instructions for use - reckmann reefing systems & … wire type e* g e* g rf90-2 105 392 92 389...

Instructions for use

www.reckmann.com

RF90

Hydraulic furling system

Aluminium foil

Wire/rod

DS

Reckmann Yacht Equipment GmbH

Siemensstr. 37-39 D-25462 Rellingen

Tel. +49(0) 4101 3849-0 Fax. +49(0) 4101 3849-50

[email protected] www.reckmann.com

As of: 12th June 2015

Copyright by Reckmann Yacht Equipment GmbH

Siemensstr. 37-39 D-25462 Rellingen

Measurements

P os : 1 /ZINDE L /R ollreffanlagen/Aus klapps eite/AK S B erechnung der P rofillänge R F90 DS @ 1\mod_1426063204544_13349.docx @ 14040 @ 11 @ 1 P os : 1 /ZINDE L /R ollreffanlagen/Aus klapps eite/AK S B erechnung der P rofillänge R F90 DS @ 1\mod_1426063204544_6.docx @ 12919 @ 22 @ 1

Notes

Notes Calculating the foil length and the offcut measurement

Calculating the forestay length

D A — E* — T

D = ________ — ________ — ________

D = ________ mm

Calculating the foil length

B = D — F — G — H

B = ________ — ________ — ________ — ________

B = ________ mm

Rod Wire

Type E* G E* G

RF90-2 105 392 92 389

RF90-3 115 445 110 450

RF90-4 347 480 332 495

RF90-5 495 530 455 555

*

H

Adjuster in middle position

Foil

R20 – R40 90

R5 – R7 100

F (top terminal length) and T (toggle length) must be measured.

Calculating the offcut measurement

C = P — B

C = ________ — ________

C = ________ mm

See packing list for furling section length P === E nde der L is te für Textmarke Inha lt ===

=== E nde der L is te für Textmarke Inha lt ===

Notes

www.reckmann.com

Contents

1

1 Packing list ............................................................................................... 4

2 About this manual .................................................................................... 7

2.1 Introduction .............................................................................................................. 7

2.2 Typographical conventions ...................................................................................... 7

2.3 Calculations ............................................................................................................. 7

3 Safety ........................................................................................................ 8

3.1 Intended use ............................................................................................................ 8

3.2 Safety instructions ................................................................................................... 8

4 Design and function ............................................................................... 10

4.1 Overview ............................................................................................................... 10

4.2 Component assemblies ......................................................................................... 11 4.2.1 Drive unit ............................................................................................................... 11 4.2.2 Adjuster (RF90-2, RF90-3) .................................................................................... 11 4.2.3 Adjuster (RF90-4, RF90-5) .................................................................................... 12

4.3 Function ................................................................................................................. 12

5 Assembly ................................................................................................ 13

5.1 Completing the forestay (R20 – R40) .................................................................... 13 5.1.1 Adjusting the foil length ......................................................................................... 13 5.1.2 Preparing the top bushing ..................................................................................... 14 5.1.3 Preparing the rod forestay ..................................................................................... 15 5.1.4 Preparing the wire forestay ................................................................................... 19 5.1.5 Fitting the furling sections ...................................................................................... 23 5.1.6 Fitting the foil reinforcement (optional) .................................................................. 25

5.2 Completing the forestay (R5 – R7) ........................................................................ 26 5.2.1 Installing the top terminal on the wire forestay ...................................................... 26 5.2.2 Installing the top terminal on the rod forestay (R5 – R7) ....................................... 26 5.2.3 Shortening the top furling section .......................................................................... 26 5.2.4 Preparing the top bushing (R5 – R7) ..................................................................... 27 5.2.5 Sliding on the top furling section ........................................................................... 29 5.2.6 Fitting the furling section connector ....................................................................... 30 5.2.7 Fitting standard furling sections ............................................................................. 30 5.2.8 Fitting the feeder section ....................................................................................... 32 5.2.9 Cold-heading the rod end ...................................................................................... 33 5.2.10 Roller-swaging the lower terminal on to the wire forestay ..................................... 33

5.3 Fitting the halyard swivel and the sail feeder (R20 – R40, R5) .............................. 34

5.4 Fitting the halyard swivel and the sail feeder (R6 – R7) ........................................ 34

5.5 Connecting the drive unit to the forestay ............................................................... 35

Contents

2

5.5.1 Preparation ............................................................................................................ 35 5.5.2 Detaching the cover ............................................................................................... 35 5.5.3 Dismantling the adjuster (RF90-2, RF90-3) ........................................................... 36 5.5.4 Dismantling the adjuster (RF90-4, RF90-5) ........................................................... 36 5.5.5 Connecting the foil to the drive unit ....................................................................... 38 5.5.6 Securing the rod forestay ...................................................................................... 38 5.5.7 Securing the wire forestay ..................................................................................... 39 5.5.8 Fitting the adjuster (RF90-2, RF90-3) .................................................................... 39 5.5.9 Fitting the adjuster (RF90-4, RF90-5) .................................................................... 40 5.5.10 Setting the adjuster to its maximum length (RF90-4, RF90-5) .............................. 40 5.5.11 Fitting the cover ..................................................................................................... 41 5.5.12 Mounting the top bushing ...................................................................................... 41

5.6 Installing the system .............................................................................................. 42 5.6.1 Toggle on the masthead ........................................................................................ 42 5.6.2 Minimum angle between forestay and halyard of 10° ............................................ 42

5.7 Hydraulic connection .............................................................................................. 43 5.7.1 Motor control .......................................................................................................... 43 5.7.2 Connecting the hydraulic hoses ............................................................................ 44

5.8 Removing the leather cover ................................................................................... 45

6 Operation ................................................................................................. 46

6.1 Wire pennant ......................................................................................................... 46

6.2 Direction of rotation ................................................................................................ 46

6.3 Reefing and unrolling the sail ................................................................................. 47

6.4 Adjusting the forestay length (RF90-2, RF90-3)..................................................... 48

6.5 Adjusting the forestay length (RF90-4, RF90-5)..................................................... 49 6.5.1 Preparation ............................................................................................................ 49 6.5.2 Shortening the adjuster ......................................................................................... 50 6.5.3 Lengthening the adjuster ....................................................................................... 52

6.6 Use as a forestay foil ............................................................................................. 55

7 Maintenance ............................................................................................ 56

7.1 Prior to each use .................................................................................................... 56

7.2 After each use ........................................................................................................ 56

7.3 Annual maintenance .............................................................................................. 56

7.4 Every five years ..................................................................................................... 56

8 Troubleshooting ...................................................................................... 57

8.1 Troubleshooting guide ........................................................................................... 57

8.2 Manual operation ................................................................................................... 58

8.3 Coupling the gear ................................................................................................... 59

Contents

3

9 Disassembly ........................................................................................... 60

9.1 Dismantling the adjuster ........................................................................................ 60 9.1.1 Dismantling the adjuster (RF90-2, RF90-3) .......................................................... 60 9.1.2 Dismantling the adjuster (RF90-4, RF90-5) .......................................................... 60

9.2 Detaching the forestay from the drive unit ............................................................. 62 9.2.1 Detaching the rod forestay .................................................................................... 62 9.2.2 Detaching the wire forestay ................................................................................... 62

9.3 Detaching the foil from the drive unit ..................................................................... 63

10 Transport and storage ........................................................................... 64

10.1 Transport ......................................................................................................... 64

10.2 Storage ............................................................................................................ 64

11 Disposal .................................................................................................. 65

12 Technical data ........................................................................................ 66

12.1 RF90-2 DS ...................................................................................................... 66

12.2 RF90-3 DS ...................................................................................................... 66

12.3 RF90-4 DS ...................................................................................................... 67

12.4 RF90-5 DS ...................................................................................................... 67

12.5 Foil cross sections ........................................................................................... 68

13 Index ........................................................................................................ 69

Pos: 1 /ZINDEL/Rollreffanlagen/Identifikation/Packliste @ 1\mod_1431429410031_13349.docx @ 14046 @ 1 @ 1

Packing list

4

1 Packing list

Date: Order number:

Dealer:

Customer:

Picture Quantity Designation Remarks

_____ Drive unit with adjuster Type: RF90 - __________________

_____ Wire forestay Length D = ______________ mm

_____ Rod forestay Length D = ______________ mm

_____ Halyard swivel Type: __________________

_____ Toggle

Toggle no.: __________________

Length = ______________ mm

_____ Rod collet

_____ Swage terminal

_____ Top terminal

_____ Shackle

Type: _________________

Size: _________________

Foil type _________________

Unshortened foil length P = _____________ mm

_____ Feeder section

3000 mm

5980 mm

_____

_____

Standard furling section

Top furling section

1500 mm

3000 mm

5980 mm

______________ mm

Packing list

5


R20 – R40

_____ Spacer hose 500 mm Marked red

_____

Spacer hose 200 mm

_____

Spacer hose 340 mm

_____

Spacer hose 600 mm

_____

Spacer hose 1740 mm

_____

Top spacer ______________ mm

R5 – R7

_____

Spacer tube 240 mm Partially slotted

_____

Spacer tube 1660 mm Partially slotted

_____ Standard bushing Split for R5 – R7 furling sections

_____ Bottom bushing

_____ Reinforcing bushing Split

_____ Connector bushing Split, with two screws each

_____ Foil reinforcement With rope

_____ Furling section connector Split for R6 and R7 furling sections

_____ Threaded plate for furling

section connector

_____ Screw for furling section

connector

_____ Top bushing Split, with screws

_____ Bottom threaded plate With screws

_____ Sail feeder with clip

_____ Sail feeder without clip

Packing list

6


_____ Hook spanner for adjuster

_____ Hex key set

_____ Winch handle

_____ Instructions

Special equipment

Compiled by:

___________________________________________

On: _______________ ___________________________________________

Signature

Pos: 2 /ZINDEL/Dokument/headline_Über diese Anleitung @ 1\mod_1400498832886_13349.docx @ 13928 @ 1 @ 1

About this manual

Introduction

7

2 About this manual Pos: 3 /ZINDEL/Dokument/Zielgruppe @ 1\mod_1400499035332_13349.docx @ 13929 @ 2 @ 1

2.1 Introduction These instructions are directed at owners of furling systems as well as anyone involved in the assembly, use or maintenance of such systems.

Its use requires the appropriate sailing qualifications. Inexperienced individuals on board must be trained and supervised by the skipper.

Assembly and repair work may only be carried out by qualified specialists.

Read the instructions before using the furling system or carrying out any assembly, disassembly or maintenance work.

Pos: 4 /ZINDEL/Dokument/Darstellungskonventionen @ 1\mod_1400502131053_13349.docx @ 13931 @ 2 @ 1

2.2 Typographical conventions

Important safety information and warnings are highlighted as follows:

Warning 'Warning' is used to mark instructions which are likely to lead to serious injury or death if not followed.

Caution 'Caution' is used to mark instructions which may lead to minor to moderate injury if not followed.

Notice 'Notice' is used to indicate the possibility of material damage.

Pos: 5 /ZINDEL/Dokument/Berechnungen finden @ 1\mod_1429777515530_13349.docx @ 14041 @ 2 @ 1

2.3 Calculations Please see the dust jacket flaps for information pertaining to the calculations required for assembly.

Pos: 6 /ZINDEL/Rollreffanlagen/Sicherheit/headline_Sicherheit @ 1\mod_1400506586530_13349.docx @ 13933 @ 1 @ 1

Safety Intended use

8

3 Safety Pos: 7 /ZINDEL/Rollreffanlagen/Identifikation/Bestimmungsgemäße Verwendung RF90 @ 1\mod_1400501979336_13349.docx @ 13930 @ 2 @ 1

3.1 Intended use

The RF90 is an advanced hydraulic furling system for fore sails.

The furling system is designed for reefing or furling a fore sail by rolling it up. It can be operated either hydraulically or manually using a winch handle. The sail can be rolled up completely (furled) or partially (reefed).

The furling system is equipped with a length adjuster for trimming of mast and sail. The length adjuster should be used at the mooring, not when sailing.

Use as a forestay foil without reefing or furling function is also possible. In this case it must be ensured that the hydraulic drive is not connected. The halyard swivel is lowered down to a position below the sail feeder.

All controls for switching the furling system on and off are provided on board. Pos: 8 /ZINDEL/Rollreffanlagen/Sicherheit/Sicherheitshinweise @ 1\mod_1400479119234_13349.docx @ 13925 @ 2 @ 1

3.2 Safety instructions • Read the instructions before using or working on the furling system.

• Always keep the instructions close to the furling system.

• In addition to this manual, the owner's manual for the yacht and manuals for other on-board equipment must be observed.

Safety

Safety instructions

9

Warning

Hazards arising from improper use − Do not carry out any conversions or modifications on the furling system. − Do not use the furling system:

• for regattas, • for attaching other objects as fore sails, • as a winch.

Risk of crushing − Maintain minimum clearances around the drive unit when carrying out assembly.

Otherwise injuries may occur due to movement of the furling system in wind. Risk of injury due to improper assembly, maintenance or use of the furling system − Use of the system requires the appropriate sailing qualifications. Inexperienced

individuals on board must be trained and supervised by the skipper. Do not leave children unattended on the furling system.

− Assembly and repair work may only be carried out by qualified specialists at a location with suitable equipment.

− The furling system must be visible from the place in which the furling system is switched on. Only switch on the furling system after ensuring that there is no one in the direct vicinity of the system.

− Controls for switching on the hydraulic drive must allow push-button operation only. − Only carry out the repairs described in these instructions. For any other repairs please

consult a service station. − Carry out all maintenance tasks at the intervals specified in this manual. − Prior to each use check the furling system for damage. Do not use the furling system if

it is damaged. − Stop using the furling system if the sail is rolling up by itself due to wind pressure. Send

the drive unit to a service station for repair.

Notice

Risk of jamming of furling system by salt deposits Salt deposits on parts of the furling system can damage the system. − After each sea voyage rinse off all parts of the furling system with fresh water. Risk of jamming of furling system by sheet and halyard Jamming of the furling system will damage the drive unit and the foil. − Always ease the sheet prior to reefing or furling. − Maintain sufficient halyard tension to prevent the halyard wrapping around the foil. − Fasten the halyard to the halyard swivel by means of a shackle. Risk of damage due to excessively long luff or incompletely hoisted sail If the luff tape is not completely fed into the foil the sail feeder and the foil may become damaged. − Only use a sail with a luff that completely fits into the foil. − Do not switch on the furling system if the sail is not fully hoisted. The luff tape must be

fully inserted in the foil groove. It must not protrude from the sail feeder.

Pos: 9 /ZINDEL/Rollreffanlagen/Aufbau und Funktion/headline_Aufbau und Funktion @ 1\mod_1400762844571_13349.docx @ 13944 @ 1 @ 1

Design and function Overview

10

4 Design and function Pos: 10 /ZINDEL/Rollreffanlagen/Aufbau und Funktion/Übersicht @ 1\mod_1400763095913_13349.docx @ 13945 @ 2 @ 1

4.1 Overview

Fig. 1: Overview

1 Top terminal

2 Forestay

3 Top bushing

4 Foil

5 Halyard swivel

6 Sail feeder

7 Drive unit

8 Adjuster

9 Toggle

Pos: 11 /ZINDEL/Rollreffanlagen/Aufbau und Funktion/headline_Baugruppen @ 1\mod_1400765840316_13349.docx @ 13947 @ 2 @ 1

Design and function

Component assemblies

11

4.2 Component assemblies Pos: 12 /ZINDEL/Rollreffanlagen/Aufbau und Funktion/Antriebseinheit @ 1\mod_1400766033623_13349.docx @ 13948 @ 3 @ 1

4.2.1 Drive unit

1 Furler drive adapter 2 Tack ring 3 Winch handle socket/emergency

manual drive

4 Adjuster axle (RF90-2, RF90-3), flange (RF90-4, RF90-5)

5 Hydraulic motor 6 Outer cover

Pos: 13 /ZINDEL/Rollreffanlagen/Aufbau und Funktion/Verstelleinheit (RF90-2, RF90-3) @ 1\mod_1400766182813_13349.docx @ 13949 @ 3 @ 1

4.2.2 Adjuster (RF90-2, RF90-3)

1 Adjuster tube

2 Locking screw Pos: 14 /ZINDEL/Rollreffanlagen/Aufbau und Funktion/Verstelleinheit (RF90-4, RF90-5) @ 1\mod_1400766404273_13349.docx @ 13950 @ 3 @ 1

Design and function Function

12

4.2.3 Adjuster (RF90-4, RF90-5)

1 Key (RF90-5: 2 keys)

2 Adjuster axle

3 Adjuster tube

4 Locking screw

5 Plug screw Pos: 15.1 /ZINDEL/Rollreffanlagen/Aufbau und Funktion/Funktion-Rollreff @ 1\mod_1400763386014_13349.docx @ 13946 @ 2 @ 1

4.3 Function

The furling system reefs the fore sail by winding it around a foil that rotates around the forestay. A groove in the foil holds the sail luff.

Pos: 15.2 /ZINDEL/Rollreffanlagen/Aufbau und Funktion/Funktion-Hydraulik @ 1\mod_1400822275032_13349.docx @ 13954 @ @ 1

The furling system is driven by a hydraulic motor.

It must be connected to an on-board hydraulic system. Pos: 15.3 /ZINDEL/Rollreffanlagen/Aufbau und Funktion/Funktion-Handkurbel @ 1\mod_1415976900103_13349.docx @ 14025 @ @ 1

If a malfunction occurs the furling system can be operated using a winch handle.

The gear is self-locking. No forces are transmitted from the sail to the winch handle. There can hence be no winch handle backlash.

Pos: 15.4 /ZINDEL/Rollreffanlagen/Aufbau und Funktion/Funktion-Verstell-allg @ 1\mod_1400822279280_13349.docx @ 13955 @ @ 1

The adjuster can be used to adjust the forestay length at the mooring. For furling systems RF90-4 and RF90-5 the mechanical adjuster is supported hydraulically.

Pos: 16 /ZINDEL/Rollreffanlagen/Montage/headline_Montage @ 1\mod_1415351350590_13349.docx @ 14024 @ 1 @ 1

Assembly

Completing the forestay (R20 – R40)

13

5 Assembly Pos: 17 /ZINDEL/Rollreffanlagen/Montage/Alu/R10 - R40/headline_Vorstag komplettieren (R10 - R40) @ 1\mod_1400585828847_13349.docx @ 13936 @ 2 @ 1

5.1 Completing the forestay (R20 – R40) Pos: 18 /ZINDEL/Rollreffanlagen/Montage/Alu/R10 - R40/Profillänge anpassen - Einführung @ 1\mod_1401706466725_13349.docx @ 13986 @ 3 @ 1

5.1.1 Adjusting the foil length

If a top furling section and a top spacer are not given in the list at the beginning of this manual, a furling section and a corresponding spacer hose must be shortened by the offcut measurement 'C'.

For the offcut measurement 'C' please see the calculations on the flap. Pos: 19 /ZINDEL/Rollreffanlagen/Montage/Alu/R10 - R40/Profil kürzen (R10 - R40) @ 1\mod_1400586602689_13349.docx @ 13937 @ 4 @ 1

5.1.1.1 Shortening the top furling section

Notice

Risk of material damage through shortening of an improper furling section Shortening of an improper furling section can make the furling section unsuitable for later assembly. − Only shorten standard furling sections of length 3000 mm. − Do not shorten the feeder section or a short furling section.

Shorten one of the 3000-mm-long standard furling sections by the calculated offcut measurement 'C' using a handsaw.

The shortened furling section will become the top furling section during assembly. Pos: 20 /ZINDEL/Rollreffanlagen/Montage/Alu/R10 - R40/Schlauch kürzen (R10 - R40) @ 1\mod_1399625751186_13349.docx @ 13907 @ 4 @ 1

Assembly Completing the forestay (R20 – R40)

14

5.1.1.2 Shortening the top spacer

Shorten the 1740-mm-long spacer hose by the offcut measurement 'C' using a sharp knife.

The shortened spacer hose will become the top spacer during assembly. Pos: 21 /ZINDEL/Rollreffanlagen/Montage/Alu/R10 - R40/Topkappe vorbereiten (R10 - R40) @ 1\mod_1399557777207_13349.docx @ 13905 @ 3 @ 1

5.1.2 Preparing the top bushing

After assembly the top bushing will cover the top furling section.

The following can be used as a top furling section:

• a standard furling section that has been shortened to a length less than 3000 mm but greater than 1500 mm,

• if furling section shortening is not necessary, a standard furling section of length 3000 mm.

1. Insert the two halves of the top bushing into the top furling section in such a way that the join line formed by their mating surfaces is lined up with the groove in the furling section.

2. Drill through the furling section and the top bushing half on each side of the furling section using a drilling bit.

Assembly


15

3. Take the top bushing halves out of the furling section and stow them for later assembly.

Pos: 22 /ZINDEL/Rollreffanlagen/Montage/Alu/R10 - R40/rod/headline_Rodvorstag vorbereiten @ 1\mod_1425888645936_13349.docx @ 14036 @ 3 @ 1

5.1.3 Preparing the rod forestay Pos: 23 /ZINDEL/Rollreffanlagen/Montage/Alu/R10 - R40/rod/Terminal auf Rod montieren R10-R40 @ 1\mod_1411647417297_13349.docx @ 14001 @ 4 @ 1

5.1.3.1 Installing the top terminal on the rod forestay

Install the top terminal according to the manufacturer's instructions.

First cold-head one end of the rod forestay. Once both ends of the rod forestay have been cold-headed, bushings or spacer hoses can no longer be fitted.

Pos: 24 /ZINDEL/Rollreffanlagen/Montage/Alu/R10 - R40/rod/Buchsen und Schläuche auf Rod aufschieben @ 1\mod_1399635546374_13349.docx @ 13908 @ 455555 @ 1

5.1.3.2 Sliding bushings and spacer hoses on to the rod forestay

Errors made in sliding on of bushings and spacer hoses can make assembly of the furling sections impossible. Take particular care when sliding on the bushings and spacer hoses. Follow the given sequence precisely.

The procedure to be taken for a wire forestay is given in Sliding bushings and spacer hoses on to the wire forestay on page 19.


16

Overview

Slide bushings and spacer hoses on to the rod forestay from below.

Assembly


17

Sliding bushings and spacer hoses on for the top furling section

1. Slide on seven standard bushings.

2. Slide on the top spacer. The top spacer is between 240 mm and 1740 mm long.

3. Slide on a standard bushing.

4. Slide on a 600-mm-long spacer hose.


6. Slide on a 500-mm-long spacer hose with ends marked red.

The furling section connectors will later be located on the spacer hoses marked red.

Sliding on bushings and spacer hoses for 3000-mm-long standard furling sections

Carry out the following steps for each of the 3000-mm-long standard furling sections. The feeder section is not included.

1. Slide on a standard bushing and a 600-mm-long spacer hose and repeat three more times.




18

Sliding on bushings and spacer hoses for a 1500-mm-long standard furling section

The following steps are only necessary if a 1500-mm-long furling section is present. If no 1500-mm-long furling section is present, continue with 'Sliding on bushings and spacer hoses for the feeder section'.







Sliding on bushings and spacer hoses for the feeder section

1. Slide on a standard bushing, a 600-mm-long spacer hose and another standard bushing.

If a foil reinforcement should be fitted, do not carry out the following steps.

2. Slide on a 600-mm-long spacer hose and a standard bushing and repeat one more time.

3. Slide on a 200-mm-long spacer hose and a standard bushing and repeat two more times.

4. Slide on three more standard bushings.

5. Only R20: slide on two additional standard bushings.

Pos: 25 /ZINDEL/Rollreffanlagen/Montage/Alu/R10 - R40/rod/Rodkopf pressen (R10-R40) @ 1\mod_1399642365968_13349.docx @ 13911 @ 4 @ 1

Assembly


19

5.1.3.3 Cold-heading the rod end

Notice After the rod end has been cold-headed no more bushings or spacer hoses can be fitted and their order can no longer be changed. Only cold-head the lower rod end after ensuring that all bushings and spacer hoses have been properly installed.

Cold-head the rod end according to the rod manufacturer's instructions.

Once the rod end has been cold-headed, continue the assembly with 5.1.5 Fitting the furling sections .

Pos: 26 /ZINDEL/Rollreffanlagen/Montage/Alu/R10 - R40/wire/headline_Drahtvorstag vorbereiten @ 1\mod_1425888923859_13349.docx @ 14037 @ 3 @ 1

5.1.4 Preparing the wire forestay Pos: 27 /ZINDEL/Rollreffanlagen/Montage/wire/Walzterminal @ 1\mod_1425396390203_13349.docx @ 14033 @ 4 @ 1

5.1.4.1 Roller-swaging the lower terminal on to the wire forestay

Warning Risk of breaking the forestay The terminal must be fitted by qualified personnel using suitable tools.

Roller-swage the supplied lower terminal on to the wire forestay.

Pos: 28 /ZINDEL/Rollreffanlagen/Montage/Alu/R10 - R40/wire/Buchsen und Schläuche auf Draht aufschieben @ 1\mod_1399643073654_13349.docx @ 13912 @ 455555 @ 1

5.1.4.2 Sliding bushings and spacer hoses on to the wire forestay

Errors made in sliding on of bushings and spacer hoses can make assembly of the furling sections impossible. Take particular care when sliding on the bushings and spacer hoses. Follow the given sequence precisely.

The procedure to be taken for a rod forestay is given in Sliding bushings and spacer hoses on to the rod forestay on page 15.


20

Overview

Slide bushings and spacer hoses on to the wire forestay from above.

Assembly


21

Sliding on bushings and spacer hoses for the feeder section

If a foil reinforcement should be fitted, skip the first four steps. In this case begin with step 5.

1. Only R20: slide on two standard bushings.

2. Slide on three standard bushings.

3. Slide on a standard bushing and a 200-mm-long spacer hose and repeat two more times.

4. Slide on a standard bushing and a 600-mm-long spacer hose and repeat one more time.

5. Slide on a standard bushing, a 600-mm-long spacer hose and another standard bushing.


The furling section connectors will later be located on the spacer hoses marked red.

Sliding bushings and spacer hoses on for a 1500-mm-long furling section

The following steps are only necessary if a 1500-mm-long furling section is present. If no 1500-mm-long furling section is present, continue with 'Sliding on bushings and spacer hoses for 3000-mm-long standard furling sections'.








22

Sliding on bushings and spacer hoses for 3000-mm-long standard furling sections

Carry out the following steps for each of the 3000-mm-long standard furling sections. The top furling section should not be included.

1. Slide on a standard bushing and a 600-mm-long spacer hose and repeat three more times.



Sliding on bushings and spacer hoses for the top furling section




4. Slide on the top spacer.

5. Slide on seven standard bushings.

Pos: 29 /ZINDEL/Rollreffanlagen/Montage/Alu/R10 - R40/wire/Terminal auf Drahtvorstag montieren R10-R40 @ 1\mod_1399872745049_13349.docx @ 13913 @ 4 @ 1

Assembly


23

5.1.4.3 Installing the top terminal on the wire forestay

Warning Risk of breaking the forestay − The top terminal must be fitted by qualified personnel using suitable tools.

Notice Once the terminal has been installed on the wire forestay, bushings or spacer hoses can no longer be fitted. Only install the terminal after ensuring that all bushings and spacer hoses have been properly installed.

− Roller-swage the terminal on to the wire forestay

or:

− Install a swageless stud terminal according to the supplied assembly instructions. Pos: 30 /ZINDEL/Rollreffanlagen/Montage/Alu/R10 - R40/Profile montieren @ 1\mod_1399872223388_13349.docx @ 13914 @ 3 @ 1

5.1.5 Fitting the furling sections

Start fitting the furling sections with the top furling section. The top furling section is the furling section with the holes drilled into it for the top cap.

1. Slide the top furling section from below up to the terminal on the forestay. The end with the drill holes for the top cap must be pointing towards the terminal.

2. Lay the two halves of a furling section connector around the spacer hose marked red.

3. Place the threaded plate in the recess in the furling section connector.

4. Slide the furling section connector with threaded plate halfway into the furling section.


24

5. Secure the furling section with two self-locking screws. Do not tighten the screws completely yet.

6. Place the threaded plate in the second recess in the furling section connector.

7. Slide a standard furling section on to the furling section connector.

8. Secure the standard furling section with two self-locking screws.

9. When all four screw threads are engaged in the tapped holes in the threaded plate, tighten the screws.

10. Repeat steps 2 to 9 with other furling sections in the following order:

• 3000-mm-long standard furling sections

• 1500-mm-long standard furling section (if present).

11.a If no foil reinforcement is to be fitted: repeat steps 2 to 9 with the feeder section.

11.b If a foil reinforcement is to be fitted: repeat steps 2 to 5. Do not fit the feeder section yet. Pos: 31 /ZINDEL/Rollreffanlagen/Montage/Alu/R10 - R40/Profilverstärkung montieren @ 1\mod_1399887096690_13349.docx @ 13915 @ 3 @ 1

Assembly


25

5.1.6 Fitting the foil reinforcement (optional)

• All furling sections except for the feeder section must be fitted.

• Only the following elements may be fitted on the forestay below the last furling section connector: standard bushing – 600-mm hose – standard bushing – 600-mm hose – standard bushing.

1. Place foil reinforcement elements on the forestay in places where there are no bushings or spacer hoses. The ends with the drill holes must point to the lower end of the forestay.

2. Thread one end of the supplied rope through the holes in the foil reinforcement and tie a knot in it.

3. Insert the other end of the rope through the feeder section.

4. Slide the feeder section over the foil reinforcement. Pull the foil reinforcement through the feeder section with the rope until the foil reinforcement reaches the lower edge of the feeder section. Slide the feeder section to the end of the furling section connector.


6. Slide the feeder section on to the furling section connector. Continue keeping the foil reinforcement at the lower end of the forestay with the rope.

7. Secure the feeder section with two self-locking screws. When all four screw threads are engaged in the tapped holes in the threaded plate, tighten the screws.

8. Take the rope out of the foil reinforcement.

Pos: 32 /ZINDEL/Rollreffanlagen/Montage/Alu/R50, R5 - R8/headline_Vorstag komplettierem (R5 - R7) @ 1\mod_1399899995211_13349.docx @ 13918 @ 2 @ 1


26

5.2 Completing the forestay (R5 – R7) Pos: 33 /ZINDEL/Rollreffanlagen/Montage/Alu/R50, R5 - R8/wire/Terminal auf Drahtvorstag montieren R50, R5-R8 @ 1\mod_1411981789578_13349.docx @ 14002 @ 3 @ 1

5.2.1 Installing the top terminal on the wire forestay

Warning Risk of breaking the forestay − The terminal must be fitted by qualified personnel using suitable tools.

− Roller-swage the terminal on to the wire forestay

or:

− Install a swageless stud terminal according to the supplied assembly instructions. Pos: 34 /ZINDEL/Rollreffanlagen/Montage/Alu/R50, R5 - R8/rod/Terminal auf Rod montieren R5-R7 @ 1\mod_1411981995568_13349.docx @ 14003 @ 3 @ 1

5.2.2 Installing the top terminal on the rod forestay (R5 – R7)

Install the top terminal according to the manufacturer's instructions.

First cold-head the upper end of the rod forestay.

Once both ends of the rod forestay have been cold-headed, it is possible that spacer tubes may no longer be able to be fitted.

Pos: 35 /ZINDEL/Rollreffanlagen/Montage/Alu/R50, R5 - R8/Profil kürzen (R50, R5 - R8) @ 1\mod_1400586612251_13349.docx @ 13938 @ 3 @ 1

5.2.3 Shortening the top furling section

If no top furling section is given in the packing list, the foil length probably has to be adapted to the forestay length. For this purpose, a furling section must be shortened by the offcut measurement 'C'.

See 'Calculating the foil length' on the flap.

If the calculated offcut measurement 'C' is greater than 5590 mm, no furling section needs to be shortened. In this case, one of the furling sections is not fitted. If the remaining luff length is not sufficient, contact a service station for a special solution.

Notice

Risk of material damage through shortening of an improper furling section Shortening of an improper furling section can make later assembly impossible. − Only shorten a standard furling section of length 5980 mm. − Do not shorten the feeder section.


27

Shorten one of the standard furling sections by the offcut measurement 'C' using a handsaw.

The shortened furling section will become the top furling section during assembly. Pos: 36 /ZINDEL/Rollreffanlagen/Montage/Alu/R50, R5 - R8/Topkappe vorbereiten (R50, R5 - R8) @ 1\mod_1399617358756_13349.docx @ 13906 @ 3 @ 1

5.2.4 Preparing the top bushing (R5 – R7)

After assembly the top bushing will cover the top furling section.

The following can be used as a top furling section:

• a shortened standard furling section, i.e. a furling section that is less than 5980 mm long,

• if furling section shortening is not necessary, a standard furling section of length 5980 mm.

1. Insert the two halves of the top bushing into the top furling section in such a way that the join line formed by their mating surfaces is lined up with the groove in the furling section. If the furling section has been shortened, insert the top bushing into the shortened side.


28

2. Drill a hole of diameter 5.2 mm through the furling section and the top bushing half on each side of the furling section using a drilling bit.

3. Take the top bushing halves out of the furling section and cut an M6 thread in each drill hole.

4. Stow the top bushing halves for later assembly.

5. Drill holes of diameter 6 mm in the furling section.

Assembly


29

6. Cut holes in the furling section for countersunk screws.

Pos: 37.1 /ZINDEL/Rollreffanlagen/Montage/Alu/R50, R5 - R8/Profile montieren - Topprofil @ 1\mod_1399892604550_13349.docx @ 13916 @ 3 @ 1

5.2.5 Sliding on the top furling section

1. Slide the top furling section on to the forestay. The end with the drill holes for the top cap must be pointing towards the terminal.

If the top furling section is less than 2130 mm long, continue with 5.2.6 Fitting the furling section connector .

2. If the top furling section is 2130 mm long or longer but shorter than 3830 mm, then mount a split standard bushing and secure it with tape. If the top furling section is 3830 mm long or longer, then repeat these steps.

Pos: 37.2 /ZINDEL/Rollreffanlagen/Montage/Alu/R50, R5 - R8/Profile montieren - Profilverbinder @ 1\mod_1399897624071_13349.docx @ 13917 @ 3 @ 1


30

5.2.6 Fitting the furling section connector 1. R5: Slide the furling section connector on to the forestay; R6, R7: mount a split connector.

2. Insert split connector bushings into the ends of the furling section connector and screw in tightly.


4. Slide the furling section connector with threaded plate into the furling section.

5. Screw the furling section connector to the furling section using two screws. (R6, R7: screw on using three screws.)

Pos: 37.3 /ZINDEL/Rollreffanlagen/Montage/Alu/R50, R5 - R8/Profile montieren - Standardprofile @ 1\mod_1399960938761_13349.docx @ 13920 @ 3 @ 1

5.2.7 Fitting standard furling sections

Carry out the following steps for each standard furling section.

1. Slide the standard furling section on to the forestay.

2. Place the threaded plate in the recess in the furling section connector and slide the standard furling section over it.

Assembly


31

3. Screw the furling section connector to the furling section using two screws (R6, R7: three screws).

4. Mount a split standard bushing on the forestay and secure it with tape.

5. Slide a 1660-mm-long spacer tube on to the forestay and slide it along with the standard bushing into the standard furling section.

6. Repeat the last two steps.

7. R5: Slide the furling section connector on to the forestay; R6, R7: mount a split connector.

8. Insert split connector bushings into the ends of the furling section connector and screw in tightly.


10. Slide the furling section connector with threaded plate into the furling section.

11. Screw the furling section connector to the furling section using two screws.

Pos: 37.4 /ZINDEL/Rollreffanlagen/Montage/Alu/R50, R5 - R8/Profile montieren - Einführungsprofil @ 1\mod_1399964250521_13349.docx @ 13921 @ 3 @ 1


32

5.2.8 Fitting the feeder section

1. Slide the feeder section on to the forestay.

2. Place the threaded plate in the recess in the furling section connector and slide the feeder section over it.

3. Screw the furling section connector to the furling section using two screws.

4. Mount a split standard bushing on the forestay and secure it with tape.

5. Slide a 1660-mm-long spacer tube on to the forestay and slide it along with the standard bushing into the standard furling section.

6. Repeat the last two steps.

7. Slide the foil reinforcement on to the forestay.

8. Insert the split connector bushing into the upper end of the foil reinforcement and screw in tightly.

9. Place the threaded plate in the recess in the foil reinforcement (not for R5):

Assembly


33

10. Slide the foil reinforcement into the feeder section.

11. Place a small split reinforcing bushing on the forestay and secure it with tape.

12. Mount a short spacer tube on the forestay and slide it along with the reinforcing bushing into the foil reinforcement.

13. Repeat steps 11 and 12 twice.

Pos: 38 /ZINDEL/Rollreffanlagen/Montage/Alu/R50, R5 - R8/rod/Rodkopf pressen (R50, R5-R8) @ 1\mod_1411983409874_13349.docx @ 14004 @ 3 @ 1

5.2.9 Cold-heading the rod end

Only cold-head the lower rod end after ensuring that the furling sections have been properly installed. Once the rod end has been cold-headed, it is possible that spacer tubes may no longer be able to be fitted.

Cold-head the rod end according to the rod manufacturer's instructions.

Pos: 39 /ZINDEL/Rollreffanlagen/Montage/wire/Walzterminal @ 1\mod_1425396390203_13349.docx @ 14033 @ 3 @ 1

5.2.10 Roller-swaging the lower terminal on to the wire forestay

Warning Risk of breaking the forestay The terminal must be fitted by qualified personnel using suitable tools.

Roller-swage the supplied lower terminal on to the wire forestay.

Pos: 40 /ZINDEL/Rollreffanlagen/Montage/Alu/Fallenschlitten und Segeleinführer montieren (R10 - R50, R5) @ 1\mod_1399976311803_13349.docx @ 13922 @ 2 @ 1

Assembly Fitting the halyard swivel and the sail feeder (R20 – R40, R5)

34

5.3 Fitting the halyard swivel and the sail feeder (R20 – R40, R5)

1. Slide the halyard swivel over the feeder section until it is above the recess for the sail feeder.

2. Place the sail feeder in the recess.

3. Snap the retaining clip for the sail feeder around the feeder section.

4. Secure the sail feeder and the retaining clip with two screws.

Pos: 41 /ZINDEL/Rollreffanlagen/Montage/Alu/Fallenschlitten und Segeleinführer montieren (R6 – R8) @ 1\mod_1400845753274_13349.docx @ 13963 @ 2 @ 1

5.4 Fitting the halyard swivel and the sail feeder (R6 – R7)

1. Slide the halyard swivel over the feeder section past the recess for the sail feeder.

2. Place the sail feeder with the tongue first in the recess.

3. Screw the threaded plate to the foil reinforcement using the supplied screws.

Pos: 42 /ZINDEL/Rollreffanlagen/Montage/headline_Anttriebseinheit mit Vorstag verbinden @ 1\mod_1400848275790_13349.docx @ 13964 @ 2 @ 1

Assembly

Connecting the drive unit to the forestay

35

5.5 Connecting the drive unit to the forestay Pos: 43 /ZINDEL/Rollreffanlagen/Montage/Vorbereitung Antriebseinheit <-> Vorstag @ 1\mod_1400849299329_13349.docx @ 13965 @ 3 @ 1

5.5.1 Preparation

Notice

Risk of scratching the drive unit casing A rough or soiled surface can scratch the drive unit casing. − Only remove the leather cover after completing assembly. − Set the drive unit down on a clean, soft surface after the leather cover has been removed from the unit.

To connect the drive unit to the forestay, lay the drive unit beside the lower end of the forestay. Pos: 44 /ZINDEL/Rollreffanlagen/Montage/Schürze abnehmen @ 1\mod_1401084496968_13349.docx @ 13968 @ 3 @ 1

5.5.2 Detaching the cover

The cover does not have to be removed for drive units RF90-2 and RF90-3.

1.a RF90-4: Unscrew the two screws in the outer cover and pull them out of the guide sleeves.

1.b RF90-5: Unscrew the four nuts in the outer cover using the supplied box spanner.

2. Detach the outer cover. Pos: 45 /ZINDEL/Rollreffanlagen/Montage/RF90-2, RF90-3/Verstelleinheit demontieren (RF90-2, RF90-3) @ 1\mod_1400849124568_13349.docx @ 13966 @ 3 @ 1

Assembly Connecting the drive unit to the forestay

36

5.5.3 Dismantling the adjuster (RF90-2, RF90-3)

1. Unscrew the locking screw.

2. Unscrew the adjuster tube from the adjuster axle.

3. Only for a rod forestay: unscrew the rod collet from the adjuster axle. (Not applicable to wire forestays)

Pos: 46 /ZINDEL/Rollreffanlagen/Montage/RF90-4, RF90-5/Verstelleinheit demontieren (RF90-4, RF90-5) @ 1\mod_1401090517041_13349.docx @ 13969 @ 3 @ 1


1. Unscrew the key-retaining screw.

2. Screw an M6 ✕ 40 screw into the second hole in the key and force the key out with it. Then remove the screw.

Assembly


37

3. RF90-5: Repeat these two steps for the second key.


5. Only for a rod forestay: unscrew the rod collet from the adjuster axle.

Pos: 47 /ZINDEL/Rollreffanlagen/Montage/Alu/Profil in Profilmitnehmer @ 1\mod_1400850447113_13349.docx @ 13967 @ 3 @ 1


38

5.5.5 Connecting the foil to the drive unit

Notice

Risk of corrosion of the foil Corrosion will lead to destruction of the foil. − Apply Tef-Gel or another galvanic corrosion inhibitor to the surfaces of the foil and the

furler drive adapter in contact with each other.

1. Insert the split bottom bushing into the feeder section.

2. Apply Tef-Gel to the bottom 10 cm of the feeder section and to the inside surface of the furler drive adapter on the drive unit.

3. Place the threaded plate in the recess in the feeder section.

4. Slide the drive unit over the forestay and the feeder section.

5. Secure the feeder section in the furler drive adapter with two cap screws. (R6, R7: screw on using three screws.)

Pos: 48 /ZINDEL/Rollreffanlagen/Montage/rod/Rodvorstag fixieren @ 1\mod_1401092898727_13349.docx @ 13970 @ 3 @ 1

5.5.6 Securing the rod forestay 1. Insert the forestay through the drive unit until the rod collet can be mounted on the forestay.

2. Grease the rod collet halves.

3. Mount the rod collet halves on the forestay and screw the rod collet all the way into the drive unit.

4. Pull the forestay back into the drive unit until the rod head is situated in the rod collet. Pos: 49 /ZINDEL/Rollreffanlagen/Montage/wire/Drahtseilvorstag fixieren @ 1\mod_1401094042287_13349.docx @ 13971 @ 3 @ 1

Assembly


39

5.5.7 Securing the wire forestay 1. Insert the forestay through the drive unit until the entire thread is protruding from the adjuster

axle.

2. Screw the special nut all the way on to the forestay.

3. Secure the special nut with the accompanying pin.

4. Pull the forestay back into the drive unit until the special nut is in contact with the adjuster axle. Pos: 50 /ZINDEL/Rollreffanlagen/Montage/RF90-2, RF90-3/Verstelleinheit montieren (RF90-2, RF90-3) @ 1\mod_1401095435145_13349.docx @ 13972 @ 3 @ 1

5.5.8 Fitting the adjuster (RF90-2, RF90-3) 1. Screw the adjuster tube to the adjuster axle. The keys in the adjuster tube must be engaged in

the grooves in the adjuster axle.

2. Screw the locking screw tightly into the adjuster tube.

Pos: 51 /ZINDEL/Rollreffanlagen/Montage/RF90-4, RF90-5/Verstelleinheit montieren (RF90-4, RF90-5) @ 1\mod_1401108727238_13349.docx @ 13974 @ 3 @ 1


40

5.5.9 Fitting the adjuster (RF90-4, RF90-5) 1. Screw the adjuster axle all the way on to the flange.

2.a RF90-4: Place the key in the recess in the adjuster axle in such a way that the untapped hole in the key is situated above the drill hole in the flange. Fasten with the key-retaining screw.

2.b RF90-5: Place the key marked '1' in the correspondingly marked recess in the adjuster axle in such a way that the untapped hole in the key is situated above the drill hole in the flange. Fasten with the key-retaining screw. Install the key marked '2' in the same way.

Pos: 52 /ZINDEL/Rollreffanlagen/Montage/RF90-4, RF90-5/Verstelleinheit auf maximale Länge einstellen (RF90-4, RF90-5) @ 1\mod_1401109962036_13349.docx @ 13975 @ 3 @ 1 xxxxxx

5.5.10 Setting the adjuster to its maximum length (RF90-4, RF90-5)

Notice

Risk of contamination of the environment by leaking hydraulic oil Hydraulic oil can escape into the environment when the plug screw on the adjuster is loosened or when the adjuster tube is unscrewed. − Collect leaking hydraulic oil and dispose of it in accordance with requirements.

For ease of mounting of the assembled furling system, the adjuster should first be set to its maximum length.

1. Loosen the plug screw.

2. Completely unscrew the locking screw.

3. Unscrew the adjuster tube all the way.

4. Screw the locking screw back in.

5. Tighten the plug screw again.

Assembly


41

Pos: 53 /ZINDEL/Rollreffanlagen/Montage/Schürze montieren @ 1\mod_1401097189689_13349.docx @ 13973 @ 3 @ 1

5.5.11 Fitting the cover

1. Place the cover with the eyes over the pins on the drive unit.

2.a RF90-4: Insert the screws through the guide sleeves and screw them tightly into the drive unit.

2.b RF90-5: Screw the cover to the drive unit using four nuts. Use the supplied box spanner to tighten the nuts.

Pos: 54 /ZINDEL/Rollreffanlagen/Montage/Alu/Topkappe montieren @ 1\mod_1400841178465_13349.docx @ 13962 @ 3 @ 1

5.5.12 Mounting the top bushing

Insert the two halves of the top bushing into the top furling section and screw in.

Pos: 55 /ZINDEL/Rollreffanlagen/Montage/headline_Anlage setzen @ 1\mod_1400509542869_13349.docx @ 13935 @ 2 @ 1

Assembly Installing the system

42

5.6 Installing the system Warning

Risk of crushing and shearing − Never stick your finger into a threaded hole when mounting the furling system.

Pos: 56 /ZINDEL/Rollreffanlagen/Montage/Toggle Masttop @ 1\mod_1400825458562_13349.docx @ 13960 @ 3 @ 1

5.6.1 Toggle on the masthead

Warning

Risk of forestay breakage The forestay is subjected to high bending moments when there is no mast toggle mounted. If the forestay breaks, severe injuries may be incurred. − Connect the forestay to the mast with a toggle.

Pos: 57 /ZINDEL/Rollreffanlagen/Montage/Fallenführung @ 1\mod_1400823922169_13349.docx @ 13957 @ 3 @ 1

5.6.2 Minimum angle between forestay and halyard of 10°

When the sail is hoisted the halyard must run at an angle of at least 10° from the halyard swivel to the forestay. Otherwise the halyard can wrap around the foil and cause the furling system to jam.

Install a halyard lead on the mast if the angle is less than 10°.

Pos: 58 /ZINDEL/Rollreffanlagen/Montage/headline_Hydraulikanschluss @ 1\mod_1401717046434_13349.docx @ 13989 @ 2 @ 1

Assembly

Hydraulic connection

43

5.7 Hydraulic connection Pos: 59 /ZINDEL/Rollreffanlagen/Montage/Motorsteuerung @ 1\mod_1401781467063_13349.docx @ 13993 @ 3 @ 1

5.7.1 Motor control

Warning Risk of uncontrolled system operation Risk of being crushed by the furling system. − Controls for switching on the hydraulic drive must allow push-button operation only.

The hydraulic motor for the furling system is controlled by a 4-way 3-position directional valve with float centre.

For furling systems RF90-4 and RF90-5 a valve block with two load control valves must be installed as close as possible to the hydraulic motor. The valve block must have a control ratio of i = 10 and an adjustment range of 70 bar to 175 bar.

RF 90-2, RF 90-3 RP90-4, RF90-5

The flow rate must not exceed the value given in the table below. If the hydraulic power pack has a higher performance, a throttle valve must be installed in the pressure line of the directional valve.

Maximum flow rate

Furling system Maximum flow rate (l/min)

RF90-2 10

RF90-3, R40 foil 11

RF90-3, R5 foil 17

RF90-4 40

RF90-5 40 … 50

Pos: 60 /ZINDEL/Rollreffanlagen/Montage/Hydraulikschläuche anschließen @ 1\mod_1401780825152_13349.docx @ 13992 @ 3 @ 1

Assembly Hydraulic connection

44

5.7.2 Connecting the hydraulic hoses

Notice Danger due to improperly installed hydraulic hoses Hydraulic hoses can become damaged if the following instructions are not followed. − Do not twist the hydraulic hoses when connecting them. − Ensure that the hydraulic hoses are not chafing on board. − Ensure that the bending radii are not lower than the minimum bending radii given in the

following table.

Minimum bending radii for hydraulic hoses

Hose size r min (mm) 540 N-5 114

540 N-6 127

540 N-8 178

Pos: 61 /ZINDEL/Rollreffanlagen/Montage/RF90-2, RF90-3/Hydraulikschläuche anschließen (RF90-2, RF90-3) @ 1\mod_1401717366081_13349.docx @ 13990 @ 4 @ 1

5.7.2.1 Connecting the hydraulic hoses (RF90-2, RF90-3) • The hydraulic motor is equipped with connections for quick couplers.

• Quick coupler sockets for the hoses are attached to the adjuster in the as-delivered condition.

Procedure 1. Screw the quick coupler sockets to the hydraulic hoses.

2. Plug the hoses with the quick coupler sockets into the connections on the hydraulic motor.

Pos: 62 /ZINDEL/Rollreffanlagen/Montage/RF90-4, RF90-5/Hydraulikschläuche anschließen (RF90-4, RF90-5) @ 1\mod_1401774422929_13349.docx @ 13991 @ 4 @ 1

Assembly

Removing the leather cover

45

5.7.2.2 Connecting the hydraulic hoses (RF90-4, RF90-5)

Screw the connecting hoses to the connections on the hydraulic motor.

Pos: 63 /ZINDEL/Rollreffanlagen/Montage/Ledercover @ 1\mod_1412156341772_13349.docx @ 14010 @ 2 @ 1

5.8 Removing the leather cover Notice

Risk of corrosion The leather cover that the drive unit is supplied in can cause considerable corrosion damage in combination with seawater. Be sure to remove the leather cover before putting the furling system into operation.

Take the leather cover off the drive unit after assembling the furling system.

Stow the leather cover for protecting the drive unit during winter storage. Pos: 64 /ZINDEL/Rollreffanlagen/Bedienung/headline_Bedienung @ 1\mod_1400840094357_13349.docx @ 13961 @ 1 @ 1

Operation Wire pennant

46

6 Operation Pos: 65 /ZINDEL/Rollreffanlagen/Bedienung/Kopfstander @ 1\mod_1400824020187_13349.docx @ 13958 @ 2 @ 1

6.1 Wire pennant

When the sail is hoisted the halyard shackle must be as close as possible to the top end of the foil.

For a sail with a shorter luff a wire pennant must be fitted between the halyard swivel and the fore sail.

Pos: 66 /ZINDEL/Rollreffanlagen/Bedienung/Drehrichtung @ 1\mod_1401198334606_13349.docx @ 13982 @ 2 @ 1

6.2 Direction of rotation

In principle, the furling system can roll up the sail clockwise or anticlockwise.

Select the direction of rotation to ensure that the side with the UV-resistant coating is facing outwards after the sail has been rolled up.

Pos: 67 /ZINDEL/Rollreffanlagen/Bedienung/Segel reffen und Segel ausrollen @ 1\mod_1401198939968_13349.docx @ 13983 @ 2 @ 1

Operation

Reefing and unrolling the sail

47

6.3 Reefing and unrolling the sail

Warning Risk of injury − Make sure the area around the furling system is clear before switching on the system. − The operator must have an adequate view of the furling system and the sail. If this is

not possible, a second person with an adequate view must maintain visual contact with the operator.

− Immediately stop the furling system if the sheet jams or the halyard starts wrapping.

Notice Risk of damage to furling system Jamming of the furling system will damage it. − Only reef or unfurl the sail with an eased sheet. − The halyard must be tensioned.

To reef or unfurl ease the sheet and actuate the corresponding switch.

In very light winds keep the sheet slightly tensioned so that the sail will furl tightly.

In strong winds ease the sheet stepwise and reef the sail.

Stop reefing when the sheet has been rolled once or twice around the sail.

Pos: 68 /ZINDEL/Rollreffanlagen/Bedienung/RF90-2, RF90-3/Spannung des Vorstags einstellen (RF90-2, RF90-3) @ 1\mod_1401278424130_13349.docx @ 13984 @ 2 @ 1

Operation Adjusting the forestay length (RF90-2, RF90-3)

48

6.4 Adjusting the forestay length (RF90-2, RF90-3)

Warning

Risk of adjuster becoming ripped apart − Stop extending the adjuster as soon as the 'STOP' mark becomes visible under the

outer cover. − After carrying out the adjustment tighten the locking screw again.

1. Completely unscrew the locking screw.

2. Rotate the adjuster tube to lengthen or shorten the adjuster.

3. Screw the locking screw back in tightly.

Operation

Adjusting the forestay length (RF90-4, RF90-5)

49

X: Maximum stroke RF90-2 50 mm

RF90-3 60 mm

Pos: 69 /ZINDEL/Rollreffanlagen/Bedienung/RF90-4, RF90-5/Spannung des Vorstags einstellen (RF90-4, RF90-5) @ 1\mod_1401709511748_13349.docx @ 13987 @ 2333 @ 1

6.5 Adjusting the forestay length (RF90-4, RF90-5)

Notice

Excessively high operating pressure Exceeding the maximum allowable operating pressure can result in damage to the adjuster. − Pressurise the hydraulic coupling on the adjuster to max. 140 bar.

Notice

Risk of contamination of the environment by leaking hydraulic oil Hydraulic oil can leak into the environment when the plug screw is taken off the adjuster. − Collect leaking hydraulic oil and dispose of it in accordance with requirements.

6.5.1 Preparation 1. Completely unscrew the locking screw.

2. Take the plug screw out of the hydraulic socket.


50

3. Connect a hydraulic hose with an R⅛″ coupling plug.

6.5.2 Shortening the adjuster

Notice

Risk of damage to the hydraulic hose − Do not use the hydraulic coupling as a stop.

1. Pressurise the hydraulic coupling until the lower edge of the adjuster tube is nearly touching the hydraulic coupling.

2. Raise the adjuster tube by rotating it with the hook spanner until it reaches the stop.

Operation


51

3. Repeat these two steps until the desired length has been reached.

4. Detach the hydraulic hose.

5. Seal the hydraulic socket with the plug screw.



52

6.5.3 Lengthening the adjuster

Notice

Risk of damage to the hydraulic hose − Do not use the hydraulic coupling as a stop.

1. Pressurise the hydraulic coupling until the adjuster tube is lowered about 2 mm. The mechanical lock on the adjuster tube is now released.

2. Lower the adjuster tube by rotating it with the hook spanner until its bottom edge is nearly touching the hydraulic coupling.

Operation


53

3. Slowly depressurise the hydraulic connection. The adjuster will now lengthen by the stroke length 'X'.

4. Repeat these three steps until the desired length has been reached. The maximum length has been reached when the visible part of the adjuster tube under the outer cover has reached the length 'Y'.

X: stroke length Y: maximum visible adjuster tube length

RF90-4 17 mm 170 mm

RF90-5 20 mm 218 mm


54

5. Detach the hydraulic hose.

6. Seal the hydraulic socket with the plug screw.


Pos: 70 /ZINDEL/Rollreffanlagen/Bedienung/Profilvorstag @ 1\mod_1412161082781_13349.docx @ 14012 @ 2 @ 1

Operation

Use as a forestay foil

55

6.6 Use as a forestay foil

Warning

Risk of injury through accidental switch-on of furling system When using the furling system as a forestay foil make sure the furling system is not accidentally switched on.

The furling system can be used as a forestay foil without a roller furling function, for example, to switch two sails with two halyards on a foil with a double groove.

To carry out preparations proceed as follows:

1. Detach the hydraulic hoses from the hydraulic motor of the drive unit, or switch off the fuse on the switchboard.

2. Remove the sail feeder.

3. Let the halyard swivel lower all the way down.

4. Install the sail feeder again.

Pos: 71 /ZINDEL/Rollreffanlagen/Wartung/headline_Wartung @ 1\mod_1400760126985_13349.docx @ 13942 @ 1 @ 1

Maintenance Prior to each use

56

7 Maintenance Pos: 72 /ZINDEL/Rollreffanlagen/Wartung/Wartung vor jeder Benutzung RF90 @ 1\mod_1412063850593_13349.docx @ 14006 @ 2 @ 1

7.1 Prior to each use • Check ropes and lashings.

• Check furling sections for external signs of damage.

• Check the functioning of manual operation.

• Check hydraulic couplings for external signs of damage and leaks. Pos: 73 /ZINDEL/Rollreffanlagen/Wartung/Wartung nach jeder Benutzung RF90 @ 1\mod_1412064459247_13349.docx @ 14007 @ 2 @ 1

7.2 After each use

Notice Risk of damage to gear through penetration by water − Do not point a pressure washer at the winch handle socket.

• Rinse off all parts with fresh water. Pos: 74 /ZINDEL/Rollreffanlagen/Wartung/Jährliche Wartung RF90 @ 1\mod_1412064665378_13349.docx @ 14008 @ 2 @ 1

7.3 Annual maintenance The furling system must be dismantled in a shipyard for annual maintenance. See 9 Disassembly.

The following tasks and checks must be carried out within the scope of annual maintenance:

• Remove all contaminants and salt deposits.

• Check the forestay for damage.

• Check the ease of movement of the halyard swivel.

• Replace the lashings and shackles.

• Polish stainless steel parts. Pos: 75 /ZINDEL/Rollreffanlagen/Wartung/Wartung alle fünf Jahre RF90 @ 1\mod_1412066944245_13349.docx @ 14009 @ 2 @ 1

7.4 Every five years The following parts must be serviced by an authorised service station every five years:

• Drive unit with adjuster

• Halyard swivel

Addresses of authorised service stations can be found at www.reckmann.com. Pos: 76 /ZINDEL/Rollreffanlagen/Störung/headline_Störungen @ 1\mod_1401196218411_13349.docx @ 13979 @ 1 @ 1

Troubleshooting

Troubleshooting guide

57

8 Troubleshooting Pos: 77 /ZINDEL/Rollreffanlagen/Störung/Störungstabelle @ 1\mod_1401198068458_13349.docx @ 13981 @ 2 @ 1

8.1 Troubleshooting guide

Fault Cause Remedy Furling system not rotating hydraulically

Electrical problem Button corroded Pump relay defective

On-board hydraulics fault Check the quick couplers. Check the on-board hydraulics.

Hydraulic power pack failure Use manual operating mode. See '8.2 Manual operation'.

Following manual operation: furling system not functioning although hydraulic motor is working

Clutch pin jammed, gear decoupled

Pull out the clutch pin. See '8.3 Coupling the gear'. Thoroughly remove salt residue with fresh water.

Partially furled sail unwinding under wind pressure

Gear no longer self-locking due to wear

Send the drive unit to the manufacturer or a service station for repair.

Halyard wrapping around forestay

No halyard tension Keep the halyard tensioned.

Fore sail not hoisted enough or not fully hoisted

Always completely hoist the fore sail. The distance between the halyard shackle and the halyard sheave must not exceed 20 cm. Use a wire pennant for a short fore sail.

Halyard swivel not moving freely

Thoroughly remove salt residue with fresh water. Send the halyard swivel to the manufacturer or a service station for repair.

Halyard wrap Insert a swivel shackle between the halyard and the halyard swivel.

Halyard angle less than 10° Install a halyard lead. See '5.6.2 Minimum angle between forestay and halyard of 10°'.

Pos: 78 /ZINDEL/Rollreffanlagen/Störung/Handbetrieb @ 1\mod_1401196356314_13349.docx @ 13980 @ 2 @ 1

Troubleshooting Manual operation

58

8.2 Manual operation

Warning

Risk of serious injury through winch handle backlash Do not use the furling system if the gear is no longer self-locking. Send the drive unit to a service station for repair.

If the drive fails or the drive energy supply is disrupted, the furling system can be operated with a winch handle. Due to the design it is not possible for the furling system to recoil against the winch handle.

This gear feature can become lost due to wear after prolonged use. If this occurs send the drive unit to a service station for repair.

1. Insert the winch handle completely into the winch handle socket. Rotate the winch handle slightly to insert it fully if it cannot be inserted all the way. The drive has now been decoupled from the gear.

2. Rotate the winch handle to furl or unfurl the sail.

3. Pull the winch handle out of the winch handle socket.

Pos: 79 /ZINDEL/Rollreffanlagen/Störung/Getriebe einkuppeln @ 1\mod_1401715230063_13349.docx @ 13988 @ 2 @ 1

Troubleshooting Coupling the gear

59

8.3 Coupling the gear After the winch handle has been used the gear may remain decoupled from the drive. This can happen if the clutch pin inside the winch handle socket does not spring back up when the winch handle is removed.

If this is the case switch the hydraulic drive on and keep it on briefly until the foil starts rotating again.

If the gear does not automatically become coupled, screw an M5 screw into the clutch pin and pull out the pin. Then remove the screw.

Pos: 80 /ZINDEL/Rollreffanlagen/Demontage/headline_Demontage @ 1\mod_1412165828515_13349.docx @ 14015 @ 1 @ 1

Disassembly Dismantling the adjuster

60

9 Disassembly Pos: 81 /ZINDEL/Rollreffanlagen/Demontage/headline_Verstelleinheit demontieren @ 1\mod_1412239952850_13349.docx @ 14018 @ 2 @ 1

9.1 Dismantling the adjuster Pos: 82 /ZINDEL/Rollreffanlagen/Demontage/Verstelleinheit demontieren (RF90-2, RF90-3) @ 1\mod_1425771830363_13349.docx @ 14034 @ 3 @ 1


1. Unscrew the locking screw.


Pos: 83 /ZINDEL/Rollreffanlagen/Demontage/Verstelleinheit demontieren (RF90-4, RF90-5) @ 1\mod_1425772183835_13349.docx @ 14035 @ 3 @ 1


1.a RF90-4: Unscrew the two screws in the outer cover and pull them out of the guide sleeves.

1.b RF90-5: Unscrew the four nuts in the outer cover using the supplied box spanner.

2. Detach the outer cover.

Disassembly

Dismantling the adjuster

61

3. Unscrew the key-retaining screw.

4. Screw an M6 ✕ 40 screw into the second hole in the key and force the key out with it. Then remove the screw.

5. RF90-5: Repeat these two steps for the second key.


Pos: 84 /ZINDEL/Rollreffanlagen/Demontage/Vorstag aus der Antriebseinheit lösen @ 1\mod_1412240416424_13349.docx @ 14019 @ 233 @ 1

Disassembly Detaching the forestay from the drive unit

62

9.2 Detaching the forestay from the drive unit

9.2.1 Detaching the rod forestay 1. Remove the top bushing from the foil.

2. Insert the forestay through the drive unit until the rod head can be seen protruding from the rod collet.

3. Unscrew and remove the rod collet.

9.2.2 Detaching the wire forestay 1. Remove the top bushing from the furling section.

2. Insert the forestay through the drive unit until the special nut can be seen protruding from the drive unit.

3. Pull the pin out of the special nut.

4. Unscrew the special nut from the forestay.

Pos: 85 /ZINDEL/Rollreffanlagen/Demontage/Profile demontieren @ 1\mod_1412243046966_13349.docx @ 14020 @ 2 @ 1

Disassembly

Detaching the foil from the drive unit

63

9.3 Detaching the foil from the drive unit 1. Unscrew the cap screws from the furler drive adapter. The drive unit can now be detached.

2. Take the threaded plate out of the recess in the feeder section.

3. Take the split bottom bushing out of the feeder section.

Pos: 86 /ZINDEL/Rollreffanlagen/Transport und Lagerung/headline_Transport und Lagerung @ 1\mod_1412157222879_13349.docx @ 14011 @ 1 @ 1

Transport and storage Transport

64

10 Transport and storage Pos: 87 /ZINDEL/Rollreffanlagen/Transport und Lagerung/Transport @ 1\mod_1412158215116_13349.docx @ 14013 @ 2 @ 1

10.1 Transport

Pack the drive unit together with the adjuster in a cushioned box for transport. Pos: 88 /ZINDEL/Rollreffanlagen/Transport und Lagerung/Lagerung @ 1\mod_1412162639833_13349.docx @ 14014 @ 2 @ 1

10.2 Storage

Notice

Risk of destruction of furling system by freezing water In regions in which there is a danger of frost disassemble the furling system prior to storing for the winter.

Store the furling system parts in a dry room.

The drive unit can be packed in the leather cover in which it was supplied to protect its surface.

Pos: 89 /ZINDEL/Rollreffanlagen/Entsorgung @ 1\mod_1412251169710_13349.docx @ 14023 @ 1 @ 1

Disposal

65

11 Disposal

Notice Risk of damage to the environment The drive unit contains gear oil which can cause severe environmental damage. Dispose of the furling system parts in an environmentally friendly manner in accordance with local requirements.

When the end of life has been reached the drive unit with the adjuster and the halyard swivel can be sent to a service station or returned to the manufacturer.

Sort the furling system parts and dispose of them in accordance with the applicable local requirements.

Pos: 90 /ZINDEL/Rollreffanlagen/headline_Technische Daten @ 1\mod_1416391342849_13349.docx @ 14026 @ 1 @ 1

Technical data RF90-2 DS

66

12 Technical data Pos: 91 /ZINDEL/Rollreffanlagen/Technische Daten RF90-2 DS @ 1\mod_1416391443697_13349.docx @ 14027 @ 2 @ 1

12.1 RF90-2 DS Foil type R20 R30

Forestay diameter (max.)

Rod -22 -40

Wire [mm] 10 12

Forestay length (max.) [m] 18.7 23.2

Sail area (max.) [m²] 75 130

Hydraulic motor

Operating pressure (max.) [bar] 120 140

Torque [Nm] 128 148

Oil flow rate (max.) [l/min] 10

Rotational speed (max.) [rpm] 60

Hydraulic couplings BSP ¼ internal (female) thread with quick coupler

Adjuster Stroke [mm] 52 (wire), 54 (rod)

Maximum allowable load [kg] 6800

Pos: 92 /ZINDEL/Rollreffanlagen/Technische Daten RF90-3 DS @ 1\mod_1416397262087_13349.docx @ 14028 @ 2 @ 1



Rod -48 -60

Wire [mm] 16 16



Hydraulic motor

Operating pressure (max.) [bar] 140

Torque [Nm] 268 448

Oil flow rate (max.) [l/min] 11 17

Rotational speed (max.) [rpm] 32 32

Hydraulic couplings BSP ¼ internal (female) thread with quick coupler

Adjuster Stroke [mm] 49 (wire), 51 (rod)



Technical data

RF90-4 DS

67



Rod -76 -91

Wire [mm] 19 22



Hydraulic motor


Torque [Nm] 918



Hydraulic couplings Motor R½ BSP / with ¾-16 fitting with internal (female) UNF thread

Adjuster

Stroke [mm] 110



Hydraulic connection R⅛ BSP internal (female) thread




Rod -91 -150

Wire [mm] 26 32



Hydraulic motor


Torque [Nm] 1102



Hydraulic couplings Motor R½ BSP / ¾-16 fitting with internal (female) UNF thread

Adjuster

Stroke [mm] 115



Hydraulic connection R⅛ BSP internal (female) thread

Pos: 95 /ZINDEL/Rollreffanlagen/Technische Daten Querschnitte Alu @ 1\mod_1416400027951_13349.docx @ 14031 @ 2 @ 1

Technical data Foil cross sections

68

12.5 Foil cross sections

Foil type Groove G [mm]

O [mm]

A [mm]

B [mm]

R20 Double 6.4 2.3 35.8 28.8

R30 Double 7.5 3.0 45.5 36.1

R40 Double 7.5 3.0 49.1 38.7

R5 Double 7.5 3.5 60.0 47.0

R6 Double 7.5 3.5 72.0 60.0

R7 Double 7.5 3.3 85.0 72.0

=== Ende der Liste für Textmarke Inhalt ===

Index

69

13 Index 4-way 3-position directional valve 43 Adjuster 10, 11, 12, 36, 40, 49, 60

dismantling 60 lengthening 52 shortening 50

Adjuster axle 11, 12 Adjuster tube 11, 12 Adjusting the foil length 13 Assembly 13 Caution 7 Cold-headed rod end (rod head) 15, 19, 26, 33 Completing the forestay (R20 – R40) 13 Cover

detaching the cover 35 Design 10 Direction of rotation 46 Disassembly 60 Disposal 65 Drive unit 10, 11 Feeder section 24, 32 Flow rate 43 Foil reinforcement 25 Forestay 10 Forestay foil 8, 55 Forestay length 48, 49 Function 12 Furler drive adapter 11, 38 Furling section cross section 68 Halyard lead 42 Halyard swivel 10, 34, 57 Hydraulic connection 43 Hydraulic hoses 44 Hydraulic motor 11 Intended use 8 Key 12 Load control valve 43 Locking screw 11, 12 Maintenance 56

Manual operation 12, 57, 58 Mast head 42 Mast toggle 42 Motor control 43 Notice 7 Outer cover 11, 41 Overview 10 Plug screw 12 Reefing 47 Safety 8 Sail feeder 10, 34 Sail UV protection 46 Shortening

top furling section 13, 26 top spacer 14

Storage 64 Swage terminal 23, 26 Swageless stud terminal 23, 26 Tack ring 11 Technical data 66 Throttle valve 43 Toggle 10 Top bushing 10, 14 Top cap 41 Top furling section 13, 23, 29 Top spacer 14 Top terminal 10, 26

rod terminal 15, 26 swage terminal 23, 26 swageless stud terminal 23, 26 wire terminal 23, 26

Transport 64 Troubleshooting 57 Typographical conventions 7 Valve block 43 Warning 7 Winch handle socket 11 Wire pennant 46

Notes

70

instructions for use - reckmann reefing systems & … wire type e* g e* g rf90-2 105 392 92 389...

Documents