ULTRAFLEX
ENGLISH
Dear Customer,
TRAFLEX product.
We would like to thank you for choosing an UL
ULTRAFLEX
UL
TRAFLEX has been a leader in steering systems for pleasure and professional boats for many years.
ULTRAFLEX
TRAFLEX production is since ever synonimous of reliability and safety.
ULTRAFLEX
UL
All UL
ULTRAFLEX
TRAFLEX products are designed and manufactured to ensure the best performance.
TRAFLEX products are guaranteed only if
To ensure your safety and to maintain a high quality level, UL
ULTRAFLEX
they are used with original spare parts (see attached document "Application Spare Parts").
UL
TRAFLEX and UFLEX Quality Management Systems are certified CISQ-IQNet by the Italian Shipping Registry
ULTRAFLEX
TRAFLEX certification No. 6669/02/S (former
(RINA), in conformity with the UNI EN ISO 9001:2000 rule. UL
ULTRAFLEX
420/96). UFLEX certification No. 8875/03/S.
The quality management system involves all the company resources and processes starting from the
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;
constantly test the products to verify their conformity with the 94/25/CE, ISO 10592 and ABYC
(American Boat and Yacht Council) requirements.
UL
TRAFLEX has over 70 years of experience in the marine industry and is a world leader in the production
"UL
ULTRAFLEX
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".
UL
TRAFLEX
ULTRAFLEX
S.
p.A
S.p.A
p.A..
16015 Casella (Genova) Italia - Via Crose, 2
ULTRAFLEX
Installation and maintenance manual
TABLE OF CONTENTS
SECTION 1 - PRODUCT DESCRIPTION
1.1
1.2
PRODUCT DESCRIPTION AND RECOMMENDED USE............................................................6
DIMENSIONS...................................................................................................................6
SECTION 2 - TRANSPORT
2.1
2.2
GENERAL WARNINGS.............................................................................................................................7
PACKAGING CONTENTS....................................................................................................................7
SECTION 3 - INSTALLATION
3.1
3.2
3,3
3,4
3.5
3.5.1
3,5,2
3.6
3.7
3.8
NECESSARY TOOLS........................................................................................................................8
LEVER CONTROL POSITIONING........................................................................................................8
ADJUSTMENT OF THE LEVER INCLINATION..........................................................................8
CONTROL CABLE POSITIONING.............................................................................................9
INSTALLATION OF CABLES C14 AND MACH 14.................................................................................9
SHIFT CABLE CONNECTION............................................................................................................9
THROTTLE CABLE CONNECTION.......................................................................................................11
FRICTION ADJUSTMENT.................................................................................................................12
LEVER CONTROL BOX MOUNTING........................................................................................12
INSTALLATION OF THE NEUTRAL SAFETY SWITCH..................................................................13
SECTION 4 - LEVER USE
4.1
!
LEVER USE............................................................................................................................14
SECTION 5 - SAFETY WARNINGS
!
5.1
5.2
SAFETY RULES DURING INSTALLATION AND USE....................................................................14
CLOTHING..........................................................................................................................14
6.1
6.2
ORDINARY MAINTENANCE.................................................................................................................15
EXTRAORDINARY MAINTENANCE.....................................................................................................15
SECTION 6 - MAINTENANCE
SECTION 7 - DISMANTLING
7.1
DISMANTLING.........................................................................................................................15
MPORTANT:
The additional documents "Application Guide" and "Spare Parts List" are attached to this manual.
SINGLE LEVER CONTROL B301 AND B302 -
page 3 of 48
ENGLISH
MANUAL USE AND SYMBOLS USED................................................................................................................4
INTRODUCTION.................................................................................................................................5
WARRANTY................................................................................................................................5
ULTRAFLEX
Installation and maintenance manual
ENGLISH
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
unloading included.
In this manual the following symbols are used to ensure the user safety and to guarantee the correct
operation of the product:
DANGER
WARNING
CAUTION
NOTICE
¯
¯
¯
¯
¯
Immediate hazards which CAUSE severe personal injury or death.
Hazards or unsafe practices which COULD CAUSE severe personal injury
or death.
Hazards or unsafe practices which COULD CAUSE minor injury or product
or property damage.
Important information for the correct installation and for maintenance, that
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
¯
STARBOARD
PORT
The picture aside explains the meaning of some
nautical words contained in this manual.
BOW
page 4 of 48 - SINGLE LEVER CONTROL B301 AND B302
ULTRAFLEX
Installation and maintenance manual
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.
UL
TRAFLEX declines all responsibility for possible mistakes in this manual due to printing errors.
ULTRAFLEX
TRAFLEX reserves the right to make those
Apart from the essential features of the described product, UL
ULTRAFLEX
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.
TRAFLEX
ALL RIGHTS ARE RESERVED. Publishing rights, trademarks, part numbers and photographs of UL
ULTRAFLEX
TRAFLEX property.
products contained in this manual are UL
ULTRAFLEX
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.
UFLEX S.r
.l.
S.r.l.
Via Milite Ignoto,8A
16012 Busalla (GE)-Italy
Tel: +39.010.962.0239 (Italy)
Tel: +39.010.962.0244 (abroad)
Fax: +39.010.962.0333
Email: ut@ultraflexgroup.it
www.ultraflexgroup.it
TECHNICAL ASSISTANCE SERVICE
North - South - Central America:
UFLEX USA
6442 Parkland Drive
Sarasota, FL 34243
Tel: +1.941.351.2628
Fax: +1.941.360.9171
Email: uflex@uflexusa.com
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 94/25/CE and to the ABYC
(U.S.A.) requirements.
We remind you that only
marked steering systems must be used on the boats marked
. ( Art. 3 and
Art. 5 of the Directive 94/25/CE). 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.
SINGLE LEVER CONTROL B301 AND B302 -
page 5 of 48
ENGLISH
INTRODUCTION
ULTRAFLEX
Installation and maintenance manual
1 PRODUCT DESCRIPTION
The B301 single lever and the B302 dual lever controls are designed as a single lever dual function per
engine. They are specifically designed to operate with outboard, stern drive (I/O) and inbord marine
propulsion engines. The controls can operate with all Ultraflex cables except the C4; included with both the
controls is the K59 kit, necessary to install Ultraflex C2, C8, C0, and Mach 0 cables.
For all the other cables the following kits are available on demand:
-
K 60 for cables Ultraflex C5 - C16 - MACH 5;
K 61 for cables Ultraflex C22;
K 62 for cables Ultraflex C36 - MACH 36.
The cables C14 and MACH14 require no installation kit.
B301
B302
1.2 Dimensions
Fig 1
page 6 of 48 - SINGLE LEVER CONTROL B301 AND B302
Distanza
minima per
Minimum
distance
la corretta
to allow
the
installazione
dei cavi
cable installation
The pictures below show the lever control B301 and B302 dimensions.
Distanza
minima per
Minimum
distance
la corretta
to allow
the
installazione dei cavi
cable installation
ENGLISH
1.1 Product description and recommended use
ULTRAFLEX
Installation and maintenance manual
2 TRANSPORT
2.1 General warnings
ENGLISH
The product weight with its packaging is 2.5kg (5.5 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.
Contents of the lever control packaging:
B301
REF
A
B
C
D
E
F
G
H
I
A
B301
B302
1 lever control
4 screws M5x35
4 nuts M5
4 washers
3 snap rings
1 kit K59 for cable installation
1 screw M5x14
1 plate
1 pin
1 lever control
4 screws M5x35
4 nuts M5
4 washers
6 snap rings
2 kits K59 for cable installation
2 screws M5x14
2 plates
2 pins
B
D
E
G
I
C
B302
A
H
F
WARNING
The packaging must be disposed of according to the existing laws.
SINGLE LEVER CONTROL B301 AND B302 -
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ULTRAFLEX
Installation and maintenance manual
3 INSTALLATION
ENGLISH
3.1 Necessary tools
Phillips
screwdriver
Open end
wrench
8mm [0,31”]
Pliers
Socket wrench
17mm [0,66”]
3.2 Lever control positioning
1 Position the lever control so as to allow the complete and free turning of the lever from the full
forward to the full reverse position and vice versa.
2 Refer to the overall dimensions indicated in paragraph 1.2 to make sure the lever can be installed in
the desired position.
WARNING
When the cable is installed avoid too narrow bends.
3 After choosing the proper position, drill till inserting the lever control by using the suitable drilling
template.
For the single and dual control installation refer to the drilling templates enclosed.
NOTICE
Connect the cables to the lever before fastening the lever control to the dashboard.
3.3 Adjustment of the lever inclination
The lever inclination can be adjusted both forward and backward according to the control position. Follow
the instructions below:
1 Remove the rubber
cover from the lever
hub (1).
2 Extract the plastic
pin (2).
2
1
3 Take out the
hexagonal head screw
(3) with a 17 socket
wrench.
3
4 Extract the lever
and turn it to the
desired position, then
reinsert it by putting
into gear with the
shaft of the control
box.
page 8 of 48 - SINGLE LEVER CONTROL B301 AND B302
ULTRAFLEX
Installation and maintenance manual
WARNING
Make sure the lever inclination does not prevent it from carrying out the complete angular range (about
180°) that is necessary.
3.4 Control cable positioning
1
Select a direct path with a minimum number of bends and without any obstacles.
WARNING
Avoid too narrow bends (the minimum bend radius is 203 mm (8")).
NOTICE
Outboard engine installations require an additional length of about 120 cm (47") of the cables to allow
engine swing.
The cables can be sustained by means of suitable cable hangers (supplied separately) or routed through
segments of conduits (supplied separately too) for long straight runs.
WARNING
To avoid the control hardening, do not fix the cables near the control outlet (the minimum fixing
distance is 500 mm) and in any case do not use fixing systems that can deform the casing.
2 CONTROL B301:
Remove the rear
cover (4) of the control
by unscrewing the
screws (5) so as to
reach easily the
elements where the
cables are to be fixed.
4
5
CONTROL B302:
Split the two boxes
(6)
(6), by removing
the screws (5)
(5).
6
6
5
5
B 301
5
B 302
3 To install each cable model a kit of fittings is supplied allowing the cable connection to the lever
control/controls. Included with both the single levers B301 and B302 is the K59 kit.
To install the cables on the control/controls follow the suitable instructions supplied with each kit.
To install the cables C14 and MACH14 follow the instructions given below.
3.5 Installation of cables C14 and Mach14
3.5.1 Shift cable connection
1 Place the control
box on a level (the
Ultraflex symbol on
the lever will be
turned upside down).
Remove the cable
clamp (7) from the
plate (8) loosening the
screws (9).
2 Mount the cable
making sure the
cylinder of the cable
(10) is placed inside
the plate hole (11).
9
8
7
10
11
SINGLE LEVER CONTROL B301 AND B302 -
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ENGLISH
5 Apply threadlocking low strencth (Loctite 222) on the screw (3) and lock it completely.
Insert the pin on the screw (2). Insert the rubber cover (1).
ENGLISH
ULTRAFLEX
3 Remount
the
cable clamp (7) on the
plate (8) aligning the
cylinder
of
the
connector (10) with the
hole of the cable
clamp.
Installation and maintenance manual
4 Fix the cable
clamp (7) to the plate
(8) with the screws (9).
7
9
8
7
10
8
5 Measure on the engine the shift lever stroke from the forward gear to the reverse gear. See the
possible strokes on the control device and select the nearest one; for instance, if the stroke on the
engine from one end of stroke to the other is 67 mm,
the cable must be connected to the more internal hole
(68 mm stroke). If a stroke of 70 mm is detected, check
if the 68 mm stroke is sufficient otherwise connect the
cable to the central hole (76 mm stroke); some
millimeters (5-6) of surplus stroke on the control device
are counterbalanced by the cable play.
6 Turn upside down
the
control
box
(internal mechanism
turned upside).
Put the pin (12) on one
of the three holes (a),
(b), or (c) of the lever
(13).
12
a
c
b
a
c
b
NOTICE
The hole is chosen according to the stroke of the cable (see the table below).
HOLE
a
b
c
STROKE [mm ]
68
76
82
page 10 of 48 - SINGLE LEVER CONTROL B301 AND B302
13
ULTRAFLEX
Installation and maintenance manual
WARNING
7 Engage the rod
(14) on the pin (12)
8 Mount the plate
(15) in the way shown
in the picture and fix
it with the screw (16)
on the hole (17).
14
16
ENGLISH
Adjust the control cable stroke of the shift so as not to force the end of strokes of the engine lever.
The non-compliance with this recommendation causes the control system malfunction such as:
- High resistance to the lever operation
- Early wear of the mechanism that can cause its locking.
15
17
12
WARNING
Check the right adjustment of the shift stroke and make sure the following condition is complied with:
During the shift enabling the lever movement must always be smooth and it must have a constant
resistance coming up against no resistance when the lever is turned as a throttle. Otherwise check the
stroke correspondence between the control and the shift on the engine.
3.5.2 Throttle cable connection
2 Mount the cable
making sure the
cylinder of the cable
(10) is placed inside
the plate hole (18).
1 Remove the cable clamp
(7) from the plate (8)
loosening the screws (9).
10
9
7
3 Remount the cable
clamp (7) on the plate (8)
aligning the cylinder of
the cable (10) with the
hole of the cable clamp.
Fix the cable clamp to
the plate with the
screws (9).
8
18
10
4 Engage the rod
(19) on the pin (20).
7
20
8
9
19
SINGLE LEVER CONTROL B301 AND B302 -
page 11 of 48
ULTRAFLEX
Installation and maintenance manual
5 Fix the cable inserting the elastic ring (21)
in the groove of the pin (20).
21
ENGLISH
20
3.6 Friction adjustment
Both the control boxes B301 and B302 allow the adjustment of the clutch. Follow the instructions below:
1
Rotate the lever in the middle throttle position;
By means of the screwdriver screw the dowel 22 to obtain the
hardening of the clutch, or unscrew it to obtain a smooth
movement. To check the friction of the lever, move it clockwise
and counterclockwise. WE RECOMMEND PREVENTING THE
CLUTCH FROM ACTING WHEN A GEAR IS ENGAGED.
2
3
CONTROL B301:
4
Place the rear cover
(4) fixing it with the
screws (5).
5
2
22
CONTROL B302:
6
6
Join the two
boxes (6) with the
screws (5).
5
5
5
B 301
B 302
3.7 Lever control box mounting
Put the control
box in the selected
position, then insert
and screw the four
screws M5x35 (23),
the washers (24) and
the nuts (25).
1
23
24
24
25
2
23
B 301
25
Place the sticker supplied on the chromium plated covering.
page 12 of 48 - SINGLE LEVER CONTROL B301 AND B302
B 302
ULTRAFLEX
Installation and maintenance manual
This optional device allows starting the engine only with the shift in neutral, avoiding all dangerous
movements of the boat.
To assemble it do as follows:
1 Put the lever
forward until the
holes on the plate 27
can be seen through
the slot on the plate 26.
2 Position the
device 30 on the
plate 29 inserting
the cylinder 31
inside the suitable
plastic guide 32.
32
29
31
28
30
27
26
3 Through the slot located on
the plate (28), insert the screw (33)
in the switch hole through the hole
of the plate (29).
Insert the nut (34) from the outer
side of the plate (29) and tighten
the screw (33).
29
33
28
34
NOTICE
If you are installing the switch X12, the screw and the nut must be inserted inside the hole (A). For the
switch X43, the reference hole is (B).
A
B
SINGLE LEVER CONTROL B301 AND B302 -
page 13 of 48
ENGLISH
3.8 Installation of the neutral safety switch
ULTRAFLEX
4 USO
Installation and maintenance manual
ENGLISH
4.1 Lever use
The lever stroke is made up of two movements
enabling the shift in the first step and the throttle in
the second one.
The boat moves forward when the lever is put
forward and it moves backward when the lever is
put backward. To enable the throttle without engaging
a gear press the button located on the lower part of
the lever and at the same time put the lever forward.
SHIFT ENABLING
T H R O T T L E
ENABLING
DANGER
Before starting the engine, if the control is not provided with safety switch, make sure it is in neutral.
5 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.
5.1 Safety warnings during installation and use
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.
WARNING
- When the system is installed, clean thoroughly to prevent foreign bodies from entering it. Even the
smallest object could damage the system permanently.
- Avoid bend radius of cables <200 mm (8").
- Avoid the cable contact with edges or sharp corners.
- Avoid the cable contact with heat sources.
5.2 Clothing
ATTENZIONE
WARNING
During installation, inspection or maintenance,
IT IS ATTENZIONE
STRICTLY FORBIDDEN to wear necklaces, bracelets or clothes which could get caught in the moving
parts.
page 14 of 48 - SINGLE LEVER CONTROL B301 AND B302
!
ULTRAFLEX
6 MAINTENANCE
Installation and maintenance manual
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 two years and must be carried out by specialized marine mechanics.
Carry out the following maintenance operations:
- Periodically wash with water and soap the components by removing any salt deposit.
- Every month check and if necessary tighten all the nuts fastening the system.
DANGER
Release or separation of one of the fasteners can cause failure of control system resulting in
property damage, injury or death.
- Periodically check the absence of corrosion on the metal parts of the cable ends and of abrasions on the
sheath.
- Replace the damage parts that could compromise the steering system integrity.
6.2 Extraordinary maintenance
Technical Support
For any information or for assistance with unusual applications please contact our technical support
personnel (See paragraph "Introduction").
7 DISMANTLING
7.1 Dismantling
When for any reason, the 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.
SINGLE LEVER CONTROL B301 AND B302 -
page 15 of 48
ENGLISH
6.1 Ordinary maintenance
ULTRAFLEX
ENGLISH
NOTES
page 16 of 48 - SINGLE LEVER CONTROL B301 AND B302
Installation and maintenance manual
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