ULTRAFLEX UP28FM Front Mount Helm Pump Instruction Manual

: August 12, 2024
: ULTRAFLEX

Table of Contents

ULTRAFLEX UP28FM Front Mount Helm Pump
Product Information
Product Usage Instructions
PRODUCT DESCRIPTION
INSTALLATION
MAINTENANCE
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ULTRAFLEX UP28FM Front Mount Helm Pump

Product Information

Specifications

Brand: ULTRAFLEX
Designed in conformity with: UNI-EN-ISO 10592 and A.B.Y.C. P21

Product Usage Instructions

Hydraulic Steering System Operation
All ULTRAFLEX hydraulic steering systems are designed for long life and safety under extreme conditions.

A hydraulic steering system consists of:

Steering pump located on the dashboard
Cylinder tied to the rudder or engine
Connecting hoses

When operating under normal conditions, turning the steering wheel pumps oil through the hoses to the cylinder, causing movement in the direction of the turn. The pumps come with or without a non-return valve, allowing operation with multiple steering stations.

Warnings for Correct Product Use

DANGER: Do not modify the steering cylinder as it may compromise safety.
WARNING: Do not install on boats with engines exceeding approved horsepower or on race boats.

FAQ

Q: Can I use ULTRAFLEX steering systems on race boats?
A: No, ULTRAFLEX steering systems are not recommended for use on race boats.
Q: How do I determine the number of steering wheel turns required for my system?
A: The number of turns is determined by the ratio between the cylinder volume and pump capacity. Make sure to choose a pump that matches your cylinder volume for optimal performance.

“`

Installation and maintenance manual

PRODUCT DESCRIPTION

1.1 Hydraulic steering system operation

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 located on the dashboard, a cylinder tied to the

rudder or to the outboard or sterndrive engine and the connecting

hoses (see picture). Under normal operating conditions, a turn of pump

the steering wheel will pump the oil, which flows in through the

engine

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 equipped with a nonreturn

valve, which prevents outgoing fluid from returning along the same

hose. allow the operation of the steering systems with two or more

steering stations. The pumps series “NV” are not equipped with a

nonreturn valve so they cannot be used with two or more steering systems. The cylinders are double-acting and they can be balanced

cylinder

or unbalanced. In unbalanced cylinders the two chambers have different volumes and therefore they require a different number of

hydraulic hoses

steering wheel turns and a different steering wheel rotation effort with the same movement in the two

directions. The unbalanced cylinders cannot be used with the pumps series “NV”. The balanced cylinders

require the same number of turns of the steering wheel to move the helm from the centre to the end of

stroke in the two opposed 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 28 cm3 [1,7cu.in.] and the cylinder has a volume of 120 cm3 [7,3cu.in.], the

formula looks like this: 120/28=4,2. Accordingly, the steering wheel will turn about 4 times 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 not recommended, as the response

of the boat to steer is slowly.

1.2 Warnings for the correct product use
DANGER Do not modify the steering cylinder in any way to fit it to your 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 steering systems must not be installed on race boats.
WARNING The pumps UP25NV F and UP33NV F cannot be used with unbalanced cylinders and with double steering system.
PUMP FOR HYDRAULIC SYSTEMS – page 7 of 101

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1.3 System configurations
The pumps UP25 – UP28 – UP33 – UP39 – UP45 can be installed in a single or double steering system and used with different types of configurations of front, side or inboard cylinders. The pumps series “NV” cannot be installed in a double steering system and they cannot be used with unbalanced cylinders.

CAUTION Always connect the hoses correctly as indicated in the installation and maintenance manuals of the corresponding hydraulic cylinders.
1.4 Pump description

The pumps UP25 – UP28 – UP33 – UP39 – UP45 have been designed and manufactured to be used as a component in the hydraulic steering systems, as described in the previous paragraph. The pumps UP25 F – UP28 F – UP33 F – UP39 F – UP45 F – UP25NV F – UP33NV F must be installed on the front part of the boat dashboard or semi-built-in through flanges X64 or X57 (supplied separately), the pumps UP28 R – UP33 R – UP39 R – UP39-I R – UP45 R – UP45-I R must be assembled on the rear part of the boat dashboard, and the pumps UP25 T – UP28 T – UP33 T – UP39 T – UP45 T must be assembled by means of tilt X52 (supplied separately). The following pictures show the main pump components:

1 Pump UP25 F – UP28 F – UP33 F – UP39 F – UP45 F – UP25NV F –
UP33NV F
2 Tank plug with bleed

6 M6 dowels for fixing the pump to the dashboard 7 Pump UP28 R – UP33 R – UP39 R – UP39-I R –
UP45 R – UP45-I R

3 Steering wheel connection shaft 4 Connections to the cylinder/s 5 Connections to the additional stations (that can be used with
series “NV”)

8 M8 dowels for fixing the pump to the dashboard 9 PumpUP25 T- UP28T -UP33 T – UP39T – UP45 T 10 Connection shaft to tilt X52

UP25 F – UP28 F – UP33 F – UP39 F – UP45 F – UP25NV F – UP33NV F

1 6

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UP28 R – UP33 R – UP39 R – UP39-I R – UP45 R – UP45-I R
5

UP25 T – UP28 T – UP33 T – UP39 T – UP45 T
5 2

1.5 Pump technical features

SPECIFICATIONS PUMP UP25 F PUMP UP25NV F

Capacity

23,5 cc/rev. – 1,4 23,5 cc/rev. – 1,4

cu.in/rev.

PUMP UP28 F
28 cc/rev. – 1,7 cu.in/rev.

PUMP UP33 F
33 cc/rev. – 2,0 cu.in/rev.

PUMP UP33NV F
33 cc/rev. – 2,0 cu.in/rev.

PUMP UP39 F
39 cc/rev. – 2,4 cu.in/rev.

PUMP UP45 F
45 cc/rev. – 2,7 cu.in/rev.

Pressure relief valve release pressure

70 bar (1000 psi)

70 bar (1000 psi) 70 bar (1000 psi)

70 bar (1000 psi)

70 bar (1000 psi) 70 bar (1000 psi)

No. of pistons
Max. steering wheel diameter Max. steering wheel height
Weight Oil

5 711 mm (28 in.)
152 mm (6 in.) 5 kg (11 lbs)
OL150 Ultraflex

711 mm (28 in.) 711 mm (28 in.)

152 mm (6 in.)
5 kg (11 lbs) OL150 Ultraflex

7 711 mm (28 in.)
152 mm (6 in.) 5 kg (11 lbs)
OL150 Ultraflex

711 mm (28 in.) 711 mm (28 in.)

152 mm (6 in.)
5 kg (11 lbs) OL150 Ultraflex

CAUTION
The release pressure of the pressure relief valves does not correspond to the system normal pressure but it represents only the use limits.

PUMP FOR HYDRAULIC SYSTEMS – page 9 of 101

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Æ67 mm [2,6 in.] M12 Æ19 mm [0,75 in.]

Æ77 mm [3,03 in.] Æ115 mm [4,53 in.]

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Installation and maintenance manual

UP25 F – UP28 F – UP33 F – UP39 F – UP45 F – UP25NV F – UP33NV F

54 mm [2,1 in.]

108 mm [4,25 in.]

90 mm [3,54 in.]

Æ67 mm [2,6 in.]

198 mm [7,80 in.]

SPECIFICATIONS
Capacity

PUMP UP28 R
28 cc/rev. – 1,7 cu.in/rev.

PUMP UP33 R
33 cc/rev. – 2,0 cu.in/rev.

PUMP UP39 R
39 cc/rev. – 2,4 cu.in/rev.

PUMP UP45 R
45 cc/rev. – 2,7 cu.in/rev.

PUMP UP45-I R
45 cc/rev. – 2,7 cu.in/rev.

Pressure relief valve release pressure

70 bar (1000 psi)

No. of pistons

Max. steering wheel diameter 711 mm (28 in.)

Max. steering wheel height Weight Oil

152 mm (6 in.) 5 kg (11 lbs)
OL150 Ultraflex

7
711 mm (28 in.)
152 mm (6 in.) 5 kg (11 lbs)
OL150 Ultraflex

CAUTION
The release pressure of the pressure relief valves does not correspond to the system normal pressure but it represents only the use limits.

UP28 R – UP33 R – UP39 R – UP45 R

Æ114 mm [4,49 in.]

90 mm [3,54 in.]

108 mm [4,25 in.]

16 mm [0,62 in.]

M12 Æ19 mm [0,75 in.] Æ77 mm [3,03 in.] Æ115 mm [4,53 in.]

min. dashboard thickness 25,4 mm [1 in.] max. dashboard thickness 38,1 mm [1,5 in.] 198 mm [7,80 in.] page 10 of 101 – PUMP FOR HYDRAULIC SYSTEMS

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UP39-I R – UP45-I R
Æ114 mm [4,49 in.]

Installation and maintenance manual

82 mm [3,22 in.]

108 mm [4,25 in.]

16 mm [0,62 in.]

ENGLISH

M12 Æ19 mm [0,75 in.] Æ77 mm [3,03 in.] Æ115 mm [4,53 in.]

min. dashboard thickness 25,4 mm [1 in.] max. dashboard thickness 38,1 mm [1,5 in.] 200 mm [7,87 in.]

SPECIFICATIONS
Capacity
Pressure relief valve release pressure

PUMP UP25 T
25 cc/rev. – 1,5 cu.in/rev.
70 bar (1000 psi)

No. of pistons

Max. steering wheel diameter

406 mm (16 in.)

PUMP UP28 T
28 cc/rev. – 1,7 cu.in/rev.
70 bar (1000 psi)
5
406 mm (16 in.)

PUMP UP33 T
33 cc/rev. – 2,0 cu.in/rev.
70 bar (1000 psi)
7
406 mm (16 in.)

PUMP UP39 T
39 cc/rev. – 2,4 cu.in/rev.
70 bar (1000 psi)
7
406 mm (16 in.)

PUMP UP45 T
45 cc/rev. – 2,7 cu.in/rev.
70 bar (1000 psi)
7
406 mm (16 in.)

Max. steering wheel height 152 mm (6 in.) 152 mm (6 in.) 152 mm (6 in.) 152 mm (6 in.) 152 mm (6 in.)

W eight Oil

5 kg (11 lbs) OL150 Ultraflex

CAUTION
The release pressure of the pressure relief valves does not correspond to the system normal pressure but it represents only the use limits.

UP25 T – UP28 T- UP33 T- UP39 T – UP45 T
174 mm [6,85 in.]

Æ115 mm [4,5in.] Æ77 mm [3,03in.]

Æ127 mm [5in.]

255 mm [10,03 in.] 6°
CAUTION The pumps UP25 T – UP28 T – UP33 T – UP39 T – UP45 T can only be used with tilt ULTRAFLEX X52 (supplied separately).
PUMP FOR HYDRAULIC SYSTEMS – page 11 of 101

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2 TRANSPORT
2.1 General warnings
The pumps UP25-UP28-UP33-UP39-UP45 weight with their packaging is 5kg (11 pounds) and so they 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.
UP25 F – UP28 F – UP33 F – UP39 F – UP45 F – UP25NV F – UP33NV F
A

l
l
B
THE STANDARD PACKAGING CONTAINS: A ) No.1 pump UP25 F or UP28 F or UP33 F or UP39 F or UP45 F or UP25NV F or UP33NV F with gaskets to fix it to the instrument panel. B ) No. 2 90° swinging unions to connect the Kit OB hoses (supplied separately);
No. 4 nuts for fixing the pump to the dashboard; No. 4 washers for fixing the pump to the dashboard; No. 1 nut for steering wheel tightening; No. 1 washer for steering wheel tightening; No. 1 key for steering wheel tightening; No. 1 label for plug.
page 12 of 101 – PUMP FOR HYDRAULIC SYSTEMS

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UP28 R – UP33 R – UP39 R – UP39-I R- UP45 R – UP45-I R
A

ENGLISH

THE STANDARD PACKAGING CONTAINS:
A ) No. 1 pump UP28 R or UP33 R or UP39 R or UP39-I R or UP45 R or UP45-I R.
B )No. 2 2 90° swinging unions (except pumps UP39-I R and UP45-I R) to connect the Kit OB hoses (supplied separately); No. 3 special screws for fixing the pump to the dashboard; No. 3 self-tapping screw for hub-cap fixing; No. 1 nut for steering wheel tightening; No. 1 washer for steering wheel tightening; No. 1 key for steering wheel tightening; No. 1 label for plug;
C) No. 1 gasket; No. 1 flange; No. 1 hub-cap.
NOTICE
Versions UP39-I R and UP45-I R are supplied with a special 1/4 NPT straight union for Ø 12 mm metal pipe. .
PUMP FOR HYDRAULIC SYSTEMS – page 13 of 101

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UP25 T – UP28 T – UP33 T – UP39 T – UP45 T

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B
THE STANDARD PACKAGING CONTAINS: A ) n°1 pump UP25 T or UP28 T or UP33 T or UP39 T or UP45 T. B ) n°2 90° swinging unions to connect the Kit OB hoses (supplied separately);
n°1 label for plug.
CAUTION The packaging must be disposed of according to the existing laws.

page 14 of 101 – PUMP FOR HYDRAULIC SYSTEMS

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INSTALLATION

3.1 Tools necessary for the installation of pumps UP25 F – UP28 F – UP33 F – UP39 F – UP45 F – UP25NV F – UP33NV F

ENGLISH

MOLYKOTE® 1000

Torque wrench

Drill

Open end

Open end 4 mm Allen

Screwdriver

wrench

wrench (only for

10 mm

19 mm

11/16″

additional

station)

3.2 Pump UP25F-UP28F-UP33F-UP39F-UP45 F – UP25NVF-UP33NVF installation

1 Select a suitable place for the steering station. Make sure that there is enough manoeuvering space for the steering wheel and for the steering pump and its pipes and fittings.
WARNING
In order to fix the pump properly, the maximum dashboard thickness must be 30 mm [1,18 in.]. Different thicknesses could compromise the driving safety. Make sure that the breaking ring of the 4 selflocking nuts supplied is engaged by the dowel thread.

min. 95 mm [3,74 in.] max. dashboard thickness 30 mm [1,18 in.]

2 Remove the plugs (1) from the pump (2) by using a

screwdriver.

3 Screw the nuts completely on the corresponding 90° unions (3), Fit and screw the unions manually as indicated in the picture until they are inserted completely. Turn them until they are positioned correctly with respect to the pipes by unscrewing them no more than one revolution, then tighten the nuts with a 11/16″ Allen wrench with a torque of 17,6 Nm
(13 lb ft) until the washer touches the nut.

System fitting

Connection for additional station*

WARNING

DO NOT USE teflon tape or adhesive tape. DO NOT PUT any thread sealant like Loctite 542 or similar products.

Connection for additional station*

System fitting
3 * except for pumps
series “NV”

PUMP FOR HYDRAULIC SYSTEMS – page 15 of 101

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4 By using the proper template supplied with this manual, make the holes (4) required by the installation in the suitable position on the dashboard.

Installation and maintenance manual 4

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5 Position the pump (2) on the dashboard front

side (5) interposing the gasket (6) and fix it by

inserting the 4 washers (7) and by tightening

the 4 self-locking nuts (8) with a 10 mm wrench

and a torque of 10 Nm (7,4 lb ft).

CAUTION

If the self-locking nuts are disassembled (8), they

must be replaced. (Contact our assistance

service, see page 6).

WARNING Install the pump by positioning the filling hole (9) towards the top (see the picture) for the right 9 pump operation and to allow filling and purging the system completely (see par. 3.11).

6 Position the steering wheel supplied separately (10) on the pump shaft (11) by using the suitable key (12). Insert the washer (13) and tighten the self- locking nut (14) with a 19 mm open end wrench and with a torque of 40 Nm (29,5 lb ft); then grease the thread by using some anti-seize grease MOLYKOTE® 1000 or a similar one.
CAUTION
If the self-locking nut (14) is disassembled, it must be replaced. (Contact our assistance service, see page 6).

page 16 of 101 – PUMP FOR HYDRAULIC SYSTEMS

8 7

7 8

6 2
12

13 14

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Installation and maintenance manual

3.3 Tools necessary forthe installation of pumps UP28 R – UP33 R – UP39 R – UP45 R

ENGLISH

MOLYKOTE® 1000

Torque wrench

Drill

Screwdriver

Open end

wrench

13 mm

19 mm

11/16″

3.4 Pump UP28 R – UP33 R – UP39 R – UP45 R installation

1 Select a suitable place for the steering station. Make sure that there is enough manoeuvering space for the steering wheel and for the steering pump and its pipes and fittings.
WARNING
In order to fix the pump properly, the minimum dashboard thickness must be 25.4 mm [1 in.] and the maximum dashboad thickness must be 38.1 mm [1.5 in.]. Different thicknesses could compromise the driving safety.

min. dashboard thickness 25,4 mm [1 in.] min. 203 mm [7,48 in.] max.dashboardthickness38,1mm[1,5in.]

2 Remove the plugs (1) from the pump (2) by using a

screwdriver.

System fitting

Connection for additional station

WARNING

DO NOT USE teflon tape or adhesive tape.

DO NOT PUT any thread sealant like Loctite 542 or

similar products.

System fitting

Connection for additional

station

PUMP FOR HYDRAULIC SYSTEMS – page 17 of 101

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4 By using the proper template supplied with this manual, make the holes required by the installation in the suitable position on the dashboard.

Installation and maintenance manual 4

5 Position the pump (2) on the dashboard rear

side (5). Then position the gasket (6) as shown in

the picture and the flange (7) with the protective

projecting part towards the dashboard outside.

Fix the pump (2) with the 3 special screws (8)

with a torque of 25 Nm (18.5 lb ft).

CAUTION
Make the shaft pass through the flange equipped with gasket by preventing the key seat from damaging the gasket itself.

WARNING

Install the pump by positioning the filling hole 8

(9) towards the top (see the picture) for the right

pump operation and to allow filling and purging the system completely (see par. 3.11).

6 Position the plastic hub-cap (10) with the water discharge towards the bottom and fix it with the 3 self-tapping screws (11) supplied with a 1,5Nm (1,13 lb ft) torque.

11 10

9 2

page 18 of 101 – PUMP FOR HYDRAULIC SYSTEMS

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7 Position the steering wheel supplied

separately (12) on the pump shaft (13) by using

the suitable key (14). Insert the washer (15) and

tighten the self-locking nut (16) with a 19 mm open

end wrench and with a torque of 40 Nm (29,5 lb ft);

then grease the thread by using some anti-seize

grease MOLYKOTE® 1000 or a similar one.

CAUTION
If the self-locking nut (16) is disassembled, it must be replaced. (Contact our assistance service, see page 6).

15 16

3.5 Tools necessary forthe installation of pumps UP39-I R – UP45-I R

Loctite MOLYKOTE® 1000 542/545

Torque wrench

Drill

Screwdriver

Open end

wrench

13 mm

19 mm

7/16″

3.6 Pumps UP39-I R – UP45-I R installation

1 Select a suitable place for the steering station. Make sure that there is enough manoeuvering space for the steering wheel and for the steering pump and its pipes and fittings.

min. dashboard thickness 25,4 mm [1 in.] min. 200 mm [7,87 in.]* max.dashboardthickness38,1mm[1,5in.]

WARNING
In order to fix the pump properly, the minimum dashboard thickness must be 25.4 mm [1 in.] and the maximum dashboad thickness must be 38.1 mm [1.5 in.]. Different thicknesses could compromise the driving safety.

*It depends on the pipe position

2 Remove the plugs (1) from the pump (2) by using a

screwdriver.

PUMP FOR HYDRAULIC SYSTEMS – page 19 of 101

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3 Put some fitting sealant type Loctite 542 or Loctite 545 on the thread. Fit and screw manually the conical fittings (3) until they are completely inserted; then tighten them with a 7/16″ open end wrench with a torque of 17.6 Nm (156 lb ft).

Installation and maintenance manual
Connection for additional station

WARNING
Do not use teflon tape or adhesive tape. Pay attention to the sealant positioning: if it is inserted into the system, it could block it and make it unusable.

System fitting
3

Connection for additional station

System fitting
3

4
4 By using the proper template supplied with this manual, make the holes required by the installation in the suitable position on the dashboard.

5 Position the pump (2) on the dashboard rear

side (5). Then position the gasket (6) as shown in

the picture and the flange (7) with the protective

projecting part towards the dashboard outside.

Fix the pump (2) with the 3 special screws (8)

with a torque of 25 Nm (18.5 lb ft).

CAUTION
Make the shaft pass through the flange equipped with gasket by preventing the key seat from damaging the gasket itself.

WARNING

Install the pump by positioning the filling hole 8

(9) towards the top (see the picture) for the right

pump operation and to allow filling and purging the system completely (see par. 3.11).

page 20 of 101 – PUMP FOR HYDRAULIC SYSTEMS

9 2

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6 Position the plastic hub-cap (10) with the water discharge towards the bottom and fix it with the 3 self-tapping screws (11) supplied.

Installation and maintenance manual 11 10

ENGLISH

7 Position the steering wheel supplied

separately (12) on the pump shaft (13) by using

the suitable key (14). Insert the washer (15) and

tighten the self-locking nut (16) with a 19 mm open

end wrench and with a torque of 40 Nm (29,5 lb ft);

then grease the thread by using some anti-seize

grease MOLYKOTE® 1000 or a similar one.

CAUTION
If the self-locking nut (16) is disassembled, it must be replaced. (Contact our assistance service, see page 6).

15 16

3.7 Tools necessary for the installation of pumps UP25 T – UP28 T – UP33 T – UP39 T – UP45 T

The tools to assemble tilt X52 are listed in the manual enclosed to tilt X52.

Open end wrench 11/16″

Screwdriver

3.8 Pump UP25 T – UP28 T – UP33 T – UP39 T – UP45 T installation

CAUTION The tilt X52 mechanism is supplied separately.

min. 260 mm [10,24 in.]

12° 12° 12° 12°

1 Select a suitable place for the steering station. Make sure that there is enough manoeuvering space for the steering wheel and for the steering pump and its pipes and fittings.

PUMP FOR HYDRAULIC SYSTEMS – page 21 of 101

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2 Remove the plugs (1) from the pump (2) by using a screwdriver.

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1 1

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3 Fix the bracket (3) supplied with tilt X52 to the

dashboard (4) by following the instructions enclosed to tilt X52.

4 Screw the nuts completely on the corresponding 90° unions (3), Fit and screw the unions manually as indicated in the picture until they are inserted completely. Turn them until they are positioned correctly with respect to the pipes by unscrewing them no more than one revolution, then tighten the nuts with a 11/16″ Allen wrench with a torque of 17,6 Nm (13 lb ft)
until the washer touches the nut.

System fitting
5

Connection for additional station
System fitting

WARNING
DO NOT USE teflon tape or adhesive tape. DO NOT PUT any thread sealant like Loctite 542 or similar products.

Connection for additional

station

page 22 of 101 – PUMP FOR HYDRAULIC SYSTEMS

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5 Fix the pump to the bracket (3) supplied with tilt X52 by using the 3 M8 screws (6) supplied with tilt X52 according to the instructions enclosed to tilt X52.
WARNING Install the pump by positioning the filling hole (7) towards the top (see the picture) for the right pump operation and to allow filling and purging the system completely (see par. 3.11).

Installation and maintenance manual 7
3 6

8
6 Align and insert the tilt universal joint into the pump shaft by loosening about 1-1.5 turns the screws (8) on the universal joint itself always according to the procedure described in the installation manual supplied with tilt X52. Retighten the screws (8) and fix the tilt.

8
NOTICE The kit ULTRAFLEX supplied separately (see the corresponding instructions) can be used on pumps UP28 R-UP33 R-UP39 R – UP39-I R – UP45 R – UP45-I R and UP25 T-UP28 T-UP33 T-UP39 T – UP45 T to simplify the hydraulic system filling and purging.
PUMP FOR HYDRAULIC SYSTEMS – page 23 of 101

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3.9 Types of installation
The pumps UP25-UP28-UP33-UP39-UP45 can be installed in a single or dual station (except the pumps series “NV”) and they can be used with different types of front mount, side or inboard cylinder configurations. The pumps series “NV” cannot be used with unbalanced cylinders.

CAUTION Connect hoses as shown in the installation and maintenance manual of the corresponding hydraulic cylinders.
MODELS UP 25 F-R-T, UP 28 F-R-T, UP 33 F-R-T, UP 39 F-R-T, UP 45 F-R-T

2 6

MODELS UP39-I R and UP 45-I R

1. main steering station 2. additional steering station (not usable
with pumps series “NV”) 3. kit OB 4. 3/8″ pipe included kit OB-2S 5. vent plug (black plug) 6. plug without vent (grey plug)
NOTICE
Kit OB-2S is supplied separately in case of applications with double station.

3 3
3

2 5

1. main steering station 2. additional steering station (not
usable with pumps series “NV”) 3. rigid metal pipe 4. vent plug (black plug) 5. plug without vent (grey plug)
NOTICE
Kit OB 120 U-2S is supplied separately in case of applications with double station.

3 3
page 24 of 101 – PUMP FOR HYDRAULIC SYSTEMS

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3.10 Hose connection to the system 3.10.1 Hose connection to the system for models UP 25 F-R-T, UP 28 F-R-T, UP
33 F-R-T, UP 39 F-R-T, UP 45 F-R-T
1 Connect the hydraulic hoses ULTRAFLEX kit OB (supplied separately) joining the pump and the cylinder by following the instructions given in the installation manual of the kit OB.
2 If one or more additional steering stations are installed (except the pumps series “NV”), use the kit OB2S by following the suitable instructions.

Position 3/8″ straight unions (1) on the pumps as indicated in the picture. Put some fitting sealant type Loctite 542 or Loctite 545 on the thread. Fit and screw manually the fittings (1) until they are completely inserted; then tighten them with a 7/16″ open end wrench with a torque of 17.6 Nm (156 lb ft).
WARNING Do not use teflon tape or adhesive tape. Pay attention to the sealant positioning: if it is inserted into the system, it could block it and make it unusable.

MAIN STEERING STATION

ADDITIONAL STEERING STATION

3 Connect pipes as shown in picture following the manual instructions.

MAIN STEERING STATION

Kit OB cylinder connecting pipe

Kit OB-2S

Kit OB-2S
Kit OB cylinder connecting pipe

Kit OB cylinder connecting pipe

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WARNING
Keep the pipes far from heat sources and from chemical substances. Protect the pipes that must pass through bulkheads by using suitable thru hulls. The bends must be perfectly smooth; any bent pipe or dent would prevent the hydraulic oil passage.

Minimum radius 250 mm

WARNING
Keep clean. Make sure that working areas are free from dust and dirt. The protective plugs of threaded holes must be removed only before the connection of fittings and pipes. Make sure that pipes are perfectly clean and free from swarf. If copper or steel pipes are used, cleaning is mandatory. If the installer uses pipes that are different from Kit OB, he must take full responsibility for it.
WARNING At the end of the installation make sure that the pipes do not interfere with the engine and with fixed or mobile parts of the boat or of the steering system itself.
WARNING
The minimum bending radius of the pipes is 250 mm. Any excessive pipe bending could break them by compromising the good operation of the system. If necessary, replace the damaged pipe.
3.10.2 How to choose the rigid pipes for models UP39-I R and UP 45-I R

PIPE MATERIAL: STEEL SPECIFICATIONS

St. 37.4 (=St 35.4, 1.0255) E 235 (= 1.0308) R37 St 52.4 (= 1.0580) E355 (= 1.0580) R50

DIN 2391/ DIN 1630 EN 10305-4 ISO 3304 DIN 2391 EN 10305-4 ISO 3304

STRUCTURE

CONDITIONS

NBK, DIN 2391-2 +N (=normal annealed) Cold-drawn NBK (=normal annealed) without welding NBK, DIN 2391-2 +N (=normal annealed) NBK (=normal annealed)

TOLERANCE BETWEEN EXT. DIAM./WALL THICKNESS
DIN 2391-1-C EN 10305-4 ISO 3304 DIN 2391-1 EN 10305-4 ISO 3304

SURFACE
Phosphated, lubricated or A3C (coated with zinc
and yellow chromium-plated)

PIPE MATERIAL: STAINLESS STEEL
1.4571 (= TP 316 Ti) 1.4541 (= TP 321) 1.4404 (= TP 316L) 1.4301 (= TP 304) 1.4401 ( = TP 316)
1.4301 (= TP 304)
1.4541 (= TP 321)

SPECIFICATIONS
DIN 2391 EN ISO 1127 o Astm A269
EN ISO 1127

STRUCTURE

CONDITIONS

Soft annealed DIN 17458
Cold-drawn without welding
Soft annealed

TOLERANCE BETWEEN EXT. DIAM./WALL THICKNESS
DIN 2391-1

Weld-in pipe

DIN 17457-K2 for 6-12 mm ext. diam., cold-drawn welded (CDW) with smooth external surface for 14-42 mm ext. diam.

D4/T3 (EN ISO 1127)

SURFACE
Smooth
Smooth, almost invisible welding

PIPE MATERIAL: COPPER
R 290

SPECIFICATIONS
EN 1057

STRUCTURE

CONDITIONS

Weldless pipe EN 1057

TOLERANCE BETWEEN EXT. DIAM./WALL THICKNESS
EN 1057

SURFACE
Clean and smooth

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NOTICE This table is only indicative.
ULTRAFLEX cannot be held responsible for the pipe choice, since the installer must do this according to the operating pressure.

WARNING ULTRAFLEX UP Series pumps are provided with a valve protecting them against overpressure when the pressure is higher than about 70 bar (1000 PSI).
The references to the standards are updated at the date of issue of this document. The installer must make sure that there are no other updates.
3.10.3 Hose connection to the system for models UP39-I R and UP45-I R

1 Connect the rigid pipes ( 12 mm external diameter) to connect the pump to the cylinder.
2 If one or more additional steering stations are installed (except the pumps series “NV”), use the kit OB 120 U-2S by following the suitable instructions.
Position 3/8″ straight unions (1) as indicated in the picture. Put some fitting sealant type Loctite 542 or Loctite 545 on the thread. Fit and screw manually the fittings (3) until they are completely inserted; then tighten them with a 7/16″ open end wrench with a torque of 17.6 Nm (156 lb ft).

WARNING
Do not use teflon tape or adhesive tape. Pay attention to the sealant positioning: if it is inserted into the system, it could block it and make it unusable.

MAIN STEERING STATION

ADDITIONAL STEERING STATION

3 Connect pipes as shown in picture and tighten them with a proper torque according to the pipe manufacturer specifications.

MAIN STEERING STATION

ADDITIONAL STEERING STATION

cylinder connecting pipe

Kit OB 120 U-2S

cylinder connecting
pipe

Kit OB 120 U-2S

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NOTICE
Kit OB 120 U-2S is supplied separately for applications with double station and it includes all the necessary unions for 12 mm copper pipe. The copper pipe must be bought separately.
DANGER The unions assembled on the pump are NOT swinging. If they are unscrewed they get broken and the pump cannot be used anymore.
NOTICE
The rigid pipe assembly (cutting, bending and bulkhead passage) must be carried out by skilled staff according to the manufacturer’s isntructions. In case of copper o steel pipes flushing is compulsory.
3.11 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.
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
NOTICE The filling and purging operations can be facilitated by using the automatic purging equipment BUBBLE BLUSTERâ (supplied separately).
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 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. According to the types of installation, it is necessary to carry out the different bleeding procedures, as it follows.
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3.11.1 Positioning of the oil bottle
To carry out this operation, it is necessary to use the oil filling kit (1 needle, 1 transparent pipe, 1 pipe connection and 1 spout for the oil bottle). This kit is NOT supplied.
– Remove the pump cap and insert the fittings. – Attach the spout to a new bottle of hydraulic oil and connect the hose
to the fittings and the bottle spout. – Turn the bottle upside down and pierce it with the 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.
WARNING While replacing the oil bottle, during the filling process, close all the bleed valves of 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 bleeding process must be started again.

pin oil bottle
spout hose
filling connection

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

3.11.2 Purging procedure
NOTICE Carry out the purging procedure as indicated in the installation and maintenance manual of the cylinder used. Then check that the oil level is suitable by turning 1/2 turn the steering wheel and by making the oil come out of the bleed valve. Close the valve and check the system.
3.12 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/s or the helm/s 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 too much, 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.
WARNING Check the system response by moving the pump.
DANGER After 24 hours repeat the purging and make sure there are no leaks.

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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.

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.

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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. – In case of installation with double station DO NOT use both stations. As a matter of fact the two
stations are always enabled on the steering compartment. The effect of the rudden rotation on both stations will double causing an undesired manoeuvre.

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 cDluorthineAgsTiTwnEshNtiacZlhlIaOctiNoounEl,dingsepteccatiuognhtorinmthaientmenoavnincge,pIaTrtIsS. STRICTLY FORBIDDEN to wear necklaces, bracelets or

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Installation and maintenance manual

5.1 Ordinary maintenance

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 3.11 and in the bleeding procedure of ULTRAFLEX cylinders. 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.
DANGER
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.
CAUTION If the self-locking nuts are disassembled, they must be replaced. (Contact our assistance service, see page 6).
5.2 Steering wheel disassembly
To remove the steering wheel from the pump shaft, use a suitable extractor. WARNING
Do not use a hammer or other tools that could seriously damage the pump.

5.3 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.

DANGER

The damaged hose must be replaced, otherwise it may cause loss of steering and severe personal injury or property damage.

· Air in the system.

The system is very difficult

to fill.

Air keeps bubbling at the

top of the steering system

tank even after filling the · Leaks from the cylinder

system completely.

bleeder.

· Repeat the filling and the bleeding procedure of the system.
· Install horizontally the hoses and in any case with a maximum inclination of 3cm each meter.
· Tighten the bleeder on the cylinder.

· Coiled hose.

· Uncoil and straighten the hose.

· Helm has been mounted upside · Mount the helm with the filling hole in

down.

up position.

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The steering system is stiff · Restrictions in hoses or fittings.

and hard to turn, even

when the moving.

boat

not

Air in oil.

The steering system is stiff and hard to turn, even when the boat is not moving.

· Wrong oil has been used.

· Look for and remove the restriction.
· Repeat the filling and the bleeding procedure of the system.
· Drain the filling and bleeding system.
WARNING ULTRAFLEX is not responsible for damage caused by fluids that are not recommended in this manual and so the warranty is cancelled.

The steering system is stiff and hard to turn, even when the boat is not moving, if unbalanced cylinders are used.

· Dirt in the valve.

WARNING
Do not use the boat and contact a specialized technician for the valve cleaning.

The steering system is easy to turn at the dock but becomes hard to turn when the boat is in motion.
When the steering wheel is turned, the rod (movable rod cylinders) or the body (fixed cylinder rod) of the cylinder do not move.
Leaks from steering system fittings.
Leaks from the tank plug.

· The steering wheel is too small. · Replace the steering wheel with a bigger one.

WARNING

· Incorrect setting of the torque tab.

· Only within the maximum dimensions allowed by the helm.
· Adjust the torque tab.

· Air in oil.

· Check the oil level and repeat the bleeding procedure as explained in this manual.

· Air in the system.

· Repeat the filling and bleeding procedure of the system.

· Oil leak.
· Helm mounted upside down.
· Bad tightening or low torque of the fittings.

· Look for the leak and contact specialized staff.
· Mount the helm with the filling hole in up position.
· Tighten the fittings with a maximum torque of 20Nm (15 in.Ibs).

· Lack of fitting sealant.
WARNING Never use teflon tape or adhesive tape on any fitting.
· Bad tightening of the plug. · The vent plug on the additional
helm is in the lower position.

· Drain and disassemble the steering system. Remove the fittings and remove the oil from threads. Put the sealant on the fittings and tighten them, install the helm.
WARNING
After this operation it is necessary to carry out another bleeding.
· Tighten the plug.
· Replace the vent plug with the plug for the additional helm kit.

· Worn and damaged seal. · Too high oil level.
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· Replace the plug.
· Follow the procedure to maintain the suitable oil level, which is described in the pump manual.

U LT R A F L E X 6 DISMANTLING

Installation and maintenance manual

6.1 Dismantling
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.

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PUMP FOR HYDRAULIC SYSTEMS – page 33 of 101

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ULTRAFLEX UP28FM Front Mount Helm Pump

Product Information

Product Usage Instructions

PRODUCT DESCRIPTION

INSTALLATION

MAINTENANCE

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