RECKMANN RF90 User manual

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. [phone]
Fax.[phone]
[e-mail]
www.reckmann.com
As of: 12th June 2015
Copyright by
Reckmann Yacht Equipment GmbH
Siemensstr. 37-39
D-25462 Rellingen

Measurements
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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
=== Ende de r Lis te für Tex tmarke In halt ===
=== Ende de r Lis te für Tex tmarke In halt ===

Notes
www.reckmann.com

Contents
1
1Packing list............................................................................................... 4
2About this manual.................................................................................... 7
2.1 Introduction.............................................................................................................. 7
2.2 Typographical conventions...................................................................................... 7
2.3 Calculations............................................................................................................. 7
3Safety ........................................................................................................ 8
3.1 Intended use............................................................................................................ 8
3.2 Safety instructions................................................................................................... 8
4Design 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
5Assembly ................................................................................................ 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
6Operation.................................................................................................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
7Maintenance ............................................................................................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
8Troubleshooting......................................................................................57
8.1 Troubleshooting guide ...........................................................................................57
8.2 Manual operation...................................................................................................58
8.3 Coupling the gear...................................................................................................59

Contents
3
9Disassembly........................................................................................... 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
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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
Picture Quantity Designation Remarks
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
Picture Quantity Designation Remarks
_____ Hook spanner for adjuster
_____
Hex key set
_____ Winch handle
_____
Instructions
Special equipment
Compiled by:
___________________________________________
On: _______________
___________________________________________
Signature
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About this manual
Introduction
7
2 About this manual
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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.
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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.
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2.3 Calculations
Please see the dust jacket flaps for information pertaining to the calculations required for assembly.
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Safety
Intended use
8
3 Safety
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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.
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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.
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Design and function
Overview
10
4 Design and function
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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
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Design and function
Component assemblies
11
4.2 Component assemblies
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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
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4.2.2 Adjuster (RF90-2, RF90-3)
1 Adjuster tube
2 Locking screw
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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
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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.
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The furling system is driven by a hydraulic motor.
It must be connected to an on-board hydraulic system.
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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.
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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.
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Assembly
Completing the forestay (R20 – R40)
13
5 Assembly
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5.1 Completing the forestay (R20 – R40)
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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.
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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.
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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.
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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
Completing the forestay (R20 – R40)
15
3. Take the top bushing halves out of the furling section and stow them for later assembly.
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5.1.3 Preparing the rod forestay
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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.
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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.

Assembly
Completing the forestay (R20 – R40)
16
Overview
Slide bushings and spacer hoses on to the rod forestay from below.