Ultraflex ND1-MM, Installation Manual

Page 1: ...Installation manual Dr n 36511 23 09 2020 ZTF TILLER SYSTEM ULTRAFLEX R PARTNER MERCURY MARINE YAMAHA SUZUKI M2 Y1 Y2 S2 ...

Page 2: ...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 cus tomer satisfaction constantly test the products to verify their conformity with EC directives ISO standards and ABYC American Boat a...

Page 3: ...S 21 3 7 TILLER HANDLE ASSEMBLY 25 3 7 1 ORIGINAL BRACKET REMOVAL 26 3 7 2 ZTF DEVICE ASSEMBLY ON TILLER HANDLE 27 3 8 TILLER HANDLE DISASSEMBLY FROM OUTBOARD ENGINE REFITTING INSTALLATION 30 3 9 WIRING 30 SECTION 2 TRANSPORTATION 2 1 GENERAL WARNINGS 9 2 2 PACKAGING CONTENTS 9 SECTION 4 MAINTENANCE 4 1 ORDINARY MAINTENANCE 31 4 2 ZTF SYSTEM FILLING AND PURGING 31 4 2 1 CONNECTING THE BUBBLE BUSTE...

Page 4: ...Installation manual ULTRAFLEX page 4 of 39 ZTF SYSTEM DOCUMENT REVISIONS Rev Rev Date Date Revision description Revision description 0 23 09 2020 First edition ...

Page 5: ...ds which CAUSE severe personal injury or death 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 Important information for the correct installation and for maintenance that does not cause any damage Denotes that a hazard ex...

Page 6: ...th South Central America UFLEX USA 6442 Parkland Drive Sarasota FL 34243 Ph 1 941 351 2628 Email sales uflexusa com www uflexusa com UFLEX S r l Via Milite Ignoto 8A 16012 Busalla GE Italy Ph 39 010 962 01 Email service ultraflexgroup it www ultraflexgroup it Thisinstallationandmaintenancemanualisanintegralpartoftheproductandshouldbeeasilyavailabletostaffincharge of use and maintenance The user mu...

Page 7: ...purged functioning and with properly connected hoses CAUTION Avoid twisting damaging bending and disconnecting the hoses CAUTION The ZTF Tiller System is meant to be used with Mercury Marine outboard engines of the 75 through 115 horsepower EFI four stroke family of engines built since 2014 Yamaha outboard engines of 90 115 130 HP produced from 2015 to date and engines of 150 175 200 HP models 2 7...

Page 8: ...ropeller torque while not actively changing steering route Turning the knob counter clockwise will disengage the ZTF Tiller valve which will allow the propeller torque to reach the tiller handle even when not actively making a steering route change WARNING It is essential that the pilot confirms the functionality and status of the ZTF Tiller System before using it To determine whether the system w...

Page 9: ...raph 3 2 Hoses Valve assembly Cylinder MERCURY YAMAHA SUZUKI KIT ND1 MM 75 115 HP ENGINES KIT ND1 Y 90 115 130 HP ENGINES FROM 2015 KIT QU1 Y 150 175 200 HP ENGINES KIT QU1 S DF150A 175A 200A ENGINES PROVIDED IN THE KIT M2 Y1 Y2 S2 1 Bracket 2 Hardware fastening the device to the bracket 2 screws M12 2 nuts 4 washers 3 Hardware fastening the cylinder link arm to the engine arm 2 special bolts ULTR...

Page 10: ...Installation manual ULTRAFLEX page 10 of 39 ZTF SYSTEM KIT ND1 MM 1 2 6 7 KIT QU1 Y 1 2 3 9 KIT ND1 Y 1 2 4 5 9 9 ...

Page 11: ...e tiller handle not included but directly supplied by the engine dealer Suzukitiller handle not included but directly supplied by the en gine dealer NOTICE If engine manufacturer s is new it will be supplied with original bracket and the required fastening screws It will be necessary to remove the original bracket in order to install the ZTF system ORIGINAL BRACKET ORIGINAL BRACKET ORIGINAL BRACKE...

Page 12: ...o not modify or add devices to the system without ULTRAFLEXwritten authorization or technical intervention which will prove the modification Installation should only be performed by well experienced and trained marine technicians NEW INSTALLATION TILLER HANDLE ASSEMBLY see par 3 7 CONNECTING SHIFT AND THROTTLE CABLES see par 3 9 Dismantling the tiller handle from the out board engine see par 3 8 R...

Page 13: ...ercury Marine engines The ZTF installation requires the use of KIT ND1 MM see also par 2 2 1 Fasten bracket 1 on device 2 using screws 3 and nuts 4 after having properly placed washers 5 Lock using 2 18mm wrenches with a tightening torque of 80 Nm 59 lb ft NECESSARY TOOLS 2 x Open end wrench 18 mm Torque wrench MOLYKOTE 1000 KIT ND1 MM Open end wrench 9 16 Open end wrench 14 mm 1 4 5 3 9 10 11 7 4...

Page 14: ...ngine arm using screws 7 and interposing washers Y fol lowing the tightening torque and the instructions included in the manual of the tiller handle CAUTION During this operation be careful not to damage bend and disconnect the hydraulic hoses 7 Y 3 Fasten the cylinder link arm 8 to the engine arm 6 by screwing a 3 8 ultrabolt 9 by interposing washer 10 tighten the ultrabolt using a 14 mm wrench w...

Page 15: ...se of KIT ND1 Y see also par 2 2 1 Fasten bracket 1 on device 2 using screws 3 and nuts 4 after having properly placed washers 5 Lock using 2 18mm wrenches with a tightening torque of 80 Nm 59 lb ft NECESSARY TOOLS 2 Screw and lock the studs 7 to the engine arm 6 follow ing the tightening torque and the instructions included in the manual of engine manufacturer s tiller handle 2 x Open end wrench ...

Page 16: ...ly of UC130 cylinder on the outboard engine by following what is reported on the installation and maintenance manual of the cylinder itself except for the fastening phase of the cylinder link arm to the engine arm which is described in the previous points WARNING Do not disconnect the hydraulic hoses for any reason 6 Assemble the tiller handle on the ZTF device as described in paragraph 3 7 3 Fast...

Page 17: ... par 2 2 NECESSARY TOOLS 2 x Open end wrench 18mm Torque wrench MOLYKOTE 1000 KIT QU1 Y Open end wrench 9 16 1 3 4 7 8 13 14 11 10 5 6 2 4 5 1 3 BOW STERN 1 Fasten bracket 1 on device 2 using screws 3 and nuts 4 after having properly placed washers 5 Lock using 2 18mm wrenches with a tightening torque of 80 Nm 59 lb ft CAUTION Apply grease to the screw shafts before tightening the nuts CAUTION The...

Page 18: ...en manually the self locking nut 11 CAUTION Apply grease to the screw shafts before tightening the nuts 9 8 7 6 1 9 6 10 11 0 69 2 Insert the two ultrabolts 6 and 7 with washers 8 into the engine arm 9 up to half of their length NOTICE The screws must protrude from the engine arm by around 15 mm 0 59 3 Assemble the device with bracket 1 on the engine arm 9 CAUTION Be careful not to bend kink or di...

Page 19: ...e cylinder to the en gine hose refer to the instructions included in the manual of the cylinder 6 Screw ultrabolt 7 letting it protrude from the cylinder link arm by at least 5 mm 0 19 then place washer 13 see picture below 7 Manually tighten the self lock ing nut 14 on screw 7 CAUTION Apply grease to the screw shaft before tightening the nut 7 12 7 7 14 13 0 19 ...

Page 20: ...ew Double check the tightening of screws and nuts by repeating the same procedure de scribed in points 8 and 9 fastening screws and nuts while holding screws CAUTION This check requires careful attention 10 Complete the assembly of UC130 cylinder on the outboard engine following what is reported on the installation and maintenance manual of the cylinder itself except for the fastening phase of the...

Page 21: ... Open end wrench 18mm Torque wrench MOLYKOTE 1000 Open end wrench 9 16 KIT QU1 S 1 3 4 7 8 13 14 11 10 5 6 15 1 Fasten bracket 1 on device 2 using screws 3 and nuts 4 after having properly placed washers 5 Lock using 2 18mm wrenches with a tightening torque of 80 Nm 59 lb ft CAUTION Apply grease to the screw shafts before tightening the nuts CAUTION The bracket must be oriented as shown in the pic...

Page 22: ...ude from the engine arm by around 15 mm 0 69 9 8 7 6 3 Assemble the device with bracket 1 on the engine arm 9 CAUTION Be careful not to bend kink or dis connect hydraulic hoses 4 Place washer 10 on the front ultrabolt 6 which is the closest to the device and tighten manually the self locking nut 11 CAUTION Apply grease to the screw shafts before tightening the nuts 1 9 6 10 11 0 69 ...

Page 23: ...der 7 12 6 Screw ultrabolt 7 letting it protrude from the cylinder link arm by at least 5 mm 0 19 then place washer 13 see picture below 7 Manually tighten the self locking nut 14 on screw 7 CAUTION Apply grease to the screw shaft before tightening the nut 7 7 14 13 8 Bring the two ultrabolts into contact with the engine tiller arm and fasten them using a 9 16 wrench with a torque of 54 Nm 40 lb f...

Page 24: ... screws and nuts while holding screws CAUTION This check requires careful attention 10 Complete the assembly of UC130 cylinder on the outboard engine following what is reported on the installation and maintenance manual of the cylinder itself except for the fastening phase of the cylinder link arm to the engine arm which is described in the previous points WARNING Do not disconnect the hydraulic h...

Page 25: ...original bracket 2 including the adjustment mechanism for connecting it to the engine arm In order to install the tiller handle on the ZTF device it is necessary to remove bracket 2 and assemble the main body 1 directly on the ZTF device To this end refer to what is reported in following paragraphs 1 2 YAMAHA 1 2 MERCURY MARINE 1 2 SUZUKI ...

Page 26: ...e connecting nut Be careful to the position of these parts since they will be reused for assembling the main body of the tiller handle to the device NOTICE During disassembly ALL components must be removed since they will be reused for the following reassembling CAUTION If these components are damaged they must be replaced In this case contact the technical service 3 7 1 Original bracket removal M...

Page 27: ...e following the same order in which they were dis assembled After having lubricated bolt 3 fasten nut 4 with a tightening torque be tween 29 4 and 34 3 Nm from 21 68 to 25 29 lb ft avoiding excessive play of the handle allowing its tilt to any angle Check that the upward and downward movements of tiller handle are correct and there is no free play along the horizontal axle enabling the proper func...

Page 28: ...ame order in which they were dis assembled After having lubricated bolt 3 fasten nut 4 with a tightening torque be tween 29 4 and 34 3 Nm from 21 68 to 25 29 lb ft avoiding excessive play of the handle allowing its tilt to any angle Check that the upward and downward movements of tiller handle are correct and there is no free play along the horizontal axle enabling the proper functioning of the de...

Page 29: ...ame order in which they were dis assembled After having lubricated bolt 3 fasten nut 4 with a tightening torque be tween 29 4 and 34 3 Nm from 21 68 to 25 29 lb ft avoiding excessive play of the handle allowing its tilt to any angle Check that the upward and downward movements of tiller handle are correct and there is no free play along the horizontal axle enabling the proper functioning of the de...

Page 30: ...engine controls throttle shift ignition etc following the instructions supplied by engine manufacturer 3 8 Tiller handle disassembly from outboard engine refitting installation 1 Remove the tiller handle from the engine arm taking care of keeping the extracted washers Check their conditions Replace any even slightly dam aged components in this case contact the technical service Proceed with assemb...

Page 31: ...ct our Technical Service See paragraph Informative letter 4 2 ZTF system filling and purging The ZTF system is already supplied oil filled and purged ready to be used Therefore no periodical oil topping up is required The following filling and purging procedure must be carried out only after having repaired a fault e g in case of hose breaking or replacement of the cylinder gaskets This kind of ev...

Page 32: ...onnected to the on the outboard engine Follow the steps below 4 2 1 Connecting the Bubble Buster to the system 4 2 2 Filling and purging operation 4 2 3 Disconnecting the Bubble Buster 4 2 4 Check the ZTF system functioning Proceed as follows if necessary please refer to the Bubble Buster instructions 1 After having assembled the system on the outboard engine loosen the by pass knob in order to se...

Page 33: ...nsparent hoses to the Bubble Buster fitting Such hoses are provided with a small and a big fast connect fittings at their end 4 Connect the other pair of transparent hoses to the cylinder purge valves Such hoses have the same dimension and are provided with fast connect fittings at their end ...

Page 34: ...inder oil together with air will start flowing 4 Without moving the tiller handle and therefore the cylinder wait for a couple of minutes until the transparent hoses show only oil with very few air bubbles 5 Move the cylinder slowly towards the opposite side port see picture 2 by always acting on the tiller handle 4 2 2 Filling and purging operation TOWARDS STARBOARD 5 Loosen the release nuts 3 fo...

Page 35: ...irections 4 2 4 Check the ZTF system functioning 4 2 3 Disconnecting the Bubble Buster TOWARDS PORT 6 Once on the port side leave the cylinder in this position and wait again for a few minutes 7 Slowly move the cylinder with the tiller handle Repeat the steering movement from starboard to port and the opposite at least 3 times 8 With the cylinder placed at the end stroke port push the handle again...

Page 36: ...DISMANTLING 5 1 Dismantling When for any reason the ZTF 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 ...

Page 37: ...ZTF SYSTEM page 37 of 39 Installation manual ULTRAFLEX NOTES ...

Page 38: ...Installation manual ULTRAFLEX page 38 of 39 ZTF SYSTEM NOTES ...

Page 39: ...ZTF SYSTEM page 39 of 39 Installation manual ULTRAFLEX NOTES ...

Page 40: ...ULTRAFLEX S p A 16015 Casella Genova Italia Via Crose 2 ...