Instaation and Maintenance manua HYDRAULIC CYLINDER FOR OUTBOARD ENGINES UC 128-SVS FRANÇAIS ITALIANO R UK I page 2 pag. 19 page 37 F PARTNER (Dr. No. 25713/a 09/03/2015)
Dear Customer, We woud ike to thank you for choosing an product. has been a eader in steering systems for peasure and professiona boats for many years. production is since ever synonimous of reiabiity and safety. A products are designed and manufactured to ensure the best performance. To ensure your safety and to maintain a high quaity eve, products are guaranteed ony if they are used with origina spare parts. 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. certification No. 6669/02/S (former 420/96). UFLEX certification No. 8875/03/S. 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 Environmenta Management System is certified CISQ-IQNet by the Itaian Shipping Registry (RINA), in conformity with the UNI EN ISO 14001 rue. certification No. EMS-1282/S. Products for peasure boats are constanty tested to check their conformity with the 2013/53/EU. " 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". S.p.A. 16015 Casea (Genova) Itaia - Via Crose, 2
TABLE OF CONTENTS MANUAL USE AND SYMBOLS USED...4 INTRODUCTION...5 WARRANTY...5 SECTION 1 - PRODUCT DESCRIPTION 1.1 HYDRAULIC STEERING SYSTEM OPERATION...6 1.2 S FOR THE CORRECT PRODUCT USE...6 1.3 CONFIGURATIONS...7 1.4 UC128-SVS CYLINDER DESCRIPTION...8 1.5 TECHNICAL FEATURES...8 SECTION 2 - TRANSPORT 2.1 GENERAL S...9 2.2 PACKAGING CONTENTS...9 SECTION 3 - INSTALLATION 3.1 MINIMUM TRANSOM REQUIREMENTS...10 3.2 NECESSARY TOOLS...10 3,3 STANDARD (STARBOARD) CYLINDER INSTALLATION...11 3,4 HOSE INSTALLATION...14 3.5 TYPES OF INSTALLATION...15 3.6 FILLING AND PURGING...16 3.6.1 POSITIONING OF THE OIL BOTTLE...17 3,6,2 SINGLE STEERING STATION/ SINGLE CYLINDER...17 3.6.3 SINGLE STEERING STATION/DUAL CYLINDER...18 3.6.4 DUAL STEERING STATION/SINGLE CYLINDER...18 3.6.5 DUAL STEERING STATION/DUAL CYLINDER...19 3.7 GENERAL RECOMMENDATION...19 SECTION 4 - SAFETY S 4.1 SAFETY S DURING USE AND INSTALLATION...20 4.2 CLOTHING...20 SECTION 5 - MAINTENANCE 5.1 ORDINARY MAINTENANCE...21 5.2 TROUBLESHOOTING...21 SECTION 6 - DISMANTLING 6.1 DISMANTLING...23! IMPORTANT: The additiona documents "Appication Guide" and "Spare Parts List" are attached to this manua. HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 3 of 71
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 Immediate hazards which CAUSE severe persona injury or death. Denotes that a hazard exists which can resut in injury or death if proper precautions are not taken. CAUTION 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 71- HYDRAULIC CYLINDER FOR OUTBOARD ENGINE
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. decines a responsibiity for possibe mistakes in this manua due to printing errors. Apart from the essentia features of the described product, 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 products contained in this manua are 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 Service. UFLEX S.r.. Via Miite Ignoto,8A 16012 Busaa (GE)-Itay Te: +39.010.962.01 Fax: +39.010.962.0333 Emai: ut@utrafexgroup.it www.utrafexgroup.it TECHNICAL ASSISTANCE SERVICE North - South - Centra America: UFLEX USA 6442 Parkand Drive Sarasota, FL 34243 Te: +1.941.351.2628 Fax: +1.941.360.9171 Emai: ufex@ufexusa.com www.ufexusa.com WARRANTY 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. 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 warranty is nu if some components are instaed on a steering system together with products of other brands. HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 5 of 71
1 PRODUCT DESCRIPTION 1.1 Hydrauic steering system operation A hydrauic steering systems are designed in conformity with UNI-EN-ISO 10592 and A.B.Y.C. P21 reguations. A 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. 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 28 cm 3 [1,7cu.in.] and the cyinder has a voume of 120 cm 3 [7,3cu.in.], the formua ooks ike this: 120/28=4,2. Accordingy, the steering whee wi turn about 4 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 not recommended, as the response of the boat to steer is sowy. pump engine cyinder hydrauic hoses 1.2 Warnings for the correct product use Before beginning the instaation, check the mounting compatibiity of the UC128-SVS 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 steering systems must not be instaed on boats equipped with engines whose maximum horsepower is higher than the horsepower rating approved by boat manufacturer. 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 71- HYDRAULIC CYLINDER FOR OUTBOARD ENGINE
1.3 Configurations The hydrauic cyinder for outboard engine UC128-SVS 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: S I N STEERING STATION NUMBER ENGINE NUMBER G LE S T A S I N G LE E N GI up to max. 350hp or up to max. 65 m.p.h. (except UC128-SVS/3 cyinder) T I O N N E With SINGLE STANDARD CYLINDER (starboard version) non-counter rotating engines up to 350 hp max of combined horsepower and up to 65 m.p.h. (except UC128-SVS/3 cyinder) D U A L S T A T I O N ADDITIONAL STATION MAIN STATION D U A L E N GI N E counter rotating engines up to 600 hp max of combined horsepower and up to 65 m.p.h.(except UC128-SVS/3 cyinder) With SINGLE STANDARD CYLINDER ( starboard version ) and TIE BAR non-counter rotating engines up to 600 hp max of combined horsepower and up to 65 m.p.h. (except UC128-SVS/3 cyinder) counter rotating engines up to 700 hp max of combined horsepower and up to 75 m.p.h. (except UC128-SVS/3 cyinder) With DUAL CYLINDER (starboard + port) On request, tripe outboard engine appications are avaiabe. For detaied information, pease contact Assistance Service. DANGER Dua engine instaations require the use of a tie bar. DANGER The power and speed imits indicated above appy ony to UC128-SVS/1 and UC128-SVS/2 cyinders (starboard and port) whie the UC128-SVS/3 cyinder can be used ony for singe engine appications and for the motor modes indicated in the encosed Appication Guide. The maximum speed aowed with the UC128-SVS/3 cyinder is 55 m.p.h. HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 7 of 71
1.4 UC128-SVS cyinder description UC128-SVS 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 three different ink arms and a proper spacer kit. For the dua engine appication, the singe cyinder must be mounted with a tie bar (see par. 1.3) or two cyinders (standard + port) connected by a tie bar can be used with the exception of UC128-SVS/3 cyinder, which is given ony in standard version (starboard) and it can be used ony on singe engine appications. In the standard version the ink arm is mounted on the starboard side, whie in the port version it is mounted on the port side (see picture in par. 1.5). The foowing picture shows the main cyinder components: 1 Cyinder body 7b 7c 2 Beeders 3 Bu horns 4 5 6 Tit tube rod Spacers Adjustment coar 7a 5 6 3 4 7a Straight ink arm UC128-SVS/1 7b Shaped ink arm UC128-SVS/2 7c Curved ink arm UC128-SVS/3 1.5 Technica features 2 1 SPECIFICATIONS UC128-SVS/1 -/2 -/3 Voume 120 cc - 7.3 cu. in Output force* 680 Kg - 1499 bs (@105 bar) Inside diameter 35 mm - 1.37" Strokr 198 mm - 7.79" Oi OL150 Utrafex 76.2 mm (3.00") 544 mm (21.43") STANDARD VERSION (STARBOARD) PORT VERSION (except UC128-SVS/3) CAUTION *The cyinder output force is a theoretica force with a system pressure of 105 bar that can ony be obtained by using SVS pumps. This force does not correspond to the one normay used by the system but it represents the imiting conditions of use. page 8 of 71- HYDRAULIC CYLINDER FOR OUTBOARD ENGINE
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. A C C1 C2 B C3 C4 CONTENTS OF THE STANDARD PACKAGING: A ) No.1 cyinder body with rod, fittings, bu horns and ink arms; B) No.1 spacer kit composed of: No.8 pastic spacers; No.2 stee spacers; No.1 ring nut for adjustement coar; C) bag containing 4 smaer bags: C1) bag with "4 stroke Suzuki, Envirude, Johnson engines instaation kit" sticker containing: No.1 screw connecting the tier arm for Suzuki, Envirude and Johnson engines + No.1 spacer. C2) No.1 screw connecting the tier arm + No.1 washer + No.1 nut. C3) No.2 caps for the threaded hoes that are not used. C4) No.2 ocknuts + n 2 washers. CAUTION The packaging must be disposed of according to the existing aws. HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 9 of 71 E N G L IS H 2.1 Genera warnings
3 INSTALLATION 3.1 Minimum transom requirements 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. A 90 C B MINIMUM SPLASH WELL DIMENSION REQUIREMENTS Engine No. A B C 1 560 mm - 21.25" 152 mm - 5.98" 152 mm - 5.98" 2 1110 mm - 43.70" 152 mm - 5.98" 152 mm - 5.98" 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 Open end wrench 9/16" Open end wrench 14mm Open end wrench 3/4" Open end wrench 11/16 Aen wrench [1/8 ] Torque wrench MOLYKOTE 1000 page 10 of 71- HYDRAULIC CYLINDER FOR OUTBOARD ENGINE
3.3 Standard (starboard) cyinder instaation CAUTION During the instaation phases use ony stainess stee toos to avoid the oxidation of the meta parts. 2 After removing the protective caps of the fittings, manuay center the rod (1) on the cyinder body (2). 1 1 In case of singe cyinder instaation mount the suppied caps on the cyinder body as shown in the picture. 4 With reference to the appication instructions contained in the Appication Guide, position the screw (3) and the washer (4) contained in the D2 bag (see par. 2.2) and connect the ink arm to the tier arm. Tighten the screw by using a 14 mm wrench with a torque of 54[Nm] (39,8 [b ft]). Thread on the ocknut (5) by using a 9/16" wrench and tighten it with a torque of 27[Nm] (19,9 [b ft]). After tightening the ocknut (5), check for the right torque 54[Nm] (39,8 [b ft]) of the screw (3). In case of Suzuki, Envirude and Johnson engine use, refer to the notice at the end of this paragraph. 2 CAUTION During this phase an oi eak from the fittings can occur. This oi must not be discharged into the sea in any case. 3 Position the engine straight so that its arm is perpendicuar to the transom. 5 Fit the set screw (6) on the adjustment coar (7) and screw it to the right side of the tit tube unti it comes into contact with the tit tube stop nut, even in case of port appications. 3 4 6 7 To tighten the screw (3) and the ocknut (5) 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. CAUTION If the ocknut (5) is disassembed, repace it. (Contact our assistance service, see page 5). 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 (5). 5 6 With reference to the' "Appication Guide" choose the spacers for the tit tube rod. 8,1 mm / 3,1" LARGE MEDIUM SMALL In this phase ensure that the cyinder body is centered on the rod and that the engine is perpendicuar to the transom. The number and position of the spacers shown in the Appication guide are indicative ony. 3,2 mm / 0,12" 1,6 mm /0,06" HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 11 of 71
7 Grease the tit tube rod (8), by using marine grease. Insert the tit tube rod through the right and eft bu horns (9) and the tit tube (10) as shown in the picture. 10 8 9 d d2 9 8 Choose and check the spacers to fi the gap between ring nut and buhorn d and d2 between tit tube and bu horn considering the thickness of the stainess washer. E N G L IS H Aways eave a minimum cearance between spacers and bu horn in order to aow the rod titing in the tit tube. 9 Once the correct spacers have been chosen, remove the tit tube rod. 10 Insert the tit tube rod (8) through a bu horn (9), then position the spacers chosen (11) between the bu horn (9) and the tit tube (10). Insert the tit tube rod (8) by making it come out on the opposite side of the tit tube (10) and position the spacers (12). 11 Make the tit tube rod (8) come out of the bu horn (9). 9 8 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. 12 10 11 9 8 12 Insert the washers (13) on the two ends of the tit tube rod (8), grease the ocknut thread (14) with some anti-seize grease type MOLYKOTE 1000 or a simiar one. Then screw them by using a 3/4" wrench and tighten them with a torque of 70[Nm] (52[b ft]). 8 13 13 Make sure the engine can tit. If whie titing the engine is bocked, reduce the overa dimensions of the spacers. 14 CAUTION If the ocknuts (14) are disassembed, repace them. (Contact our assistance service, see page 5). page 12 of 71- HYDRAULIC CYLINDER FOR OUTBOARD ENGINE
14 Unscrew the adjustment coar (7) and bring it into contact with the stainess washer, unti the cearance is eiminated, Do not use any too for this operation. 16 Tighten the set screw (6) on the adjustment coar (7) by using an 1/8" wrench with a torque of 3[Nm] (2 [b ft]). 7 15 Check the correct cyinder instaation by moving manuay the engine on the right and on the eft. The rotation must be as symmetric as possibe between port and starboard so that the steering ange is the same on both sides. 15 The engine must stop through the cyinder end stroke without coming into contact with the mechanica stop (15) on the engine. Otherwise it is necessary to modify the instaation, by changing the thickness of the spacers and by repeating the procedure from point 9. 6 7 17 Check again the correct engine movement both during the right/eft rotation and during the titing. Check periodicay the cearance absence between the ring nut and the tit tube otherwise eiminate the cearance through the adjustment coar (7). 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. FOR INSTALLATION WITH SUZUKI, ENVIRUDE AND JOHNSON ENGINES With reference to the appication instructions contained in the Appication Guide, position the screw (16) contained in the D1 "4 stroke Suzuki, Envirude, Johnson engines instaation kit" bag (see par. 2.2) and the washer (4) contained in the D2 bag (see par. 2.2) and connect the ink arm to the tier arm. Tighten the screw by using a 14 mm wrench with a torque of 54[Nm] (39,8 [b ft]). Position the spacer (17) contained in the D1 "4 stroke Suzuki, Envirude, Johnson engines instaation kit" bag (see par. 2.2), thread on the ocknut (5) contained in the D2 bag (see par. 2.2) by using a 9/16" wrench and tighten it with a torque of 27[Nm] (19,9 [b ft]). After tightening the ocknut (5), check for the right torque 54[Nm] (39,8 [b ft]) of the screw (16). 16 4 Pay the most attention not to exchange the spacer with the washer. 17 5 HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 13 of 71
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: A 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 ). 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; 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 When the cyinder UC128-SVS is used with the pump UP28 F-SVS or UP33 F-SVS, the hydrauic hoses as we must be SVS (Kit OB-SVS). page 14 of 71- HYDRAULIC CYLINDER FOR OUTBOARD ENGINE
3.5 Types of instaation The UC128-SVS hydrauic cyinder for outboard 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: CAUTION Connect hoses as shown in the foowing pictures: SINGLE STATION / SINGLE CYLINDER: 1 4 2 3 4 SINGLE STATION / DUAL CYLINDER: 2 7 5 1 8 8 6 4 3 1. hem 2. starboard cyinder 3. "T" fittings 4. kit OB-SVS 1. hem 2. starboard cyinder 3. port cyinder 4. "T" fittings 5. "T" fittings 6. tie bar 7. kit OB-2C-SVS 8. kit OB-SVS 1 DUAL STATION / SINGLE CYLINDER: 1 DUAL STATION / DUAL CYLINDER: 3 7 5 6 6 6 2 6 1. upper station hem 2. ower station hem 3. starboard cyinder 4. "T" fittings 5. kit OB-2S 6. kit OB-SVS 3 4 9 10 10 10 10 6 2 1. upper station hem 2. ower station hem 3. starboard cyinder 4. port cyinder 5. "T" fittings 8 5 4 6. "T" fittings 7. tie bar 8. kit OB-2C-SVS 9. kit OB-2S 10.kit OB-SVS HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 15 of 71
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 The fiing and purging operations can be faciitated by using the automatic purging equipment BUBBLE BLUSTER (suppied separatey). DANGER Use oi or other compatibe ois. Hydrauic oi OL150 has been specificay formuated for to ensure high quaity performance eve of 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. hydrauic oi compies with standard ISO 10592 concerning hydrauic steering systems. 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 are: - She Teus T15 and She Teus T22 - Mobi DTE 11M 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 10592 concerning hydrauic steering systems. Under no circumstances 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 16 of 71- HYDRAULIC CYLINDER FOR OUTBOARD ENGINE
3.6.1 Positioning of the oi botte To carry out this operation, it is necessary to use the oi fiing kit (1 neede, 1 transparent pipe, 1 pipe connection and 1 spout for the oi botte). This kit is NOT suppied. - Remove the pump cap and insert the fittings. - Attach the spout to a new botte of hydrauic oi and connect the hose to the fittings and the botte spout. - Turn the botte upside down and pierce it with the 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. Whie repacing the oi botte, during the fiing process, cose a the beed vaves of 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. 3.6.2 Singe steering station/ singe cyinder - Unscrew the two beed vave protections and oosen 1.5 turns max. the nuts "A" of the two beed vaves. pin 1 hose fiing connection oi botte spout 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 3.6.1. 2 - 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, Hod the cyinder body with the hand to prevent movements caused by the air present in the cyinder chamber (picture 2). 3 - 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. HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 17 of 71
- 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. The described procedure is the same even in case of singe station, dua engine, singe cyinder and tie bar. 3.6.3 Singe steering station/ dua cyinder - Manuay unscrew the two beed vaves on the cyinder "T" fittings and push the cyinders to one side up to the end stroke. - Position the oi botte as described in paragraph 3.6.1. - Foow the same beeding procedure described for the singe steering station/ singe cyinder (paragraph 3.6.2). Whie turning the steering whee be carefu because both cyinders move. - Repeat the entire procedure severa times to ensure the air absence in the system. beed vaves 3.6.4 Dua steering station/ singe cyinder - Manuay unscrew the two beed vaves on the cyinder "T" fittings and push the cyinders to one side up to the end stroke. back vent pug - Position the oi botte near the main steering station (upper) according to what is described in paragraph 3.6.1. siver non-vent pug Wait unti the oi reaches the ower tank and both tanks are fied. - Foow the same beeding procedure described in paragraph 3.6.2 starting from the ower station and repeat it for the upper station. beed vaves page 18 of 71- HYDRAULIC CYLINDER FOR OUTBOARD ENGINE
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. The purging procedure is the same for dua station, dua engine, singe cyinder and tie bar. 3.6.5 Dua steering station/dua cyinder - Manuay unscrew the two beed vaves on the cyinder "T" fittings and push the cyinders 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 3.6.1. back vent pug beed vaves Wait unti the oi reaches the ower tank and both tanks are fied. - Foow the same purging procedure described in paragraph 3.6.2 starting from the ower station and repeat it for the upper station. siver non-vent pug 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 entire procedure at east 4 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/s or the hem/s 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 too much, 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. HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 19 of 71
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 RESPECT STRICTLY the foowing safety rues. 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 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 IS STRICTLY FORBIDDEN to wear neckaces, braceets or cothes ATTENZIONE which coud get caught in the moving parts. page 20 of 71- HYDRAULIC CYLINDER FOR OUTBOARD ENGINE!
5 MAINTENANCE 5.1 Ordinary maintenance 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 29). 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. 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 thecyinder. 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 up position. Look for and remove the restriction. Repeat the fiing and the beeding procedure of the system. HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 21 of 71
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. Drain the fiing and beeding system. 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 up position. 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. page 22 of 71- HYDRAULIC CYLINDER FOR OUTBOARD ENGINE
6 DISMANTLING 6.1 Dismanting 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. HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 23 of 71
S.p.A. 16015 Casea (Genova) Itaia - Via Crose, 2