Harken Tensioner CT0 Operating instructions

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Tensioner CT0
USER AND MAINTENANCE MANUAL

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INDEX
1. Glossary....................................................................................................................................... 4
2. Symbols ....................................................................................................................................... 4
3. Safety information....................................................................................................................... 5
4. General advice............................................................................................................................. 6
5. Harken®limited worldwide warranty.......................................................................................... 6
6. Product information.................................................................................................................... 7
7. Product identification.................................................................................................................. 8
8. Maximum Loads .......................................................................................................................... 8
9. Weights........................................................................................................................................ 9
10. Product composition................................................................................................................... 9
11. Rope diameter........................................................................................................................... 10
8. Installation procedure............................................................................................................... 11
8.1 Electric Tensioner Outline ......................................................................................................... 11
8.2 Hydraulic Tensioner Outline...................................................................................................... 12
8.4 Installation - Technical info ....................................................................................................... 13
8.5 Tensioner Mounting Template.................................................................................................. 14
9 Motorized use ........................................................................................................................... 16
9.1 Hydraulic equipment (HY) ......................................................................................................... 16
9.1.1 Motor................................................................................................................................. 16
9.1.2 Manifold ............................................................................................................................ 16
9.1.2 Manifold performance data .............................................................................................. 16
9.1.3 Hydraulic motor installation procedure................................................................................... 17
9.1.3 Tensioner manifold installation procedure.............................................................................. 17
9.1.4 PLC Control requirements........................................................................................................ 17
9.1.5 Tensioner Manifold structure .................................................................................................. 18
9.1.6 Hydraulic Motor connections................................................................................................... 19
9.2 Hydraulic performance graph ................................................................................................... 21
9.3 Electric equipment (EL) ............................................................................................................. 22
9.3.1 Electric motor.................................................................................................................... 23
9.3.2 Electric unit wirings ........................................................................................................... 24
9.3.3 Electric unit equipment use............................................................................................... 24
9.3.2 Performance data.............................................................................................................. 25
9.3.3 Electric performance graph............................................................................................... 25

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10. Installation procedure............................................................................................................... 26
10.1 Cleaning and maintenance........................................................................................................ 26
10.2 Internal maintenance procedure .............................................................................................. 27
10.2.1 Maintenance product........................................................................................................ 27
10.2.2 Tools .................................................................................................................................. 28
10.2.3 Disassemble procedure.......................................................................................................... 29
11. Assembly ................................................................................................................................... 33
11.1 Lipped rings ............................................................................................................................... 34
11.2 Torque ....................................................................................................................................... 34
11.3 Marking ..................................................................................................................................... 34
12. Troubleshooting ........................................................................................................................ 35
13. Ordering spare parts ................................................................................................................. 36
14. Contact us.................................................................................................................................. 36

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1. Glossary
-Intended use: specific and proper use of the tensioner for which it is designed
-Improper use: use of the device in a different way from that indicated in the instructions
for use specified in this manual
-Qualified operator: person who has attended specialisation and training about the use of
the tensioner
-User: person who uses the winch and the tensioner regularly
-Maximum working load (MWL): maximum value of the load the tensioner can bear
2. Symbols
WARNING!
This denotes the existence of the potential danger, which could cause injury or
damage if the information or instructions are not followed
NOTE!
This denotes important information concerning the device

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3. Safety information
WARNING! Read this manual carefully and fully understood before using the
system to avoid personal injury or property damage during system operation.
-This manual is an integral part of the device and aims to provide all the
information needed for its safe and correct use and for proper maintenance.
-This manual gives technical information on installation and maintenance.
-This information is destined exclusively for qualified operators.
-Installation of the device by personnel who are not experts may cause serious
damage to users and those in the proximity product.
-Install and use the tensioner only as described in the technical information
supplied.
-Improper use can cause severe harms to users, equipment and the boat.
-Never substitute any tensioner part with one that is not original. Even though they
look similar and are both made by Harken®, the non-original part may not be
suitable and the warranty will be invalidated.
-Modifications carried out by the user, without explicit written authorization from
the manufacturer, will invalidate the warranty and relieve the manufacturer of any
responsibility for damage caused by the defective product.
-Failure to install the tensioner will void the warranty of the device itself and the
Harken®product to which it is connected.
-Refer to the warranty on the web site www.harken.com
-Do not apply to the tensioner loads greater than the MWL (Maximum Working
Load).
-If the tensioner is powered by a hydraulic motor:
•Do not operate the hydraulic motor during installation or maintenance
•Do not let the oil in the system come into contact with your eyes or skin. Harken
cannot be responsible for damage or injury resulting from unsafe product use,
lack of maintenance or incorrect product and /or system installation or operation.
-Wear suitable clothing when using the tensioner, to avoid loose ends of fabric
becoming entangled in the tensioner.
-Periodical maintenance must be carried out regularly as specified in the chapter
on Maintenance. In case of doubt, contact Harken Tech Service.
-This manual is available only in English. If you do not fully understand the English
language, do not carry out the operations described in this Manual. For any
doubts, questions or comments contact the Harken distributors nearest to you,
Special Project assistance, or contact the Harken Italy Technical Service by e-
mail: [e-mail]
-See www.harken.com for additional safety information.

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4. General advice
Intended use
The Harken devices are designed and manufactured for a use on sailing boats to control
ropes, halyards and related sail and rig systems. For any other usage, contact the Harken
Italy Technical Service by e-mail: [e-mail]
Improper use
- The Harken device must not be used for purposes different from those outlined in ‘Intended
use’ chapter, or for purposes not mentioned in this manual or different from those mentioned.
- The Harken device must not be used if unauthorized modifications or interventions have
been carried out.
- Do not use the tensioner for hauling, mooring the boat or weighing the anchor.
- Do not use the tensioner to divert a line (cross-sheeting).
5. Harken®limited worldwide warranty
The Harken product is covered by a warranty: if during the warranty period the tensioner
proves defective or suffers breakages, as indicated in the warranty, the manufacturer, after
checking the device, will repair or replace the defective components.
NOTE!
Refer to the Harken®Limited Worldwide Warranty in the Harken Catalogue and
on the website www.harken.com

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6. Product information
Harken Tensioner CT0 is needed to a double purpose:
1. Avoid slack and the entanglement of the rope on the Captive drum.
2. Keep tension on the rope wrapped on the Captive drum.
The Tensioner removes the slack when loading and unloading line on the spool.
Two independently low friction rollers guide the rope along the entry line direction for
constant and reliable tension.
Tensioner CT0 can be used with a maximum dynamic load of 3T.
One unit has two possible motor assemblies for flexible installation:
-by an electric motor
-by a hydraulic motor
Tensioner CT0 is used both for Hydraulic Captive Winch and for Electric Captive Winch.
As regards the differences, refer to:
- the installation procedures in the ‘Installation’ chapters of the Hydraulic Tensioner CT0 and
of the Electric Tensioner CT0 of this manual;
- the performance graphs in the relative chapters of the electric and of the hydraulic versions
of this manual.

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Legend
Rope diameter:
Ø10-12mm
Ø14-16mm
Motorization type:
EL = Electric motor
HY = Hydraulic motor
Voltage
EL →24V
HY →50cc
7. Product identification
The product identification is based on its composition and technical functions:
8. Maximum Loads
Loads associated to Tensioner CT0 are:
- Maximum tensioning load: 12Kg
- Maximum working load (MWL) on the rope: 3000 Kg (Maximum dynamic load)
- Maximum static load on the rope: 5000Kg
Tensioner
CT0
Maximum working
load (MWL)
Maximum static load
Maximum tensioning
load
lb
Kg
lb
Kg
lb
Kg
6600
3000
11000
5000
26,5
12
WARNING!
Subjecting the tensioner to loads above the Maximum Working Load can cause
the winch to fail or pull off the deck suddenly and unexpectedly during high loads
causing severe injury or death.
Product
Size
Rope diameter
Motorization
type
Voltage/displacement
Tensioner
CT0
XX
EL/HY
XXX

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9. Weights
NOTE!
Weights refer to the tensioner with the motorization.
10. Product composition
Tensioner CT0 is composed by the following groups:
Version
Weight [Kg]
EL
3.8
HY
6.8

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11. Rope diameter
WARNING!
For safety and correct performances, use ropes of the diameters indicated below.
NOTE!
For safety and for correct performance of the Tensioner use only rope of the best
brands.
The rope diameter when is not stretched cannot exceed the 5% of the nominal
value specified at the Captive order.
Two configurations of Tensioner CT0 are available in function of the rope diameter:
Ø10-12mm and Ø14-16mm.
Every Tensioner is assembled considering the specific rope diameter defined at the order.
The parts that change between the two configurations are the hubs and the lipped rings:
Tensioner description
Ø rope
Hub code
Lipped ring code
min
max
in
mm
in
mm
Tensioner CT0 10-12
0.39
10
0.47
12
S734630052
S737290080
Tensioner CT0 16-18
0.55
14
0.63
16
S734620052
S737300080