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Contents

Page

1 Introduction

1.1.

Key features

1.2.

What’s included?

1.3.

Main dimensions

1.4.

Safety precautions

1.5.

Sail information

2 Assembly preparations

2.1. Tools

2.2.

Mast and deck attachment

2.3.

Wire length calculation

2.4.

Top extrusion length calculation

3 Assembly

3.1.

Luff assembly

3.2.

Fitting sta-lok wire terminal

3.3.

Fitting eye terminal to swaged stud

3.4.

Fitting lower eye terminal to rod stay

3.5.

Drum unit assembly

4 Installation

4.1.

Mast attachment

4.2.

Deck attachment

4.3.

Installation on a stepped mast

4.4.

Installation on an un-stepped mast

4.5.

Adjusting the forestay length

4.6.

Furling line installation

4.7.

Check list

5 Operation

5.1. Hoisting

5.2

Unfurling the sail

5.3

Furling the sail

5.4 Reefing

5.5 Racing

6 Maintainence

6.1. Inspection

6.2. Service

6.3. Storage

6.4. Dismantling

6.5.

Trouble shooting

6.6.

Spares and accessories

6.7

Toggles & links

7 Warranty conditions

Содержание Furlex 404S

Страница 1: ...1 Manual and Spare parts list Furlex 404S 597 181 E 2016 03 03 404S ...

Страница 2: ... 3 4 Fitting lower eye terminal to rod stay 16 3 5 Drum unit assembly 17 4 Installation 4 1 Mast attachment 18 4 2 Deck attachment 19 4 3 Installation on a stepped mast 20 4 4 Installation on an un stepped mast 20 4 5 Adjusting the forestay length 20 4 6 Furling line installation 22 4 7 Check list 23 5 Operation 5 1 Hoisting 24 5 2 Unfurling the sail 25 5 3 Furling the sail 25 5 4 Reefing 26 5 5 R...

Страница 3: ...ring diameter in combination with a low profile shackle or an optional soft shackle reduces the amount of effort needed to furl in that first turn compared to earlier models Soft shackle ready The tack ring and halyard swivel eyes are prepared for using textile loops All surfaces are smooth and nicely rounded Aero grooves Similar to the dimples on a golf ball the Furlex AERO groove system reduces ...

Страница 4: ...en better on your boat Foil pack wire pack and eye pack The Furlex system also includes a foil pack with luff extrusions distance tubes and connectors A complete forestay is also supplied with every Furlex including a swaged stud eye solution no adjuster or a Sta Lok eye terminal fitting with or without rigging screw On new boats delivered with a complete new Seldén rig the forestay is usually inc...

Страница 5: ...isting forestay Incorrect halyard routing can result in halyard wrap which may cause severe damage to the forestay and put the entire rig at risk The angle between the halyard and the forestay must never be less than 15 Incorrect halyard routing can also cause the halyard shackle to wear agains the luff extrusion If using a winch for the furling line first check that there is no obstruction which ...

Страница 6: ...mpatible with the Furlex luff extrusion geometry Use webbing loops at the sail head and tack instead of grommets cringles The sail will then form tightly round the luff extrusion when furling and achieve a better shape when reefed 1 5 Sail information Fig 1 5 a Fig 1 5 c It is most important that the halyard swivel is located so that the halyard satisfies the 15 20 angle requirement If the sail pr...

Страница 7: ...estay can articulate in all directions both in the top and at deck level Toggles must be used in most cases to ensure sufficient articulation The toggle on the furling unit should always be fitted directly to the chain plate If the unit is to be fitted below deck or if it needs to be raised an extension toggle can be used but always make sure that the toggle that comes with the drum unit is attach...

Страница 8: ...uding rigging screw See Fig 2 4 a 9500 T Deduction for lower terminal 280 H If links or extra toggles are to be used deduct this length H from FL See table 6 7 0 WL Cutting measurement The new forestay wire is to be marked at this point For stays with swaged stud WL equals the length of the finished stay as shown in fig 4 2 a and NOT the cutting length 9220 If a Sta lok terminal with or without ri...

Страница 9: ...ite the actual forestay length Note If the calculation gives a top extrusion length D that is shorter than 400 mm 15 3 4 the calculation must be reworked by exchanging one of the 2400 mm 94 1 2 extrusions with the uncut 1700 mm 67 top extrusion By doing so the top extrusion will be cut from a 2400 mm 94 1 2 length and its length will then exceed 400 mm 15 3 4 If the calculation gives a top extrusi...

Страница 10: ... N x 2400 94 1 2 3 x 2400 7200 D Length of top luff extrusion D WL A B C 9920 1330 7200 690 E Length of the top distance tube E D 300 11 13 16 690 300 390 If as in our example D becomes less than 400 mm it is necessary to recalculate as below and cut one of the full length luff extrusions according to Dnew and one of the full length distance tubes according to Enew Note that the original top luff ...

Страница 11: ... distance tube is oriented correctly Also add another short joining sleeve 6 Fit a short connecting plate into the second luff extrusion as shown Push the first joining sleeve down into the second luff extrusion to lock the connector 7 Connect the two luff extrusions 8 Push the first joining sleeve back up into the first luff extrusion to lock the join Use the second joining sleeve to push on the ...

Страница 12: ...s and secure with the screw Tighten moderately 13 Fit the halyard swivel from the top and slide it down until it stops on top of the sail feeder Then fit the top guard and push it into the top luff extrusion until it stops Secure it with the four pre fitted screws Tighten the screws until they bottom but do not over tighten 14 Fit the bearing plug halves and push them up ito the long joining sleev...

Страница 13: ...sist cutting Carefully cut the wire using a hacksaw 3 Unscrew the socket wedge and former from the terminal part or Furlex rigging screw if to be used 4 Thread the socket onto the wire 5 Slide the wedge over the core 7 strands of the wire The core of the wire should protrude approx 2 mm 5 64 from the wedge 3 2 Fitting Sta lok eye terminal Note For systems with swaged stud terminal skip this part a...

Страница 14: ...eaded hole of the terminal part or rigging screw Lubricate the socket s thread with a long bead of locking adhesive Screw the terminal part onto the socket and tighten carefully forcing the wire further into the terminal 9 Unscrew and check that the outer strands are evenly distributed around the wedge If some strands are crossed correct their positions 10 If assembly is unsuccessful and needs to ...

Страница 15: ...nal 3 4 Fitting lower eye terminal to rod stay 1 Screw out the socket on the lower terminal part and remove the wedge and the former These three parts are not to be used in rod application 2 Add 2 3 drops of locking adhesive on the thread and screw the terminal together Check that the rod head sits correctly in the seat and that the seat sits correctly in the socket 3 Tighten firmly for permanent ...

Страница 16: ...e eye terminal meets the two ribs inside the drum unit tube shaft If a Furlex rigging screw is used the flat faces on all three components must be aligned As the two ribs on the inside of the tube shaft matches the flat faces it will securely lock the rigging screw When fitting the drum unit the rigging screw should be unscrewed halfways Refit the clevis pin through the tube shaft and the hole in ...

Страница 17: ...luff section 1 and then connect to the upper hub 2 When the forward half is in postion fit the aft half 3 and click the halves together Make sure that the screws go in smoothly so that the screw threads are not damaged Tighten the screws firmly 6 Refit the toggle Secure the split pin 4 Turn the drum unit so that the small knob in the upper hub is oriented as shown in relation to the luff extrusion...

Страница 18: ... or masts of other brands it may be necessary to fit halyard leads or to fit a new halyard box The Extended Pack includes two halyard leads These are easy to install and fit on most mast brands Halyard leads should be inspected once a year and any sharp edges smoothed with a file The halyard lead should be replaced when wear reaches 50 Alternatively a sheave box can be fitted to the mast to meet t...

Страница 19: ...estay is improved The disadvantage is a more complicated route for the furling line resulting in increased furling resistance The diagrams below illustrate various methods of installation For the furling line to be wound evenly onto the line drum the first turning point stanchion block must be at least 300 mm 11 13 16 away The tack should be located as close to deck level as possible Regardless of...

Страница 20: ...e fitting and cover seperates Remove the line guide fitting It may be necessary to loosen the screw on the underside a few extra turns for the line guide fitting to come off 2 Pull out the lock block 3 Remove the cover 4 5 1 Removing line guide fitting and cover Fig 4 5 1 a Fig 4 5 1 b Fig 4 5 1 c 1 Slacken the backstay as much as possible but do not remove it 2 Pull the mast forward using a genoa...

Страница 21: ...nding on the attachment points the line arrangement chosen and possibly also the type of other blocks on the boat We recommend a swivel block which is free to self align The maximum working load of the block should not be less than 15000 N 1500 kg 3300lb Fig 4 5 2 c Fig 4 5 2 d Fig 4 5 2 e If the sail s ultraviolet UV protection is fitted on the starboard side of the sail the furling line should e...

Страница 22: ...ake care not to scratch the foil Use cloth or paper for protection 4 Secure the drum unit in this position for example by using a spare halyard connected to the tack ring shackle 5 Place one wrench over the flat faces of the wire terminal and another wrench over the flat faces of the rigging screw body Adjust the rigging screw length by turning the body of the rigging screw until the desired fores...

Страница 23: ...t the angle between the halyard and forestay is 15 20 when the sail is hoisted Check that the clearance between the halyard swivel and the top guard is at least 50 mm Check that all the sails used have the sufficient luff length or an extension pendant fitted so that the 15 20 requirement is satisfied Check that no halyards can get caught in the halyard swivel or wrapped around the luff extrusion ...

Страница 24: ... initial resistance when furling the sail 8 Hoist the sail The pre feeder helps guide the sail in towards the sail feeder at a small angle If the pre feeder is not included then feed the sail manually through the sail feeder 9 Tension the halyard until a vertical crease appears in the luff of the sail then slacken off until the crease disappears 10 After hoisting the sail remove the pre feeder com...

Страница 25: ...it can run freely 2 Release the leeward sheet but keep a little tension on it for example by placing a turn around a winch Furl the sail by pulling the furling line It is important to furl the sail tightly and evenly as a sail which is furled too loosely can blow out a little in strong winds If the boat is left unattended the sail may flap until it tears A very loosely furled sail may also cause u...

Страница 26: ...cken the sheet when furling 3 Belay the furling line When the sail is reefed it may be necessary to adjust the sheeting position The Furlex can be easily and quickly reconfigured from a furling jib system to a twin groove headfoil The sail can then be tacked at deck level enabling the full hoisting length of the headfoil to be utilized The twin luff grooves offer the option of quick sail changes D...

Страница 27: ...n unwashed or damp Furlex system be wrapped in plastic or any other impervious material In areas where frost can occur the Furlex should be stored in a dry place or with its centre extrusions raised This is to avoid ice damage to luff extrusions at sub zero temperatures 6 Maintenance Fig 6 3 a Wash and rinse the entire Furlex system with fresh water and a mild detergent to remove dirt and salt Not...

Страница 28: ...lock block 3 Remove the cover 6 4 Dismantling Never take the halyard swivel or the drum unit apart as you will find it difficult to re assemble them correctly The ball bearings are loose and difficult to refit Contact your Furlex dealer if service is required 6 4 2 Line guide and cover 6 4 1 Sail feeder Fig 6 4 1 c 1 2 3 Remove the screw The nut is inte grated in the plastic connector Bend open th...

Страница 29: ...stemhead the drum unit can be slid down over the terminal or rigging screw and removed 1 Unscrew the two screws holding the adaptor halves together Take care not to loose the screws 2 Remove the clevis pin that goes through the tube shaft in the drum unit 3 Remove the toggle 4 The lower bearing unit can now be slid down over the eye terminal and removed Note The complete drum unit can be removed i...

Страница 30: ...t again 7 Cut all wire strands protruding outside the wedge at the bend by approx 5 mm 13 64 8 Prise the wedge apart slightly by inserting a small screwdriver into the slot and turning Tap on the screwdriver so that the wedge slides off the wire 9 Twist the wire strands into the correct positions around the core counter clockwise when seen from underneath and remove the socket 10 The wire can now ...

Страница 31: ...g distance tubes and joining sleeve until all joins disconnect Hold tight on the luff extrusion while knocking on the joining sleeve with a hammer Use a piece of wood or similar so that the joining sleeve is not damaged 6 Collect the connectors at each join and pull out the wire 6 4 8 Halyard swivel The halyard swivel is removed from the system by sliding it downwards in conjunction with dismantli...

Страница 32: ...und the system and wind more line onto the drum The forestay is too slack Increase forestay tension Excessive wind pressure on the sail Let the leeward sheet off more Windward sheet is not released Release the sheet The sheet has become tangled Sort out the sheet The free turn is not functioning Rinse the bearings with fresh water and lubricate with Furlex grease Large turning angles in the furlin...

Страница 33: ...ection is on the inside of the furled sail The furling line is wound on the drum in the wrong direction Remove the sheet from the sail and gather the sail around the Furlex system with a rope Pull on the line until the drum is empty Wind a couple of turns onto the drum by hand in the opposite direction Re attach the sheet and unfurl the sail Furl in and check that there are 3 5 turns left on the d...

Страница 34: ...34 ...

Страница 35: ...ing plug halves 1 549 438 01R 549 438 01R 5 Drum unit incl shackle clevis pin and split pin 1 549 400 10R 549 400 10R 6 Lock block 1 549 411 01R 549 411 01R 7 Cover assembly incl lock block and screws 1 549 409 10R 549 409 10R 8 Brim assembly two brims incl screws 1 549 407 01R 549 407 01R 9 Halyard swivel incl shackle 1 549 416 01R 549 416 01R 10 Clevis pin and split pin 1 165 566 01R 165 566 01R...

Страница 36: ...01 062 73 1 Rigging screw pack 1 174 570 11 174 571 11 2 Eye pack stud 1 301 660 11 301 661 11 3 Eye pack sta lok 1 301 668 11 301 669 11 Serie 404S Forestay wire size Description Dimension Qty Ø12 mm Ø14 mm 13 Furlex grease 100g 1 312 501 312 501 14 Furling line Ø12 L 40000 1 612 036 01 612 036 01 15 Stanchion block For Ø25 30 1 538 210 02R 538 210 02R 16 Pre feeder pack 1 505 538 01R 505 538 01R...

Страница 37: ... sleeve 1 pcs distance tube and 1 pcs connecting plate Description Dimension Qty Art No Luff extrusion pack FL 15300 1 549 432 02 Description Qty Art No Luff extrusion Joining sleeve Distance tube Conn plate Single luff extrusion pack 1 549 430 01 L 1000 L 1225 L 149 Single luff extrusion pack 1 549 431 01 L 1700 L 300 L 1400 L 75 Single luff extrusion pack 1 549 432 06 L 2400 L 300 L 2100 L 75 Lu...

Страница 38: ...5 Ø Eye D1 20 20 Ø Clevis pin D2 19 19 Fork width W2 22 22 Fork Fork toggle Article No 517 052 02 517 053 02 Length H 65 80 Ø Clevis pin D1 19 22 Fork width W1 20 5 20 5 Ø Clevis pin D2 19 22 Fork width W2 21 23 Eye fork Extensionlink Article No 517 075 01 517 076 01 Length H 190 190 Ø Clevis pin D1 19 22 Fork width W1 20 5 20 5 Ø Eye D1 D2 20 22 5 Gauge W2 12 16 ...

Страница 39: ... loads in excess of those indicated in the brochure and instructions Complete shipment and warranty conditions are to be found on Seldéns website www seldenmast com See Resources Partners information General information General conditions of sale 595 546 E If the system is repaired by anyone other than Seldén Mast AB or one of our authorized dealers the guarantee ceases to be valid Seldén Mast AB ...

Страница 40: ...x 33 0 251 362 185 e mail info seldenmast fr Seldén Mast Asia Ltd Hong Kong Tel 852 3572 0613 Fax 852 3572 0623 e mail info seldenmast com hk www seldenmast com Dealer DINGHIESKEELBOATSYACHTS The Seldén Group is the world s leading manu facturer of mast and rigging systems in carbon and aluminium for dinghies keelboats and yachts Our well known brands are Seldén and Furlex The worldwide success of...

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