Thank you for purchasing a Navteo Integral Backstay Adjuster. Navtec pioneer- ed the integral concept over decade ago, and all of our ‘experience has gone into your q OWNER'S MANUAL Saving 7 integtal tis madof tha highest qually materials and wil 5 provide increased salingpleasiratfor many years to come. itil help you = Doin higher. relieve’ unnecessary. hull Stresses while on the mooring, and ease Use olyourlier We belove tis tho fnest_ aps unit offs ype available in the word, with postvemecharicallockingofallparstroughout for higher lovels of confidence and safety than simiar unis, Yourintegral combines ahigh pressurehydraulic cylinder and pump in one convenient package for ease of installation. Shou'd service be required, Navtecis committed. to getting you sailing again quickly with the largest worldwide network of marine hydraulic service centers and a loaner rogram in case repairs cannot be accomplished to meet your schedule. Fa ps) Fy e Pl zt 3 Fe iy 3 7 9 cs PY BS SY 5 4 Ky Pl & 5 I 3 Fs WARNING: The two primary ways Integral Backstay Adjusters got damaged are: |. Over tightening the release knob: This knob controls a precision nigh Pressure valve which must seal PERFECTLY to hold pressure. NEVER. OVER TIGHTEN THIS KNOB: Doing so will damage the sealing surtace of the valve. Two fingers are all that is necessary to close this valve. Damage to this valve due to abuse is not covered by your warranty, so please be careful 2. Damaging the piston rod: This rod’s surface passes back and forth thvough a pressure seal in the cylinder of your integral unit. Any scratch or ding that you can feel by running your fingernail across the surface will damage the seal. Take the time to have ANY rod damage checked by your authorized Navtec hydraulic service center. INTEGRAL ADJUSTER SPECIFICATIONS pra an Fin oe arg alte Sti? Leng Cand Sika aig nro ie eg Tee in os "npaudstogens i300 98. 2 hpaudsliogar a 4000p, a mpunehogane SOE p= 4 Sepuao ing aaeto repay farcda 90. Phase earn YALSNraV TWHDALNI Z S3lIYAS|INGTALLATION In most oases, you will have to chorten the backstay to ‘accomodate the adjuster. However, if there is a Navtec turnbuckle with an extra long screw in the backstay, this may not be necessary. The backstay should be long ‘enough to allow easy hook-up with the cylinder approximately two-thirds open. ‘The oylinder mustbe mountedwith the rodend up. Since the adjusters are shined fully retracted, yo must extend the rod prior to final installation. This is most easily done by attaching the adjuster to the chainplate, ‘opening the release valve (A), and using a halyard attached to the upper clevis, extending the rod._ If you wish to rotate the Integral 90 degrees for more convenient ‘operation, a special eye/iaw toaaleis available from your Naviec dealer. OPERATING INSTRUCTIONS To increase tension, work the pump handle back and forth with the release valve closed (its normal position) Until the desired tension or position is reached. The pump works on just one stroke; the other stroke is an intake stroke, To reduce tension (slack offstay), open the valve marked RELEASE (A), Itisa sensitive valve and a gradual elease can be obtained by opening the valve slightly. When the desired tension or position has been reached, close the release valve. This valve (A) has been designed to seal tightly when the valve is closed gently. DO NOT OVERTIGHTEN the valve as this will greatly reduce is ite. Two fingers are all thats need to close the valve. It tension bleeds off over time, the unit mustbe returnedto Navtecfor repair. Overtightening the valve willonly damage the unit turter. BLEEDING Ifthe cylinder fails to retract when operating the pump with the release valve shut, the likely cause is an airlock which can be solved by bleeding the pump as follows: 4. With the rod end up, fully extend the cylinder (see instructions above) 2. Open the release valve fully and pump slowly for approximately one minute. The pump and cylinder are now bled. RELIEF VALVE ‘The relief valve is factory set at approximetely 4,000 psi (3,500 if unit isa -6 ora-12). Atthat pressure, the force (of A -10 integral is 4,625 pounds. The Relief Valve can he adjusted as follows: 1. Lay the unit dawn sa that the handle faces up. Put a rag under the unit as thera will he some all Iaakage 2. Open release valve to depressurize unit, then close release valve. 3. Remove plug (C) below the NAVTEC sticker. A slotted screw under this plug controls the relief valve tension. 4. Toincrease relief valve setting, rotate screw clockwise. After makina a small adjustment, replace plug (C) and ‘pump up unit until pressure fails to rise further while pumping. This pressure is the new relief valve setting. Iffurther relief valve pressure change is desired, repeat steps 1 - 4.9. Replace plug. Oil loss will probably be slight If plug Is not left otf for long periods. If oll loss exceeds about 1/2 Cup, refill oilby following the ol filling procedures described below. GAUGE The Navtec gauge (B) has double endedneedieso that two scales 2 canbe used, The top scale which reads in thousands of pounds v2 3 per square inch, indicates the pressure within the cylinder. The. KPst lower scale which reads in thousands of pounds force, indicates, narec | § the force being exerted by the cylinder. ~ Hg o OIL LEVEL a% The reservoir is filed at the factory and should not need filing. However, ifthe cylinder falls to respond to bleeding instructions, orif excessive ols lost changing relief valve pressure, you may wish to check the level. ‘The correctlevelis achieved when the oll level ust touches the bottom ofthe fil hole (D) when the adjuster is lying on its sels 1. Go through the bleeding procedure described above ance, 2, With the cylinder rod stil fully extended. lie the unit down on its side with the oil fill plug (D) facing up. ‘3. Remove the black oil fill plug (D) which is located nearest the top of the unit. Keeping the unit level, add clean #10 hydraulicoi or non detergent motor oil unt the oillevelin the reservoir reaches the bottom of the fil hole, NEVER. use brake fluid as it wil destroy the seals. DO NOT tip the unit while filing. Replace the oil plug, 4. Stand the unit up and pump it all the way down with the release valve closed. 5. Extend the unit halfway (3-4 inches) and pump it down again. Open Release Valve (A). 6. Extend the unitfully. Lie the unit down on its side with the ol fil plug up. Wrap screwdriver with a rag and remove the oil fil plug. Keeping the unit level, fill the reservoir until the oil level reaches the bottom of the fil hole as in step 3, Replace the oil fil plug (0). 7. Close the release valve and pump until retracted. WARNING: If the pump handle springs back after a pumping stroke, the reservoir is overfiled and you are trying to pump oll through the cylinder tube wall, Flexing of this wall ‘causes the spring action. DO NOT continue pumping. If pumping is continued with the unit overfilled, the port plug seal may blow. Follow this procedure to correct for overtiling: 4) Releuse all pressure by opening the release valve, ) Back off ol fill plug stowly until some oil leaks out ©) Close release valve and pump very slowly and thy excess ol will ak (rom ie louse oil ill plug, 4) Once the rod is fully retracted, tighten the ol fil plug MAINTENANCE ‘No regular maintenance is required other than keeping the unit clean. Thepiston rod shouldbe inspected occasionally for dente or ecratchos. If pieton rod ie damaged. the unit should be returned to an authorized NAVTEC hydraulic service center for repair or replacement.WARRANTY 1. WARRANTY: Ntsc warants ts products, noymalutage. 10 be ee of lcs in mate rd workmanship fr apd one yar Fm date tonal pucrase bye wer, subject the condone and imtatons boom Any Pata groves oe delecre intra! vse Sig atone {year porod willbe epaed or raced by Naviaw The waranty lssubet "9h owing coors er ators [A Nava’ abit shal interop oreplacarr chlo! emedy a vtec option) goods orpasdlective atari orwornanshp sgecneatans.C. Delerminaton oe sutabiy of a materaltar thus cartompaadby fetes tha seaport ofthe buyr anahae ‘Stallhaveo response comecton wsuchsutabatyD. Naver shall beable or any harm esting fo (tue dos ute ar prods ‘appcatons tr win! ny sree 2) ara coon, var sng ea mpopernsaaean ne eeae ot 609909 wo ‘nproper instalation ncudes, buts rl, the use toa raging end tings oan ase manele by Nave or mesing Heise’ specitoatens.rroper staan also ase, bat nt ht fo, te ve ol das cher than thoe leased by Nave Aumorwed Nave Fepeesertaen To de top depo are reames re pe Spe, Rasen nt Oe responsi fs) ‘hagas oristaiaton aor assoced wih any waranty cams. Sareeby anyone ber ban Auhorzed Representatives shal vibe waar Uns in sconce wit Nave gues and sands of woransh. 2. DISCLAMEROF IMPLIED WARRANTIES. Thorearonowaranioeolmercantbity, Fras orpupoee, of any er kind, expressed rnp, andor shal bo imply aw. Tha carahon a ary such wares ral we ronan med yaw eh ben consume sale ed ‘eaperod otaneyea'Fromenghalputcneseby no seer, Some sates 6 ot alow taensca Now ong a gies wataniylase soe above ay ot apy 0 you, 4. LIMFTATIONS OF CONSEQUENTIAL DAMAGES. Nave sala be ible for consequertl damages yachts, equpment or ater ope, ‘orpersons due toany fale f Nac ecuipment. Some sats donot sow he excueanoiaton ct nena er consequent apes, SS Shove bmtaton or nusion nay nts you 4 The warany vs you spec gal pts and you may to have ae hs whic vay rom sae ott OTHER NAVTEC PRODUCTS RIGGING MAINTENANCE MULTIFUNCTION PANELS ‘SUPPLIES NAVTEC, INC., NEW WHITFIELD STREET - P.O, BOX 88 - GUILFORD, CT 06437-0366 - 203-458-3169 - FAX 203-456-0291 4