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Ultraflex ND1-MM Installation Manual

Tiller system
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Installation manual
ZTF
TILLER SYSTEM
MERCURY MARINE
YAMAHA
M2
Y1, Y2
SUZUKI
S2
ULTRAFLEX
R
PARTNER
(Dr. n° 36511 - 23/09/2020)

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Summary of Contents for Ultraflex ND1-MM

  • Page 1 Installation manual TILLER SYSTEM MERCURY MARINE YAMAHA Y1, Y2 SUZUKI ULTRAFLEX PARTNER (Dr. n° 36511 - 23/09/2020)
  • Page 2 EC directives, ISO standards and ABYC (American Boat and Yacht Council) requirements. To ensure your safety and to maintain a high quality level, ULTRAFLEX products are guaranteed only if they are used with original spare parts.

  • Page 3: Table Of Contents

    ULTRAFLEX Installation manual TABLE OF CONTENTS ���������������������������������������������������������������������������������������������������������������������������������� DOCUMENT REVISIONS ��������������������������������������������������������������������������������������������������������������� MANUAL USE AND SYMBOLS USED ��������������������������������������������������������������������������������������������������������������������������������� INTRODUCTION LETTER ���������������������������������������������������������������������������������������������������������������������������������������������������� WARRANTY SECTION 1 - PRODUCT DESCRIPTION ����������������������������������������������������������������������������������������������������������������� ZTF SYSTEM DESCRIPTION ���������������������������������������������������������������������������������������������������������������������� OPERATING PRINCIPLE SECTION 2 - TRANSPORTATION ������������������������������������������������������������������������������������������������������������������������� GENERAL WARNINGS ����������������������������������������������������������������������������������������������������������������������...
  • Page 4 ULTRAFLEX Installation manual DOCUMENT REVISIONS Rev. Rev. Date Date Revision description Revision description 23/09/2020 First edition page 4 of 39 - ZTF SYSTEM...
  • Page 5 ULTRAFLEX Installation manual MANUAL USE AND SYMBOLS USED THE INSTALLATION AND MAINTENANCE MANUAL should be kept for regular reference by the owner of the boat and transferred to any new owner with the boat. It is necessary to read carefully the manual, before ANY ACTIVITY involving the product, handling and unloading included.
  • Page 6 ULTRAFLEX declines all responsibility for possible mistakes in this manual due to printing errors. Although the main features of the type of product described are not subject to change, ULTRAFLEX reserves the right to modify any parts, details and accessories it deems necessary to improve the product or for manufacturing or commercial requirements, at any time and without being obliged to update this manual immediately.

  • Page 7: Ztf System Description

    Do not use this device for purposes other than those it was made for, as specified in the installation manual. CAUTION For installations other than the ones required for above-mentioned Mercury Marine, Yamaha and Suzuki engines, please contact ULTRAFLEX Technical Service. page 7 of 39...

  • Page 8: Operating Principle

    ULTRAFLEX Installation manual 1.2 Operating principle The hydraulic valve and corresponding cylinder of the ZTF Tiller System opens and closes when the pilot pushes or pulls the tiller handle. When the pilot steers straight (keeping the steering route), the hydraulic valve is closed thus removing the steering load from propeller torque on the tiller handle.

  • Page 9: General Warnings

    Cylinder Hoses Accessory kit based on installation type, (see the following chart with related drawings and paragraph 3.2) MERCURY YAMAHA SUZUKI KIT ND1-Y KIT ND1-MM KIT QU1-Y KIT QU1-S (90-115-130 HP (75-115 HP (150-175-200 HP DF150A / 175A / ENGINES FROM...
  • Page 10 ULTRAFLEX Installation manual KIT ND1-MM KIT QU1-Y KIT ND1-Y page 10 of 39 - ZTF SYSTEM...
  • Page 11 ULTRAFLEX Installation manual QU1-S CAUTION The packaging must be disposed of according to the existing laws. 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.

  • Page 12: Safety Warnings

    DO NOT PUT HANDS BETWEEN THE MOVING PARTS. Do not disable in any way the safety devices. Do not modify or add devices to the system, without ULTRAFLEX written authorization or technical intervention which will prove the modification. Installation should only be performed by well experienced and trained marine technicians.

  • Page 13: Installation With 75-115 Hp Mercury Marine Engines

    ULTRAFLEX Installation manual 3.3 Installation with 75-115 HP Mercury Marine engines The ZTF installation requires the use of KIT ND1-MM (see also par. 2.2). KIT ND1-MM NECESSARY TOOLS (2 x) Open end MOLYKOTE® 1000 Torque wrench wrench 18 mm Open end wrench...
  • Page 14 ULTRAFLEX Installation manual Fasten the device with the bracket on the engine 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.

  • Page 15: Installation With 90-115-130 Hp Yamaha Engines From 2015 To Date

    ULTRAFLEX Installation manual 3.4 Installation with 90-115-130 HP Yamaha engines from 2015 to date The ZTF installation with 90-115-130 HP engines from 2015 KIT ND1-Y requires the use of KIT ND1-Y (see also par. 2.2). NECESSARY TOOLS Open end wrench 9/16"...
  • Page 16 ULTRAFLEX Installation manual Fasten the device with the bracket on the engine arm using nuts (X) and interposing washers (Y), follow- ing the tightening torque and the instructions included in the manual of engine manufacturer's tiller handle Apply grease to the pivots before tightening the nuts.

  • Page 17: Installation With 150-175-200 Hp Yamaha Engines

    ULTRAFLEX Installation manual 3.5 Installation with 150-175-200 HP Yamaha engines The ZTF installation with 150-175-200 HP engines re- The ZTF installation with 150-175-200 HP engines re- quires the use of KIT QU1-Y (see also par. 2.2). quires the use of KIT QU1-Y (see also par. 2.2).
  • Page 18 ULTRAFLEX Installation manual Insert the two ultrabolts (6) and (7) with washers (8) into the engine arm (9) up to half of their length. Insert the two ultrabolts (6) and (7) with washers (8) into the engine arm (9) up to half of their length.
  • Page 19 ULTRAFLEX Installation manual Place the cylinder link arm (12) on the rear screw (7). NOTICE In order to complete the fastening process of the cylinder to the en- gine hose, refer to the instructions included in the manual of the cylinder.
  • Page 20 ULTRAFLEX Installation manual 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.-ft.). CAUTION This operation requires careful attention. Afterwards, while holding a screw with a 9/16"...

  • Page 21: Installation With 150-175-200 Hp Suzuki Engines

    ULTRAFLEX Installation manual 3.6 Installation with 150-175-200 HP Suzuki engines The ZTF installation with 150-175-200 HP engines re- quires the use of KIT QU1-S (see also par. 2.2). QU1-S NECESSARY TOOLS Open end wrench MOLYKOTE® 1000 Torque wrench (2 x) Open end 9/16"...
  • Page 22 ULTRAFLEX Installation manual Place 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 (0,69"). Assemble the device with bracket (1) on the engine arm (9).
  • Page 23 ULTRAFLEX Installation manual Place the cylinder link arm (12) on the rear screw (7). NOTICE In order to complete the fastening process of the cylinder to the engine hose, refer to the instruc- tions included in the manual of the cylinder.
  • Page 24 ULTRAFLEX Installation manual Afterwards, while holding a screw with a 9/16" wrench, fasten the corresponding nut with a torque of 54 Nm (40 lb.-ft.). Repeat this operation on the other nut always by holding its screw. Double-check the tightening of screws and...

  • Page 25: Tiller Handle Assembly

    ULTRAFLEX Installation manual 3.7 Tiller handle assembly The tiller handle is composed of the main body (1) and the 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.

  • Page 26: Original Bracket Removal

    ULTRAFLEX Installation manual 3.7.1 Original bracket removal In order to install the tiller handle on the ZTF device, it is necessary to remove the original bracket, taking care not to damage the screw, the bushings, the washers and the 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.

  • Page 27: Ztf Device Assembly On Tiller Handle

    ULTRAFLEX Installation manual 3.7.2 ZTF device assembly on tiller handle MERCURY MARINE The main body of the tiller handle must be fastened to the device in line with the fork. Fasten the tiller handle (1) to device (2), taking care of positioning bush-...
  • Page 28 ULTRAFLEX Installation manual YAMAHA The main body of the tiller handle must be fastened to the device in line with the fork. Fasten the tiller handle (1) to device (2), taking care of positioning bush- ings, spacers and washers as shown...
  • Page 29 ULTRAFLEX Installation manual SUZUKI The main body of the tiller handle must be fastened to the device in line with the fork. Fasten the tiller handle (1) to device (2), taking care of positioning bush- ings, spacers and washers as shown...

  • Page 30: Tiller Handle Disassembly From Outboard Engine ("Refitting" Installation)

    ULTRAFLEX Installation manual 3.8 Tiller handle disassembly from outboard engine ("refitting" installation) MERCURY MARINE 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).

  • Page 31: Ordinary Maintenance

    This kind of events entails oil leakage from the system and, consequently, refilling is required. Fault situations must be examined on case-by-case basis. The purging procedure of the ZTF system requires the use of Ultraflex Bubble Buster, which is not provided in this kit. NECESSARY TOOLS...

  • Page 32: Connecting The Bubble Buster To The System

    Installation manual NOTICE In order to proceed with the system filling and purging, an hydraulic oil (Ultraflex OL150 or compatible ones) is recommended, as indicated in the use and maintenance manual of UC130 cylinder. Before connecting the Bubble Buster to the system, read its manual in order to identify its related parts.
  • Page 33 ULTRAFLEX Installation manual 3. Connect the pair of transparent hoses to the Bubble Buster fitting. Such hoses are provided with a small and a big fast connect fittings at their end, Small 4. Connect the other pair of transparent hoses to the cylinder purge valves. Such hoses have the same dimension...

  • Page 34: Filling And Purging Operation

    ULTRAFLEX Installation manual 5. Loosen the release nuts (3) for enabling the oil to pass through. Do not unscrew more than one turn and a half. Use a 16 mm wrench. 6. Connect the battery clamps: the red clip to the positive terminal and the black one to the negative terminal.

  • Page 35: Disconnecting The Bubble Buster

    ULTRAFLEX Installation manual 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.

  • Page 36: Dismantling

    ULTRAFLEX Installation manual 5 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 ULTRAFLEX Installation manual NOTES page 37 of 39 ZTF SYSTEM...
  • Page 38 ULTRAFLEX Installation manual NOTES page 38 of 39 - ZTF SYSTEM...
  • Page 39 ULTRAFLEX Installation manual NOTES page 39 of 39 ZTF SYSTEM...
  • Page 40 ULTRAFLEX S.p.A. 16015 Casella (Genova) Italia - Via Crose, 2...

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Nd1-yQu1-yQu1-s

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