Installation and Maintenance Manual

HYDRAULIC CYLINDER FOR

OUTBOARD ENGINES
UC 94-OBF

E N G L IS H
IT A L IA N O
F R A N Ç A IS

ULTRAFLEX
R

PARTNER

UK I F
page. 2 pag. 23 page. 45

(Dr. No. 31069 04/02/2015)

 ULTRAFLEX
Dear Customer,
We would like to thank you for choosing an ULTRAFLEX product.

ULTRAFLEX has been a leader in steering systems for pleasure and professional boats for many years.
ULTRAFLEX production is since ever synonimous of reliability and safety.

All ULTRAFLEX products are designed and manufactured to ensure the best performance.
To ensure your safety and to maintain a high quality level, ULTRAFLEX products are guaranteed only if
they are used with original spare parts.

ULTRAFLEX and UFLEX Quality Management Systems are certified CISQ-IQNet by the Italian Shipping
Registry (RINA), in conformity with the UNI EN ISO 9001:2008 rule. ULTRAFLEX certification No. 6669/02/S
(former 420/96). UFLEX certification No. 8875/03/S.

The quality management system involves all the company resources and processes starting from the
ENGLISH

design, in order to:

- ensure product quality to the customer;
- maintain and improve the quality standards constantly;
- pursue a continuous process improvement to meet the market needs and to increase the customer
satisfaction

ULTRAFLEX Environmental Management System is certified CISQ-IQNet by the Italian Shipping Registry
(RINA), in conformity with the UNI EN ISO 14001 rule. ULTRAFLEX certification No. EMS-1282/S.

Products for pleasure boats are constantly tested to check their conformity with the 2013/53/EU.

"ULTRAFLEX has over 80 years of experience in the marine industry and is a world leader in the production
of mechanical, hydraulic and electronic steering systems, control boxes and steering wheels for any
kind of pleasure, fishing or commercial boats.
The key factors which explain the increasing success of our products all over the world are the reliability
of our products and the before and after sale service, the quality of the company organization and of the
human resources and the continuous spending in research and development".

ULTRAFLEX S.p.A.
16015 Casella (Genova) Italia - Via Crose, 2
 ULTRAFLEX Installation and Maintenance Manual

TABLE OF CONTENTS
MANUAL USE AND SYMBOLS USED................................................................................................................4
INTRODUCTION.................................................................................................................................5
WARRANTY................................................................................................................................5

E N G L IS H
SECTION 1 - PRODUCT DESCRIPTION
1.1 HYDRAULIC STEERING SYSTEM OPERATION..................................................................................6
1.2 WARNINGS FOR THE CORRECT PRODUCT USE ......................................................................6
1.3 CONFIGURATIONS.........................................................................................................................7
1.4 UC94-OBF CYLINDER DESCRIPTION......................................................................................................8
1.5 TECHNICAL FEATURES..........................................................................................................................8

SECTION 2 - TRANSPORT
2.1 GENERAL WARNINGS.............................................................................................................................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 TYPE OF INSTALLATION...........................................................................................................................15
3.6 FILLING AND PURGING.......................................................................................................................16
3.6.1 POSITIONING OF THE OIL BOTTLE ...................................................................................16
3,6,2 SINGLE STEERING STATION...............................................................................................17
3.6.3 DUAL STEERING STATION......................................................................................................................18
3.7 GENERAL RECOMMENDATIONS................................................................................................................18

SECTION 4 - SAFETY WARNINGS !

4.1 SAFETY WARNINGS DURING USE AND INSTALLATION ........................................................................19
4..2 C L O T H I NG ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9

SECTION 5 - MAINTENANCE
5.1 ORDINARY MAINTENANCE.................................................................................................................20
5.2 TROUBLESHOOTING.........................................................................................................................20

SECTION 6 - DISMANTLING
6.1 DISMANTLING................................................................................................................................22

IMPORTANT:
The additional documents "Application Guide" and "Spare Parts List" are attached to this manual.

HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 3 of 67

 ULTRAFLEX Installation and Maintenance Manual

MANUAL USE AND SYMBOLS USED

THE INSTALLATION AND MAINTENANCE MANUAL is the document accompanying the product from its sale
to its replacement and discharge. The manual is an important part of the product itself.
It is necessary to read carefully the manual, before ANY ACTIVITY involving the product, handling and
E N G L IS H

unloading included.
In this manual the following symbols are used to ensure the user safety and to guarantee the correct
operation of the product:
Denotes that an extreme intrinsic hazard exists which would result in
DANGER high probability of death or irreparable injury if proper precautions are
not taken.

Denotes that a hazard exists which can result in injury or death if proper
WARNING precautions are not taken.
IT A L IA N O

Denotes a reminder of safety practices or directs attention to unsafe

CAUTION practices which could result in personal injury or damage to the craft or
components or to the environment.

Important information for the correct installation and for maintenance, that
NOTICE does not cause any damage.

The symbol aside indicates all the operations which must be carried out
by qualified or skilled staff, in order to avoid hazards.
We recommend training the staff in charge of the product installation
and checking their knowledge.

STERN

The picture aside explains the meaning of some

nautical words contained in this manual.
STARBOARD PORT
LEGEND
m.p.h. = miles per hour
km/h = kilometres per
hour

10 m.p.h. = 8,69 knots

10 m.p.h. = 16,1 km/h
10 knots = 11,5 m.p.h.
10 knots = 18,5 km/h
10 km/h = 6,21 m.p.h.
10 km/h = 5,4 knots
BOW

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 ULTRAFLEX Installation and Maintenance Manual

INTRODUCTION
This installation and maintenance manual represents an important part of the product and must be available
to the people in charge of its use and maintenance.
The user must know the content of this manual.

E N G L IS H
ULTRAFLEX declines all responsibility for possible mistakes in this manual due to printing errors.
Apart from the essential features of the described product, ULTRAFLEX reserves the right to make those
modifications, such as descriptions, details and illustrations, that are considered to be suitable for its
improvement, or for design or sales requirements, at any moment and without being obliged to update this
publication.
ALL RIGHTS ARE RESERVED. Publishing rights, trademarks, part numbers and photographs of ULTRAFLEX
products contained in this manual are ULTRAFLEX property.
Great care has been taken in collecting and checking the documentation contained in this manual to
make it as complete and comprehensible as possible. Nothing contained in this manual can be interpreted
as warranty either expressed or implied - including, not in a restricted way, the suitability warranty for any
special purpose. Nothing contained in this manual can be interpreted as a modification or confirmation of
the terms of any purchase contract.

WARNING
To ensure the correct product and component operation, the product must be installed by qualified staff.
In case of part damage or malfunction, please contact the qualified staff or our Technical Assistance Service.

TECHNICAL ASSISTANCE SERVICE

U F L E X S.r.l. North - South - Central America:
Via Milite Ignoto,8A U F LE X USA
16012 Busalla (GE)-Italy 6442 Parkland Drive
Ph: +39.010.962.01 Sarasota, FL 34243
Fax: +39.010.962.0333 Ph: +1.941.351.2628
Email: [email protected] Fax: +1.941.360.9171
www.ultraflexgroup.it Email: [email protected]
www.uflexusa.com

WARRANTY
ULTRAFLEX guarantees that its products are well designed and free from manufacturing and material defects,
for a period of two years from the date of manufacturing.
For the products which are installed and used on working or commercial boats the warranty is limited to
one year from the date of manufacturing.
If during this period the product proves to be defective due to improper materials and/or manufacture, the
manufacturer will repair or replace the defective parts free of charge.
Direct or indirect damage is not covered by this warranty. In particular the company is not responsible and this
warranty will not cover the damage resulting from incorrect installation or use of the product (except for
replacement or repair of defective parts according to the conditions and terms above).
This warranty does not cover the products installed on race boats or boats used in competitions.
The descriptions and illustrations contained in this manual should be used as general reference only.
For any further information please contact our Technical Assistance Service.
ULTRAFLEX steering system components are marked according to the Directive 2013/53/EU.
We remind you that only marked steering systems must be used on the boats marked . We inform
you that the ULTRAFLEX warranty is null if some ULTRAFLEX components are installed on a steering system
together with products of other brands.

HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 5 of 67

 ULTRAFLEX Installation and Maintenance Manual

1 PRODUCT DESCRIPTION
1.1 Hydraulic steering system operation
E N G L IS H

All ULTRAFLEX hydraulic steering systems are designed in conformity with UNI-EN-ISO 10592 and A.B.Y.C. P21
regulations. All ULTRAFLEX steering systems can operate at temperatures between -18°C (0°F) and +77°C
(+170°F). All the components are made for the marine environment, using materials and working processes
which offer long life and safety under the most extreme conditions. A hydraulic steering system consists of
a steering pump, a cylinder tied to the rudder or to the outboard or
sterndrive engine and the connecting hoses (see picture). Under
pump
normal operating conditions, a turn of the steering wheel will pump engine l
the oil, which flows in through the hoses to the cylinder, according
to the turn direction. With the consequent cylinder movement the oil
will flow to the pump through the hoses and at the same time moves
the engine or the helm which are connected to the cylinder. The
pumps are equipped with a nonreturn valve, which prevents outgoing l
fluid from returning along the same hose. It also allows the operation l

of the steering systems with two or more steering stations. The

IT A L IA N O

cylinders are double acting and may be balanced or unbalanced. In

the unbalanced cylinders the two chambers have different volumes cylinder
and so they need a different number of turns of the steering wheel hydraulic
l
and a different rotation effort. The balanced cylinders have same hose
number of steering wheel turns in order to move the helm from the
center to the end stroke in the two opposite directions. A well balanced steering system needs a correct
choice of the pump for the cylinder. ULTRAFLEX produces different pump models, which have different capacity
(cm3 of oil moved each steering wheel turn) and for each type of installation. While choosing the pump it is
important to consider the cylinder volume. The number of starboard and port turns is determined by the
ratio between the cylinder volume and the pump capacity.
Example: if the pump has a capacity of 20 cm3 [1,2cu.in.] and the cylinder has a volume of 94cm3 [5,7cu.in.], the
formula looks like this: 94/20=4,7. Accordingly, the steering wheel will turn 4 times and an half before the
cylinder will completely turn from one side to the other. In case of installations with double cylinders
connected in parallel the cylinder volume must be added. Applications with less than 4 turns are not
recommended, as they need a higher effort, also applications with more than 8 turns are also not
recommended, as the response of the boat to steer is slowly. The maximum operating pressure is 7,0MPa
(70 bar) (1000 PSI).

1.2 Warnings for the correct product use

WARNING
Before beginning the installation, check the mounting compatibility of the UC94-OBF cylinder to the engine
by consulting the attachted document "Application Guide" contained in the packaging.

DANGER
Do not modify the steering cylinder in any way to fit it to your engine application, otherwise the cylinder will
no longer operate in safety and it will endanger the boat and the occupants.

WARNING
All ULTRAFLEX steering systems must not be installed on boats equipped with engines whose maximum
horsepower is higher than the horsepower rating approved by boat manufacturer.

WARNING
ULTRAFLEX hydraulic steering systems must not be installed on race boats.

DANGER
It is forbidden to disassemble the components which are supplied preassembled to avoid compromising
the product integrity.

page 6 of 67 - HYDRAULIC CYLINDER FOR OUTBOARD ENGINE

 ULTRAFLEX Installation and Maintenance Manual

1.3 Configurations
The hydraulic cylinder for outboard engine UC94-OBF model can be installed on boats a single engine used
with a single or dual steering system.

E N G L IS H
STEERING STATION
NUMBER
S
I
N
G
L
E
S
T
A
T
I
O ENGINE NUMBER
N

S
I
N
G
L up to 150hp max
E
D E
U MAIN STATION
N
A G
L ADDITIONAL I
STATION N With SINGLE CYLINDER
S E
T
A
T
I
O
N

NOTA
CAUTION
In case of single engine applications with a horsepower which exceeds 150hp, it is necessary to assemble
the Ultraflex UC 128-OBF or UC128-SVS cylinder.

HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 7 of 67

 ULTRAFLEX Installation and Maintenance Manual

1.4 UC94-OBF cylinder description

UC94-OBF is a hydraulic outboard front mount cylinder which has been designed and manufactured to be
used as a component in the hydraulic steering systems, as described in the previous paragraph.
The cylinder is installed to the tilt tube rod of the available engines on the market as shown in the attached
E N G L IS H

document "Application guide". It is possible to meet all the different cylinder applications due to the two
different link arms and a proper spacer kit. The following picture shows the main cylinder components:

7b
1 Cylinder body

2 Fittings and bleed valves

6
3 Bull horns 7a
4 Tilt tube rod 4 5
IT A L IA N O

5 Spacers
6 Adjustment collar 3

7a Straight link arm (UC94-OBF/1)

2
7b Curved link arm (UC94-OBF/3) 1

1.5 Technical features

SPECIFICATIONS UC94-OBF/1 -/3
78 mm (3.08")

Volume 94 cc - 5.7 cu. in

Max.cylinder
outout force*
thrust* 354 kg - 780 lbs (@ 70 bar)
Inside diameter 30 mm - 1.18"
Stroke 186 mm - 7.3"
Oil OL150 Ultraflex 546 mm (21.5")

UC94-OBF/1 UC94-OBF/3

CAUTION
* The cylinder thrust shown above is a theoretical value calculated considering a pressure system of 70 bar (1000
psi). This value is not the one considered for the system normal use but for the system use in extreme conditions.

page 8 of 67 - HYDRAULIC CYLINDER FOR OUTBOARD ENGINE

 ULTRAFLEX Installation and Maintenance Manual

2 TRANSPORT
2.1 General warnings

E N G L IS H
The product weight with its packaging is 8kg (18 pounds) and so it can be handled manually.

WARNING
The staff in charge of handling must operate with protective gloves and safety shoes.

2.2 Packaging contents

Before using the equipment check that the product has not been damaged during transport.
Also make sure that all the standard components are in the packaging (see list). In case of damage,
notify the claim to the forwarder and inform the supplier.

A l

l l C
l

CONTENTS OF THE STANDARD PACKAGING:

E A ) No.1 cylinder body with rod, fittings and bull horns;
B ) No.1 link arm kit composed of:
- tilt tube rod (2 pieces) + No.1 lockpin
- No.2 locknuts + No.2 washers;
C ) No. 1 spacer kit composed of:
- No.8 plastic spacers;
- No.2 steel spacers;
- No.1 ring nut for adjustement collar;
D) No.1 kit composed of:
- No.2+1 locknuts;
- No.2 lock washers;
- No.1 short hexagon headed screw
- No.1 long hexagon headed screw (code 73584U);
E ) No.1 plastic hose for the hydraulic circuit bleeding;

CAUTION
The packaging must be disposed of according to the existing laws.
HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 9 of 67
 ULTRAFLEX Installation and Maintenance Manual

3 INSTALLATION
3.1 Minimum transom requirements
E N G L IS H

The following picture shows the minimum splash well dimensions. These dimensions must be respected in
order to prevent the cylinder from being damaged when the outboard engine is completely tilted upwards.
The picture shows also the minimum transom dimensions, needed for the installation and the correct
operation of the engine steering cylinder.

°
90
³

C
IT A L IA N O

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"

WARNING
ENGINE JACK PLATE APPLICATION TO THE TRANSOM.
A jack plate installation will change all the application clearances. A new clearance check must be completed
with the tilting of the engine in conjunction with the vertical movement of the jack plate in all the possible
positions. If the steering cylinder comes into contact with the splash well, transom and/or jack plate, stop
the installation immediately! Use the jack plate manufacturer's instructions to limit the upper or lower
direction in which the interference occurs. If this is not possible please contact specialized staff.

3.2 Necessary tools

Allen wrench Open end Open end Open end Open end Pliers Torque wrench MOLYKOTE® 1000
4 mm [5/32”] wrench wrench wrench wrench
3/4'' 14mm 11/16” 5/8”

CAUTION
During installation use only stainless steel tools to prevent the corrosion of the metal parts.

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 ULTRAFLEX Installation and Maintenance Manual

3.3 Cylinder installation

1 After removing the protective caps of the 2 Position the engine straight so that its arm is
fittings, manually center the rod (1) on the cylinder perpendicular to the transom.
body (2).

E N G L IS H
l 3

1 l 4
l

2 3 With reference to the application instructions

contained in the Application Guide, position the
screw (3) contained in the D2 bag (see par. 2.2)
CAUTION and connect the link arm to the tiller arm. Tighten
During this phase an oil leak from the fittings can the screw with a torque of 40[Nm] (29.5 [lb ft]).
occur. This oil must not be discharged into the sea in Thread on the locknut (4) and tighten it with a torque
any case. of 25[Nm] (18.5 [lb ft]). After tightening the locknut
(4), check for the right torque 40[Nm] (29.5 [lb ft]) of
the screw (3).
4 Grease the two parts of which the tilt tube rod
is made up (5) and (6), by using marine grease to WARNING
prevent the corrosion of the metal parts.
To tighten the screw (3) and the locknut (4) on the
tiller arm ask your mechanic for the maximum
5 Insert the first part of the tilt tube rod (5) into the torque allowed. If it is lower than the one indicated
tilt tube. in this manual, tighten with the torque indicated
by the mechanic.

5
WARNING
l It is important to check periodically, at least every 3
months (or every month for professional uses), the
right torque of this screw (3) and of the locknut (4).

7 Position the bolt (8) and the nut (9) on the

adjustment collar (10) and screw it to the right
6 Insert the secord part of the tilt tube rob (6) by side of the tilt tube until it comes into contact with
locking it by means of the pin (7), then holding the the tilt tube stop nut.
pin with your hand continue to insert the tilt tube
rod into the tilt tube.

8
l
10 l

9
6

HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 11 of 67

 ULTRAFLEX Installation and Maintenance Manual

8 With reference to the' "Application Guide" 9 Insert the right and left bull horns (11) by
choose the spacers for the tilt tube rod. connecting the rod and the tilt tube rod as shown
in the picture.

1,6 mm /0,06"
3,2 mm / 0,12"
E N G L IS H

8,1 mm / 3,1"

SMALL
11
LARGE MEDIUM
11
l

WARNING l

The number and position of the spacers shown in

the Application Guide is only indicative.

11 Once the correct spacers have been chosen,

NOTICE remove the bull horns.
In this phase ensure that the cylinder body is
centered on the rod and that the engine is 12 Insert the plastic and stainless steel spacers
perpendicular to the transom. and the two stainless washer on the tilt tube rod..
IT A L IA N O

NOTICE
10 Choose the spacers to fill the gap between ring
nut and bullhorn d and d2 between tilt tube and bullhorn Both the stainless steel spacers must be positioned
considering the thickness of the stainless washer. towards the tilt tube on the opposite side of the
bull horns to avoid their wear during engine lifting
and lowering.

13 Insert the right and left bull horns (11) by

connecting rod and tilt tube rod as shown in the
picture.

11
11
l

WARNING
l
Always leave a minimum clearance between
spacers and bullhorn in order to allow the rod tilting
in the tilt tube.

14 Insert the washers (12) on the two ends of the 15 Position washers(14) and tighten both locking
tilt tube rod and tighten the nuts (13), with a torque nuts (15) with a torque of 60[Nm] (22 [lb ft]).
of 70[Nm] (52[lb ft]). after greasing them with ma-
rine grease.
NOTICE
The lock washer tabs must be bent afterwards (see
point 20).

14 15
12 13
l
l

l l
16 Check the correct tilting of the engine.

WARNING
WARNING
Check the correct torque of both nuts. If while tilting the engine is blocked, reduce the
overall dimensions of the spacers.

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 ULTRAFLEX Installation and Maintenance Manual

17 Unscrew the adjustment collar (10) and bring 19 Tighten the set screw (8) on the adjustment
it into contact with the stainless washer, until the collar (10) with a torque of 3[Nm] (2 [lb ft]).
clearance is eliminated,

10

E N G L IS H
l 10
l
l
8

18 Check the correct cylinder installation by moving 20 Bend the tabs of the
manually the engine on the right and on the left. lock washers (14)
bringing them into
NOTICE contact with the screw
The rotation must be as symmetric as possible so
l 14
head and taking care
that the steering angle is the same on both sides. not to damage the bull
horns while using the
WARNING pliers.
16 The engine must stop through
l the cylinder end stroke without 21 Check again the correct engine movement
coming into contact with the both during the right/left rotation and during the
mechanical stop (16) on the
tilting.
engine.
NOTICE WARNING
Otherwise it is necessary to modify the installation, In this phase clearance should be enough to
by changing the thickness of the spacers and by avoid frictions but it should not be excessive since
repeating the procedure from point 13. it could cause engine instability. In case of contact
with the transom, stop the installation and contact
the specialized staff.
NOTICE FOR INSTALLATION
The bolt identified with the reference 73584U (Pict.C) is the connection screw between the cylinder's link arm
and the engine's tiller arm that must be used with the following engines:
- SUZUKI 100-115-140 (2008 - to date).
- Engines with the tiller arm shaped like in Pict.A and thickness (S) between 10 and 22 mm (0.4" and 0.85").
For the other engines with tiller arm shaped like in Pict.A and thickness (S) max. 10 mm (0.4"), please use the
standard bolt (shorter than ref. 73584U ).
When the link arm is shaped like in Pict.B the KIT ref. 41954W (not included in the present kit), containing the
dedicated spacer, must be used.
In case the tiller arm differs from the above measures, please contact our after sales service.
PICT.A PICT.B PICT.C
51.45mm/2.026in

Sec.A-A (ref. 73584U)

Sec.A-A

CAUTION
After installation, check that the nylon part of the self-locking nut is tightened on the screw thread.

HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 13 of 67

 ULTRAFLEX Installation and Maintenance Manual

3.4 Hose installation

The two fittings mounted on the cylinder body are already oriented and are ready to be used. If for practical
reasons the orientation must be changed, do as follows:
E N G L IS H

A
IT A L IA N O

1. loose 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[lb ft]) until the washer comes into contact with it.

Screw the hoses on the cylinder fittings with a torque of 20[Nm] (15[lb ft]) according to the following instructions:

- minimum hose bend radius 250 mm;

- no interference during engine tilting; mi
nim
- no interference with the transom; um
ra
di u
s2
50
mm

WARNING
An excessive hose bend could result in its internal breaking which
will cause a bad operation of the system. In this case it is necessary to

NO
replace the damaged hose.

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 ULTRAFLEX Installation and Maintenance Manual

3.5 Type of installation

The UC94-OBF hydraulic cylinder for outboard engines can be installed with a single or dual steering system.
The possible configurations are:

E N G L IS H
CAUTION
Connect hoses as shown in the following pictures:

SINGLE STATION / SINGLE CYLINDER: SINGLE STATION / SINGLE CYLINDER:

1 l

1
2
3
l
l
2
l
l
l
l
5
l
l

3 4

1. helm
2. cylinder 1. upper station helm
3. bleed valves 2. lower station helm
3. cylinder
4. bleed valves
5. kit OB-2S

HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 15 of 67

 ULTRAFLEX Installation and Maintenance Manual

3.6 Filling and purging

After the first installation and after maintenance operations it is necessary to fill the system with hydraulic
oil. This operation must avoid the air in the system, to ensure the good system operation. The hydraulic
system must be filled from the highest point of the system, which means from the upper steering station.
E N G L IS H

CAUTION
To avoid air bubbles in the oil, it is necessary to fill the tank slowly.
WARNING
The filling and bleeding operations must be carried out at least by two operators.
DANGER
Use ULTRAFLEX oil or other compatible oils.
Hydraulic oil OL150 has been specifically formulated for ULTRAFLEX to ensure high quality performance
level of ULTRAFLEX products throughout time.
Its special "Zinc Free" formula enhances protection against marine oxidation. The special mix of anti-wear
and stabilizing components of OL150 allow ensuring great results as far as the product duration and
IT A L IA N O

performances are concerned in several environmental conditions.

ULTRAFLEX hydraulic oil complies with standard ISO 10592 concerning hydraulic steering systems. ULTRAFLEX
is not to be held responsible for any damages or performance deterioration if oils different from OL150 are
used.
DANGER
Do NOT use ATF Dexron II transmission oils or brake oils which could cause the steering system seizing.
Oils which are compatible with OL150 ULTRAFLEX are:
- Shell Tellus T15 and Shell Tellus T22
- Mobil DTE 11M
NOTICE

ULTRAFLEX will not be able to ensure the compatibility of the above mentioned oils with OL150 if the oil
manufacturers vary their formulation; in particular, it will not be able to ensure its compliance with standard
ISO 10592 concerning hydraulic steering systems. Under no circumstances ULTRAFLEX is to be held responsible
for any damages or performance deterioration.

In the days after the filling, check the oil level; if necessary top off the system.
At the beginning the oil level can lower, as small amounts of air can be released in a homogeneous way.

DANGER
After 24 hours repeat the purging and check the absence of leaks.

3.6.1 Positioning of the oil bottle

The oil filling must be carried out by using the proper kit (including spout, flexible hose, fitting and pin)
which is NOT supplied.

- Remove the pump cap and insert the fitting.

- Attach the spout to a new bottle of hydraulic oil and connect the hose to the fitting and the bottle spout.
- Turn the bottle upside down and pierce it with the supplied pin, as shown in the picture, to ease the oil
passage towards the pump. Fill the pump until no air bubbles are visible in the hose.

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 ULTRAFLEX Installation and Maintenance Manual

pin
WARNING oil bottle
While replacing the oil bottle, during the filling process, close all the bleed valves
on the cylinder/s. To bleed the system, check that oil is always present in the
filling hose. If some air is in the system during the bleeding process, the whole spout
bleeding process must be started again.

E N G L IS H
hose

filling
CAUTION connection
Replace the bottle before it empties and use recovered oil only after 24 hours.

3.6.2 Single steering station

- Unscrew the two bleed valve protections and loosen 1.5 turns max. the nuts
"A" of the two bleed valves. 1

- Manually push the cylinder body to one side until it stops as shown in picture 1.

- Position the oil bottle as explained in paragraph 3.6.1.

2
- Close the bleed valve on the cylinder end stroke side and put a purged oil
tank near the other bleed valve (as shown in picture 2).

- Turn the steering wheel slowly (as shown in picture 2) so that the oil can
come out of hoses,

NOTICE
Hold the cylinder body with the hand to prevent movements caused by the air
present in the cylinder chamber (picture 2).

- When the oil comes out of the bleed valve (without air bubbles), close the 3
bleed valve and continue to turn the steering wheel in the same direction to
fill the cylinder chamber (picture 3).
During this phase the cylinder body will move to the opposite direction up to
the end stroke.

HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 17 of 67

 ULTRAFLEX Installation and Maintenance Manual

- Open the other bleed valve and move purged oil tank to the other side.
Holding the cylinder body in this position, turn the steering wheel as shown 4
in picture 4, until oil without air bubbles comes out of the bleed valve.
Then close the bleed valve.
E N G L IS H

- Repeat the entire procedure to ensure the absence of air in the system.

3.6.3 Dual steering station

IT A L IA N O

- Manually unscrew the two bleed valves on black vent plug

the cylinder and push the cylinder to one
side up to the end stroke.
l

- Position the oil bottle near the main steering

station (upper) according to what is
described in paragraph 3.6.1.
silver non-vent
plug
WARNING
Wait until the oil reaches the lower tank and l
both tanks are filled. l

- Follow the same bleeding procedure

described in paragraph 3.6.2 starting from
the lower station and repeat it for the upper
station. bleed valves

WARNING
For the additional steering station (lower) tank use only the silver non-vent plug (supplied with the "kit OB-
2S"). For the main steering station (upper) tank use only the black vent plug.

- Repeat the procedure at least 3 times to ensure the absence of air in the system.

3.7 General recommendation

WARNING
It is very important to check the absence of air in the system before using the boat! We recommend trying
to manually move the engine towards port and starboard, making sure that there is no movement of the
cylinder body on the main cylinder shaft.
If the cylinder body moves more than 1/6 inches (15mm), there is still air in the system. The air presence in
the system can cause bad responses to the controls and so it can cause damage, injuries or death.

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 ULTRAFLEX Installation and Maintenance Manual

4 SAFETY WARNINGS
This section shows the safety rules which must be followed for the correct equipment operation.
We recommend reading carefully this section and also the other manuals supplied with the steering system
components.

E N G L IS H
4.1 Safety warnings during use and installation
RESPECT STRICTLY the following safety rules:
ULTRAFLEX declines all responsibility in case the user does not follow these rules and it is not responsible for
negligence during the use of the system.

DANGER
- DO NOT PUT HANDS BETWEEN THE MOVING PARTS.
- Do not disable the safety devices.
- Do not modify or add devices to the system, without ULTRAFLEX written authorisation or technical
intervention which will 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 installation and maintenance manual.
- Do not let non-specialized staff perform the installation.
- Do not disassemble the hydraulic connections before bleeding the oil in the system completely.
The hoses can contain high pressure oil.

ATTENZIONE
WARNING
- Do not put the feet on the cylinder.
- Check the system after the installation and the purging but before operating the vessel. Turn the
steering wheel until the cylinder/s reaches/reach the end stroke.
Turn the steering wheel to the opposite direction. Repeat on each installed helm to verify the
correct installation and the system operation.
- Carefully use sealing fluid (such as Loctite). If it reaches the hydraulic system, it may cause
damage and mechanical failure.
- Do not use teflon tape or adhesive tape to seal the fittings, as this material may be injested, by
causing the system fail.
- During the system installation, prevent foreign matters from entering the system.
Even a little object may cause lasting damage that are not detected immediately.
- 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 Clothing

WARNING
ATTENZIONE
During installation, inspection or maintenance,
IT IS STRICTLY FORBIDDEN to wear necklaces, bracelets or clothes which could get caught in the moving
parts.

! HYDRAULIC CYLINDER FOR OUTBOARD ENGINE - page 19 of 67

 ULTRAFLEX Installation and Maintenance Manual

5 MAINTENANCE
5.1 Ordinary maintenance
E N G L IS H

WARNING
Poor installation and maintenance may result in loss of steering and cause property damage and/or personal
injury. Maintenance requirements change according to climate, frequency and the use. Inspections are
necessary at least every year and must be carried out by specialized marine mechanics. Check the cylinder
fittings and the seals and the helm gaskets to prevent leaks. Replace them if necessary. To keep a suitable
oil level in the tank, fill and bleed the system as described in this manual in paragraph 3.6.
Check the hose and the entire system wear, the nut and bolt tightening every six months and make sure that
they are not damaged. Clean the system using water and non-abrasive soap.
WARNING
Use only compatible hydraulic oils, indicated in the paragraph "technical features" and "filling and purging".
Do not use brake oils or automatic transmission fluid (ATF) in any case.
WARNING
IT A L IA N O

After the first 10 hours of use and then periodically check the connection integrity and tightening.
CAUTION
If the locknuts are disassembled, replace them. (Contact our assistance service, see page 5).
5.2 Troubleshooting
WARNING
Whenever the following checks need the removal and/or disassembly of the steering system components,
such work must be carried by specialized staff. ULTRAFLEX offers general information only and is not
responsible for any consequences resulting from incorrect disassembly.
PROBLEM CAUSE SOLUTION
During the filling, the • Blockage in the hoses between • Replace hoses.
steering system becomes steering system and cylinder.
completely jammed. WARNING
The damaged hose must be replaced,
otherwise it may cause loss of steering
and severe personal injury or property
damage.

The system is very difficult • Air in the system. • Repeat the filling and the bleeding
to fill. procedure of the system.
Air keeps bubbling at the • Install horizontally the hoses and in
top of the steering system any case with a maximum inclination
tank even after filling the of 3cm each meter.
system completely.
• Leaks from the cylinder • Tighten the bleeder on the
bleeder. cylinder.

• Coiled hose. • Uncoil and straighten the hose.

• Helm has been mounted upside • Mount the helm with the filling hole in
down. up position.

The steering system is stiff • Restrictions in hoses or fittings. • Look for and remove the restriction.
and hard to turn, even
when the boat is not • Repeat the filling and the bleeding
moving. • Air in oil
procedure of the system.

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 ULTRAFLEX Installation and Maintenance Manual

The steering system is • Wrong oil has been used. • Drain the filling and bleeding system.
stiff and hard to turn, even
when the boat is not
moving. WARNING
ULTRAFLEX is not responsible for damage
caused by fluids that are not

E N G L IS H
recommended in this manual and so the
warranty is cancelled.

The steering system is • Dirt in the valve.

stiff and hard to turn, even WARNING
when the boat is not Do not use the boat and contact a
moving, if unbalanced specialized technician for the valve
cylinders are used. cleaning.

The steering system is • The steering wheel is too • Replace the steering wheel with a bigger one.
easy to turn at the dock but small.
becomes hard to turn
when the boat is in motion. WARNING
Only within the maximum dimensions
allowed by the helm.
• Incorrect setting of the torque • Adjust the torque tab.
tab.

• Air in oil. • Check the oil level and repeat the

bleeding procedure as explained in this
manual.
When the steering • Air in the system. • Repeat the filling and bleeding
wheel is turned, the rod procedure of the system.
(movable rod cylinders)
or the body (fixed • Oil leak. • Look for the leak and contact
cylinder rod) of the specialized staff.
cylinder do not move. • Helm mounted upside down. • Mount the helm with the filling hole in
up position.
• Bad tightening or low torque • Tighten the fittings with a
Leaks from steering
of the fittings. maximum torque of 20Nm (15 in.Ibs).
system fittings.
• Lack of fitting sealant. • Drain and disassemble the steering
system. Remove the fittings and remove
the oil from threads. Put the sealant on the
WARNING fittings and tighten them, install the helm.
Never use teflon tape or adhesive
tape on any fitting. WARNING
After this operation it is necessary to carry
out another bleeding.

Leaks from the tank plug. • Bad tightening of the plug. • Tighten the plug.
• The vent plug (black) on the • Replace the vent plug (black) with the
additional helm is in the plug for the additional helm kit (silver).
lower position.
• Worn and damaged seal. • Replace the plug.

• Too high oil level. • Follow the procedure to maintain the

suitable oil level, which is described
in the pump manual.

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 ULTRAFLEX Installation and Maintenance Manual

6 DISMANTLING
6.1 Dismantling
E N G L IS H

When for any reason, the steering system is put out of service, it is necessary to follow some rules in order
to respect the environment.
Sheaths, pipelines, plastic or non-metallic components must be disassembled and disposed of separately.

The steering system CONTAINS POLLUTING OILS

which must be disposed of according to the rules in force in the country.
IT A L IA N O

page 22 of 67 - HYDRAULIC CYLINDER FOR OUTBOARD ENGINE

 ULTRAFLEX Manuel d'installation et d'entretien

NOTES

F R A N Ç A IS

VERIN HYDRAULIQUE POUR MOTEUR HORS-BORD - page 67 de 67

 ULTRAFLEX S.p.A.
16015 Casella (Genova) Italia - Via Crose, 2