Plastimo 406-S Assembly Instructions Manual Download Page 2

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ASSEMBLY INSTRUCTIONS FOR S-SERIES

406-S 608-S 810-S

I N D E X

Technical specifications of 406-S, 608-S, 810-S

Description of specific parts for each model

Tools needed

FLAT ASSEMBLY (forestay dismantled)

Dismantling the forestay

Assembly of the jib reefing system

IN SITU ASSEMBLY (directly onto the boat)

Measuring the length of the forestay

Cutting the last spar

Assembling the top end stop

Assembling the spars

Assembling the base spar

Assembling the boltrope prefeeder

Assembling the drum unit

Adjusting the reefing line feeders

RECOMMENDATIONS

Recommendations

Maintenance

Troubleshooting

OPTIONS

Optional extras

Spare parts

Summary of Contents for 406-S

Page 1: ...PLASTIMO JIB REEFING SYSTEMS S SERIES 406 S 608 S 810 S GB ...

Page 2: ...ismantling the forestay 9 Assembly of the jib reefing system 10 IN SITU ASSEMBLY directly onto the boat Measuring the length of the forestay 13 Cutting the last spar 14 Assembling the top end stop 15 Assembling the spars 15 Assembling the base spar 17 Assembling the boltrope prefeeder 18 Assembling the drum unit 18 Adjusting the reefing line feeders 19 RECOMMENDATIONS Recommendations 20 Maintenanc...

Page 3: ...nplate version 25722 Réf N turnbuckle version 25723 Forestay diameter mm 4 7 Luffrope diameter mm 6 5 Length Achainplate m Length A turnbuckle m 6 20 6 28 Length B m 5 95 Length C chainplate mm Length C turnbuckle mm 85 170 Lenth D m 5 82 S m 12 ØE mm 8 5 Bearings Delrin Coupling units aluminium screws Number of grooves 1 ...

Page 4: ... N turnbuckle version 25725 Forestay diameter mm 4 7 Luffrope diameter mm 6 5 Length Achainplate m Length A turnbuckle m 9 22 9 40 Length B m 8 94 Length C chainplate mm Length C turnbuckle mm 115 285 Lenth D m 8 80 S m 25 Ø E mm 12 5 Bearings Delrin stainless steel Coupling units aluminium screws Number of grooves 1 ...

Page 5: ...e 810 S Réf N chainplate version Réf N turnbuckle version 25374 Forestay diameter mm 4 7 Luffrope diameter mm 6 5 Length A m 11 05 Length B m 10 44 Length C mm 220 Length D m 10 49 S m 35 Ø E mm 14 3 Bearings Delrin Torlon Coupling units aluminium screws Number of grooves 1 ...

Page 6: ...OF SPECIFIC PARTS FOR EACH MODEL 406 S model 1 drum unit 1 halyard swivel 2 TCL screws M4 x 12 to secure reefing line feeder 406 S 608 S model 1 drum unit 1 halyard swivel Enrouleur 810 S 1 drum unit 1 halyard swivel ...

Page 7: ...ard parts for all models 1 boltrope prefeeder 1 top end stop 2 bearings Coupling sleeves 406 S ð Qty 4 608 S ð Qty 6 810 S ð Qty 7 1 base spar Intermediate spars 406 S ð 3 spars 608 S ð 5 spars 810 S ð 6 spars ...

Page 8: ...ws 2 608 S ð 10 screws 2 810 S ð 12 screws 2 4 N 7 TF screws 3 9 x 9 5 to secure prefeeder 1 N 10 TF screw 4 8 x 12 7 1 Chc M5 x 12 screw to secure base spar to drum TOOLS NEEDED Hammer Pliers Comfortable bosun s chair Plastimo Allen key 4 Electric or hand drill 1 4 mm drill Hacksaw Tape measure Screwdriver Silicone filler ...

Page 9: ... the halyards to relieve the strain on the forestay Dismantle the lower part of the forestay this usually consists of removing a removing a rigging screw pin or a screw and a nut Note it is important to measure the distance between the forestay eye and the hole of the forward mounting plate in order to find the correct adjustments again For a turnbuckle assembly measure the distance between the mo...

Page 10: ...tment Slide a bearing into the drum Insert a coupling sleeve into the base spar ensure that the hole in the coupling sleeve is in line with the pre drilled hole of the base spar Slide the base spar into the drum unit until the two holes are in line insert the Chc M5 x 12 screw after putting some silicone filler in the hole in order to reduce the stainless steel aluminium electrolytic couple and ti...

Page 11: ...ss filler with a cloth Insert PVC liners as you go along ensure they are flush against the prefeeder Repeat the process until only one spar is left Cutting the last spar Position the last spar so that it lies flush against the previous spar but do not install it Measure a distance of 5 cm back from the sleeve of the forestay Mark and cut the spar with a hacksaw Put a coupling sleeve into position ...

Page 12: ...e top end stop Before putting the screw into position do not forget to slide the halyard swivel into place ensure that the conical end of the halyard swivel faces downwards Put the top end stop back into position Put some silicone filler into the hole Insert and tighten N 10 TF screw 4 8 x 12 7 Your jib reefing system is now assembled and can be put into position hoist it up to the masthead with a...

Page 13: ...order for this jib reefing system to be perfectly adapted to your boat the length X needs to be known Helpful hint Slide a small shackle around the forestay Ensure that it lies flush against the sleeve Slacken the backstay Secure the mast with a halyard Dismount the lower part of the forestay Assemble the drum unit Reassemble the lower part of the forestay Undo the halyard and tighten the backstay...

Page 14: ...el with the top of the drum unit Lower the shackle X CUTTING THE LAST SPAR Stretch out flat the piece of rope used to measure the length of the forestay Lay the aluminium spars parallel to the piece of rope take note of base spar see page 7 Mark the spar level with the mark on the piece of rope Cut the spar 3 cm safety margin below the mark 3 cm location of mark on the piece of rope ...

Page 15: ...he end of the spar IMPORTANT refer to diagram below for positioning of the hole in the top end stop c Drill a hole using a 4 mm drill ASSEMBLING THE SPARS Dismount theforestay from the stemhead fitting Install the following on the forestay Top end stop Bearing The spar that you have cut and drilled N 10 screw PVC liner N 10 screw Halyard swivel IMPORTANT see drawing below for position of halyard s...

Page 16: ... holes before tightening the screws in order to reduce the electrolytic couple between the stainless steel screw and the aluminium Insert an M5 x 8 screw Wipe away any excess silicone with a cloth Slide another aluminium spar into position Insert a PVC liner IMPORTANT keep the base spar to one side you will be assembling it last Repeat the process as many times as necessary ...

Page 17: ...ted into drum Cutting the PVC liner Slide the prefeeder into position from the bottom of the spar until it is in line with the holes in the spar IMPORTANT ensure that the prefeeder is the right way up Insert a N 7 screw Position a PVC liner mark and cut to required length Remove the prefeeder and install the cut PVC liner position ofprefeeder ...

Page 18: ... boat Position the sleeve or turnbuckle on the drum depending on model Slide a bearing into the drum Insert a coupling sleeve into the base spar ensure that the hole in the coupling sleeve is in line with the pre drilled hole of the base spar Insert the base spar into the drum unit Put some silicone filler in the pre drilled hole Insert the Chc M5 x 12 screw Attach the jib reefing system to the fo...

Page 19: ...h direction you prefer to reef To fasten the reefing line feeder use the two M4 x 12 nuts and bolts see page 6 starboard assembly port assembly The angle is adjusted by loosening the two screws that hold the chainplate screws 608 S 810 S models The angle of reefing line feeders on 608 S 810 S models is adjusted by loosening the two nuts and bolts see diagram below nut and bolts ...

Page 20: ... and in order to avoid direct strain on mechanical parts and on the knot of the reefing line there should be a minimum length of one halyard turn on the drum Halyard forestay angle ý This angle should never be more than 20 25 as this makes it impossible to tauten and reef the sail What is more this undue strain on the forestay could cause it to unravel and even dismast the boat 25 maxi When sailin...

Page 21: ...en ahalyard feeder to themast or a diverter to the forestay The halyard tends to wrap itself around the spar when the genoa is hoisted Halyard is worn and thus twists in the direction of the rope strands ý Change the halyard Reefing line fouls Wrong angle onreefing line ý First sheave too far from drum unit ý Genoa unfurled too quickly ý Change position of first sheave Slow down the unfurling of t...

Page 22: ...halyard swivel turns 2 options are available to solve this problem Option 1 Halyard diverter wheel To install the diverter wheel it is necessary to dismantle the forestay Ref 25720 Option 2 Halyard feeder To install the halyard feeder it is not necessary to dismantle the forestay 2 sizes are available we recommend Ref 25677 ý 608 810 models Ref 26140 ý 406 model Ref 25677 Ref 26140 ...

Page 23: ... Screw TH 8 x 30 1 22831 Screw TH 12 x 35 22855 Screw TH 14 x 40 K 18048 Nut M8 1 22832 Nut M12 22857 Nut M14 L 18045 Nut M4 2 2 M 18076 Washer L8 1 18078 Washer L12 N 18090 Split pin 2x20 1 18092 Split pin 2 5x30 O 22836 Shoudered clevis pin dia 8 1 22837 Shoudered clevis pin dia 12 P V 22844 1 4 1 4 Q 17067 Halyard swivel 1 1 17070 R 19451 Crank shackle S 26321 top end stop 1 1 T 25674 Screw Chc...

Page 24: ...24 V L E T U G C W J K Q I S P A H F M B D O N 406 S ...

Page 25: ... 30 22831 Screw TH 12 x 35 1 22855 Screw TH 14 x 40 K 18048 Nut M8 22832 Nut M12 1 22857 Nut M14 L 18045 Nut M4 M 18076 Washer L8 18078 Washer L12 1 N 18090 Split pin 2x20 18092 Split pin 2 5x30 1 O 22836 Shoudered clevis pin dia 8 22837 Shoudered clevis pin dia 12 1 Q 17067 Halyard swivel 17070 1 1 R 19451 Crank shackle 1 1 S 26321 top end stop 1 1 T 25674 Screw Chc M5 x 12 1 1 U 25672 Screw N 10...

Page 26: ...26 V T U C W Q R S P A F B D G J K I O M N 608 S ...

Page 27: ...w TH 8 x 30 22831 Screw TH 12 x 35 22855 Screw TH 14 x 40 1 K 18048 Nut M8 22832 Nut M12 22857 Nut M14 1 L 18045 Nut M4 M 18076 Washer L8 18078 Washer L12 N 18090 Split pin 2x20 18092 Split pin 2 5x30 O 22836 Shoudered clevis pin dia 8 22837 Shoudered clevis pin dia 12 Q 17067 Halyard swivel 17070 1 R 19451 Crank shackle 1 S 26321 top end stop 1 T 25674 Screw Chc M5 x 12 1 U 25672 Screw N 10 4 8x1...

Page 28: ...28 T G J K I V U C W Q S P A F B R D 810 S ...

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