm] (2 [b ft]) ENGLISH 18 Check the correct cyinder instaation by moving manuay the engine on the right and on the eft. NOTICE The rotation must be as symmetric as possibe so that the steering ange is the same on both sides. 16 The engine must stop through the cyinder end stroke without coming into contact with the mechanica stop (16) on the engine. NOTICE Otherwise it is necessary to modify the instaation, by changing the thickness of the spacers and by repeating the procedure from point Bend the tabs of the ock washers (14) bringing them into contact with the screw head and taking care not to damage the bu horns whie using the piers. 21 Check again the correct engine movement both during the right/eft rotation and during the titing. In this phase cearance shoud be enough to avoid frictions but it shoud not be excessive since it coud cause engine instabiity. In case of contact with the transom, stop the instaation and contact the speciaized staff. 14 NOTICE FOR INSTALLATION The bot identified with the reference 73584U (Pict.C) is the connection screw between the cyinder's ink arm and the engine's tier arm that must be used with the foowing engines: - SUZUKI ( to date). - Engines with the tier arm shaped ike in Pict.A and thickness (S) between 10 and 22 mm (0.4" and 0.85"). For the other engines with tier arm shaped ike in Pict.A and thickness (S) max. 10 mm (0.4"), pease use the standard bot (shorter than ref U ). When the ink arm is shaped ike in Pict.B the KIT ref W (not incuded in the present kit), containing the dedicated spacer, must be used. In case the tier arm differs from the above measures, pease contact our after saes service. PICT.A PICT.B PICT.C 51.45mm/2.026in Sec.A-A Sec.A-A (ref U) CAUTION After instaation, check that the nyon part of the sef-ocking nut is tightened on the screw thread. HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 13 of 67

14 Instaation and Maintenance Manua 3.4 Hose instaation The two fittings mounted on the cyinder body are aready oriented and are ready to be used. If for practica reasons the orientation must be changed, do as foows: ITALIANO ENGLISH 1. oose the stop nut (A) by using an 11/16" wrench; 2. orient the fittings according to the requirements; DANGER Do not unscrew the fittings more than one turn (360 ). A 3. tighten again the stop nut with a torque of 20[Nm] (15[b ft]) unti the washer comes into contact with it. Screw the hoses on the cyinder fittings with a torque of 20[Nm] (15[b ft]) according to the foowing instructions: - minimum hose bend radius 250 mm; - no interference during engine titing; - no interference with the transom; minimum radius 250mm 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. NO page 14 of 67 - HYDRAULIC CYLINDER FOR OUTBOARD ENGINE

15 Instaation and Maintenance Manua 3.5 Type of instaation The UC94-OBF hydrauic cyinder for outboard engines can be instaed with a singe or dua steering system. The possibe configurations are: CAUTION Connect hoses as shown in the foowing pictures: SINGLE STATION / SINGLE CYLINDER: SINGLE STATION / SINGLE CYLINDER: ENGLISH hem 2. cyinder 3. beed vaves 1. upper station hem 2. ower station hem 3. cyinder 4. beed vaves 5. kit OB-2S HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 15 of 67

16 Instaation and Maintenance Manua ITALIANO ENGLISH 3.6 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 OL150 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 OL150 aow ensuring great resuts as far as the product duration and performances are concerned in severa environmenta conditions. ULTRAFLEX hydrauic oi compies with standard ISO concerning hydrauic steering systems. ULTRAFLEX is not to be hed responsibe for any damages or performance deterioration if ois different from OL150 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 OL150 ULTRAFLEX are: - She Teus T15 and She Teus T22 - Mobi DTE 11M NOTICE ULTRAFLEX wi not be abe to ensure the compatibiity of the above mentioned ois with OL150 if the oi manufacturers vary their formuation; in particuar, it wi not be abe to ensure its compiance with standard ISO 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. DANGER After 24 hours repeat the purging and check the absence of eaks Positioning of the oi botte The oi fiing must be carried out by using the proper kit (incuding spout, fexibe hose, fitting and pin) which is NOT suppied. - Remove the pump cap and insert the fitting. - Attach the spout to a new botte of hydrauic oi and connect the hose to the fitting and the botte spout. - Turn the botte upside down and pierce it with the suppied pin, as shown in the picture, to ease the oi passage towards the pump. Fi the pump unti no air bubbes are visibe in the hose. page 16 of 67 - HYDRAULIC CYLINDER FOR OUTBOARD ENGINE

17 Instaation and Maintenance Manua Whie repacing the oi botte, during the fiing process, cose a the beed vaves on the cyinder/s. To beed the system, check that oi is aways present in the fiing hose. If some air is in the system during the beeding process, the whoe beeding process must be started again. CAUTION Repace the botte before it empties and use recovered oi ony after 24 hours. pin hose fiing connection oi botte spout ENGLISH Singe steering station - Unscrew the two beed vave protections and oosen 1.5 turns max. the nuts "A" of the two beed vaves. 1 A - Manuay push the cyinder body to one side unti it stops as shown in picture 1. - Position the oi botte as expained in paragraph 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). - Turn the steering whee sowy (as shown in picture 2) so that the oi can come out of hoses, 2 NOTICE 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 HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 17 of 67

18 Instaation and Maintenance Manua - 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 ITALIANO ENGLISH - Repeat the entire procedure to ensure the absence of air in the system Dua steering station - Manuay unscrew the two beed vaves on the cyinder and push thecyinder to one side up to the end stroke. - Position the oi botte near the main steering station (upper) according to what is described in paragraph Wait unti the oi reaches the ower tank and both tanks are fied. - Foow the same beeding procedure described in paragraph starting from the ower station and repeat it for the upper station. back vent pug siver non-vent pug beed vaves For the additiona steering station (ower) tank use ony the siver non-vent pug (suppied with the "kit OB- 2S"). For the main steering station (upper) tank use ony the back vent pug. - Repeat the procedure at east 3 times to ensure the absence of air in the system. 3.7 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 1/6 inches (15mm), 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 18 of 67 - HYDRAULIC CYLINDER FOR OUTBOARD ENGINE

19 Instaation and Maintenance Manua 4 SAFETY S 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. 4.1 Safety warnings during use and instaation ENGLISH RESPECT STRICTLY 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 HANDS BETWEEN THE MOVING PARTS. - 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. ATTENZIONE - 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 ATTENZIONE During instaation, inspection or maintenance, IT IS STRICTLY FORBIDDEN to wear neckaces, braceets or cothes which coud get caught in the moving parts.! HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 19 of 67

20 ITALIANO ENGLISH ULTRAFLEX 5 MAINTENANCE 5.1 Ordinary maintenance 5.2 Troubeshooting 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 3.6. 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 purging". Do not use brake ois or automatic transmission fuid (ATF) in any case. After the first 10 hours of use and then periodicay check the connection integrity and tightening. CAUTION If the ocknuts are disassembed, repace them. (Contact our assistance service, see page 5). 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 CAUSE SOLUTION 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 20 of 67 - HYDRAULIC CYLINDER FOR OUTBOARD ENGINE

21 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. ENGLISH 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 (15 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 OUTBOARD ENGINE - page 21 of 67

22 ITALIANO ENGLISH ULTRAFLEX 6 DISMANTLING 6.1 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. Sheaths, pipeines, pastic or non-metaic components must be disassembed and disposed of separatey. The steering system CONTAINS POLLUTING OILS which must be disposed of according to the rues in force in the country. page 22 of 67 - HYDRAULIC CYLINDER FOR OUTBOARD ENGINE

23 Manue d'instaation et d'entretien NOTES FRANÇAIS VERIN HYDRAULIQUE POUR MOTEUR HORS-BORD - page 67 de 67

24 S.p.A Casea (Genova) Itaia - Via Crose, 2