Harken Mk-IV Furler Unit 1 Installation Manual 7/1/2013

Harken Mk-IV Furler Unit 1 Installation Manual 7/1/2013
MKIV JIB REEFING & FURLING
Unit 1
Installation Manual – Intended for specialized personnel or expert users
4417 7/13
Preassembly
Safety Precautions/Parts Descriptions
2
Sizing Check
3
Parts4
Rigging Parts Check/Tools
5
Dimensions/Sailmaker's Instructions
6
Toggle Deductions/Stay Into Foil Options
7
Top Foil Length
8
Short Top Foil
9
Confirm Foil Length
10
Assembly
Foils/Connectors11–17
Halyard Swivel
17
Drum Assembly
18
Rod Rigging
19
Turnbuckle/Toggle
20–21
Final/Feeder
22–23
Commissioning
Turnbuckle24
Line to Cockpit
25
Halyard Wrap/Prevent Halyard Wrap
26
Pendant/Halyard Restrainer/ Halyard Tension27
Operation
Spinnaker Halyards/Headstay Tension
Raise Sails
Furl/Reef
Secure Sail
Race Conversion
28
29
29–30
30
31
Maintenance
Clean/Inspect32
Replace Line
32
Storage/Remove Furler
32
Troubleshoot33
Online Warranty/Product Registration
33
Appendix34–35
Please read these instructions carefully before installing, servicing, or operating the equipment.
This manual may be modified without notice. See: www.harken.com/manuals for updated versions.
PLEASE SAVE THESE INSTRUCTIONS
Safety Precautions/Parts Description
Introduction
This manual gives technical information on installation and service. This information is destined exclusively for
specialized personnel or expert users. Installation, disassembling, and reassembling by personnel who are not
experts may cause serious damage to property or injury to users and those in the vicinity of the product. If you
do not understand an instruction contact Harken.
The user must have appropriate training in order to use this product.
Harken accepts no responsibility for damage or harm caused by not observing the safety requirements and
instructions in this manual. See limited warranty, general warnings, and instructions in www.harken.com/manuals.
Purpose
Harken® Jib Reefing and Furling is designed for rolling sails on sailboats to reduce sail size or to completely roll
so wind has little effect on the sail. Use of this product for other than normal sailboat applications is not covered
by the limited warranty.
Safety Precautions
WARNING! This symbol alerts you to potential hazards that may kill or hurt you and others
if you don't follow instructions. The message will tell you how to reduce the
chance of injury.
CAUTION! This symbol alerts you to potential hazards that may hurt you and others if
you do not follow instructions. The message will tell you how to reduce the
chance of injury.
WARNING! Strictly follow all instructions to avoid potential
hazards that may kill or hurt you and others. See www.harken.com/
manuals for general warnings and instructions.
8
9
7
6
5
2
3
1
4
Parts Descriptions
1) Toggle Assembly
2) Crosspin
3) Shackles
4) Drum Assembly
2
5) Foil Clamp
6) 2' (610 mm) Bottom Foil
7) Feeder
8) Connector Bushing
MKIV Unit 1
9) Bottom Connector
10) 7' (2.13 m) Foil
11) Connector Screws
12) Connector Wedge
13) Connector
14) Halyard Swivel
15) Trim Cap
16) Trim Cap Screws
Preassembly
Sizing Check
16
14
15
12
13
11
10
Online Product Registration
www.harken.com/FurlingWarranty
9
Size Check
1. Check headstay and clevis pin dimensions in chart below.
WARNING! Do not drill boat's chainplate or toggle. This may result in rig failure. Use the correct
size toggle and clevis pin.
2. Harken does not recommend drilling boat’s chainplate or toggle. In some cases bushings are available
to fit boats with smaller clevis pin sizes.
3. Will drum fit on bow? See page 6. If necessary, use an additional toggle to slightly raise unit. To clear
anchor use a Harken Long Link Plate which can be cut to various lengths.
Unit Part No.
Sizing Check
Description
Wire Sizes
1/4", 9/32", 5/16"
7411.10
MKIV Unit 1
Rod Sizes
-8, -10
Toggle Part No.
Description
6 mm, 7 mm, 8 mm
5.72 mm, 6.35 mm
Chainplate Clevis Pin Size
7411.20 1/2
Eye/jaw reversible
1/2"
12.7 mm
7311.20 1/2
Jaw/jaw
1/2"
12.7 mm
7311.20 5/8
Stud/jaw
5/8"
15.9 mm
7311.21 1/2
Long link plate w/toggle
1/2"
12.7 mm
7311.21 5/8
Long link plate w/toggle
5/8"
15.9 mm
MKIV Unit 1
Chainplate Clevis Pin
3
PreassemblyParts
2' (610 mm)
Bottom Foil
7' (2.13 m)
Foils
Bottom
Connector
Connectors
Connector Bushings
Trim Cap
Plastic
Connector
Wedges
Foil Screws
Trim Cap Screws
Halyard Swivel
Drum Assembly
Bow Shackles
2.5, 4, 5 mm
Hex Keys
Feeder
Prefeeder
Line
Red Loctite
®
Injector
5200
Adhesive
Main Components
Part No.
Quantity
Description
HFG291
1
Drum assembly with foil clamp
Part No.
Quantity
H-39812
1
Halyard swivel
7411.31
5
7" (177.8 mm) Connectors
7411.32
1
10.75" (273 mm) Bottom connector
HFG295
1
Connector bushing set (12-H-42062/12-H-42063)
HFG299
1
Plastic connector wedge set (14-H-39625)
HFG343
1
Foil screw set (30-HFS1105)
HFG680
1
Trim cap set (H-37361/H-37362)
HFG629
1
Trim cap screw set (3-HFS1126)
Other Components
Foils (Standard Package)
Part No.
Quantity
Description
7411.30
6
7' (2.13 m) Foils
7411.33
1
2' (610 mm) Bottom foil
Line (Standard Package)
Part No.
HFG233
Quantity
Description
70' (21.3 m) 7 mm Single braid polyester
Tools
Quantity
1 Each
4
Description
2.5, 4, 5 mm Hex keys
MKIV Unit 1
Description
947
1
Prefeeder
H-39683
1
Feeder with screw and tab
2110
3
6 mm Bow shackles
HFG739
2
Red Loctite® (for foil screws)
HFG725
1
Injector, 1 oz. 5200 Adhesive (HFG722)
Preassembly
Rigging Parts Check/Tools
1. Harken toggle assembly required. Sold separately.
2. Mating turnbuckle components must be purchased separately.
3. Headstay may require cutting and shortening to fit Harken toggle.
Headstay may remain uncut by replacing lower stud of turnbuckle
with stud/eye thus eliminating extra toggle.
4. Rod rigging requires Harken rod adapter stud.
5. Order Harken 7404 Lead Block Kit and one additional 7403 if
necessary. Fits 1" (25 mm) stanchions.
WARNING! A stay that is old or
damaged may break suddenly,
causing an accident. Headstay
condition should be checked by a
professional rigger before reusing.
ROD RIGGING
Harken Rod Adapter
Stud Required
(Sold Separately)
ALL UNITS
Harken Toggle (Sold Separately)
Thread
- 18LH
5/8"
7404 Lead Block Kit
(Sold Separately)
Thread
- 18RH
5/8"
Thread
- 20RH
1/2"
Jaw/Jaw Toggle
7311.20 1/2
Stud/Jaw Toggle
7311.20 5/8
Long Link Plate w/Toggle*
7311.21 1/2
7311.21 5/8
Eye/Jaw Toggle Reversible
7411.20 1/2
7422 -8
7424 -12
7423 -10
Rod Adapter Studs
Includes 3 x 7403; 1 x 7401;
1 x 7402; 1 Horn Cleat
*Requires drum assembly with four threaded holes in base. See page 21.
Tools You Will Need
Adhesive Alert
MKIV Furlers are shipped with 3M 5200
adhesive. Use adhesives on dry connectors
and foils using the special injection system
described in the assembly section. Parts
may immediately be exposed to rain. Cure
is best at 70F (22C) with 50% humidity. Do
not apply at temperatures below 40F
(5C) and above 100 F (38C).
5
3
4
1
12
2
8
15
10
6
7
9
11
13
14
1. Long tape measure
6. Side cutters
11. Center punch
2. Short tape measure
7. Rat-tail file
12. Rigging or black tape
3. Power drill
8. Hex keys (provided)
13. Scissors
4. Drill bit – 1/8" (3 mm)
9. Slotted/phillips screwdrivers
14. Metal straight edge
5. Hacksaw
10. Needle-nose pliers
15. Hammer
MKIV Unit 1
Although adhesive has not cured it will
remain in place on foil joints whether
they are left on the ground or raised up
on boat. Foils can be raised immediately
after assembly and sails fitted.
Note: A small amount of adhesive may
bulge out of injection ports. If possible
let system sit for a couple days before
sailing. If adhesive gets on sails remove
using acetone. For faster-curing adhesive,
purchase 4200 Fast Cure.
Note: Damaged foils can be repaired.
Use a hand-held propane torch to heat
joints until foils can be pulled apart.
5
Preassembly
Dimensions/Sailmaker's Instructions
Luff Length
Note offsets above and below sail.
A shorter luff may be required if a halyard restrainer is necessary
(page 27) or a toggle or long toggle assembly is used to raise drum.
If luff of sail is not long enough to put halyard swivel near top of
headstay foil, a pendant must be added (see page 26).
7"
(177 mm)
43/4"
(120 mm)
Tack Setback
Note setback for tack shackle and cut the sail accordingly.
Luff Tape Size
Unit 1 requires #6 (6/32" or 5 mm) luff tape.
Luff Tape Length
Cut off top of luff tape so it is 18 to 24" (450 to 600 mm) below head
of sail. This allows head to lag behind rest of sail to help flatten sail.
It will also help head to roll more smoothly.
Note feeder height and extend bottom of luff tape downward so it is
below feeder. This will prevent luff tape from catching in feeder as
sail is lowered.
Tack and Head Shackles
Make sure tack and head shackles fit sail
rings. Minimum inside dimensions of
standard head and tack shackles are:
(A) 11/16" (27 mm)
(B) 1/2" (13 mm)
Min
421/4" (1073 mm)
Max
461/4" (1175 mm)
2"
(51mm)
65/8"
(168 mm)
Sun covers may be installed on either side of the sail.
Be sure to match other sails in the customer's inventory.
Note: If a long link plate is used, add the following dimensions to feeder,
shackle and drum height (based on whether plate is used full-length or
shortened to one of five hole positions). Do not add to halyard swivel or top
terminal dimensions.
1/2" (12.7 mm) Clevis Pin
Add 131/2" to 63/8" (343 mm to 162mm)
5/8" (15.9 mm) Clevis Pin
Add 111/4" to 43/8" (286 mm to 111 mm)
27/8" (71 mm)*
5" (129 mm)**
Toggle Used
6
B
Sun cover
93/4" (247 mm)*
12" (305 mm)**
*1/2" (12.7 mm)
**5/8" (15.9 mm)
A
MKIV Unit 1
Preassembly
Toggle Deductions/Stay Into Foil Options
Use dimensions of Harken toggle below to build stay to correct length.
Tip: Turnbuckles should be 1/2– to 2/3rds open to allow shortening for new wire stretch and for
fine-tuning mast rake.
Thread
5/8"
37/8"
(98 mm)
- 18 LH
87/8"
(225 mm)
Crosspin
31/4"
(83mm)
Crosspin
Stud/Jaw
5/8" (15.9 mm)
Clevis Pin
Fork
Attachment
Tang
Attachment
Eye/Jaw Reversible
1/2" (12.7 mm)
Clevis Pin
Make sure your toggle
looks like this!
3"
(76 mm)
For tang-down installations,
switch plugs to this position.
*25/16" (59 mm)
**211/16" (68 mm)
Most boats have a chainplate with a single tang.
If boat has two plates forming a jaw, reverse
eye/jaw toggle so eye is down.
Important! Remove black plastic caps and
install them so crosspin will be 90 degrees
to lower clevis pin.
Jaw/Jaw
1/2" (12.7 mm)
Clevis Pin
Make sure your toggle
looks like this!
Long Link Plate w/Toggle
*1/2" (12.7 mm) Clevis Pin)
**5/8" (15.9 mm) Clevis Pin
Options for Snaking Stay into Foils
1. Swage stud at end of wire.
2. Open end of wire and install Norseman or Sta-Lok® stud after foil is assembled.
3. Rod adapter nosepiece for Harken rod adapter stud: Threaded nosepiece must
have a positive lock as well as adhesive. Use Harken stud with cotter pins
(see page 19).
WARNING! Using a threaded nosepiece with only adhesive at the
upper rod eye terminal may result in headstay system failure.
Make sure there is a mechanical lock.
MKIV Unit 1
7
Preassembly
Top Foil Length
Measure A and add to this chart
and length chart below
Inches
mm
B
.5*
13*
E
24.0
610
F
19.1
485
A
Make sure upper
measurement points
of A and pin-to-pin
are the same.
*Add 1.12" (29 mm) if using a Halyard
Deflector.
A
A
Pin
to
Pin
TOP FOIL LENGTH WORKSHEET
G
Total A+B+E+F+G
Alternate
Measurement
Point
1
Pin-to-Pin Length
2
Subtract ABEFG
3
Result (Pin-to-Pin – ABEFG)
B
C
–
Subtract D –
4
To find “D” pick number from chart below that is closest to,
but not greater than total from step 3.
Inches
mm
3 x 2133.6 = 6400.8
3 X 84 = 252
4 x 2133.6 = 8534.4
4 X 84 = 336
5 x 2133.6 = 10668
5 x 84 = 420
6 x 2133.6 = 12801.6
6 x 84 = 504
7 x 2133.6 = 14935.2
7 x 84 = 588
8 x 2133.6 = 17068.8
8 x 84 = 672
D
Example–If result from Step 3 is:
500 inches “D” = 420 inches 12000 mm “D” = 10668 mm
Result (C) Top Foil Length
5
Pin
to
Pin
Length Check
After completing worksheet above fill in A, C, D, and G below. Add
“A” through “G” to confirm total equals your pin-to-pin measurement.
Length Chart
Dimensions
A Center of Pin to Bottom of Terminal
B Bottom of Terminal to Top of Foil
C Top Foil Length
D Number of Foils ________ x 84" (2133.6 mm)
E Bottom Foil
F Bottom of Foil to Crosspin
G Crosspin to Clevis Pin
Inches
mm
.5*
13*
E
24.0
19.1
610
485
Pin-to-Pin Length
*Add 1.12" (29 mm) if using a Halyard Deflector.
G Toggle Distance from Lower Clevis Pin to Crosspin Hole
Toggle Part No.
7411.20 1/2
7311.20 1/2
7311.20 5/8
7311.21 1/2
7311.21 5/8
Type
Eye/Jaw reversible
Jaw/Jaw
Stud/Jaw
Long Link Plate w/Toggle
Long Link Plate w/Toggle
Clevis Pin
G Distance
12.7 mm 1.75" 44 mm
1/2"
12.7 mm 1.75" 44 mm
5/8"
15.9 mm 4.00" 102 mm
1/2"
12.7 mm 15.00" 381 mm
5/8"
15.9 mm 15.25" 387 mm
1/2"
Note: If long link plate is shortened, dimension must be changed or foil will be too short.
Measure distance from crosspin down to where clevis pin attaches toggle to boat and
use this dimension in G above.
8
MKIV Unit 1
F
G
Preassembly
Short Top Foil
21/2 (64 mm)
2" (51 mm)
11/2" (38 mm)
1" (25 mm)
7" (178 mm)
If top foil is shorter than 7" (177.8 mm), use one of the following special techniques to ensure sufficient bearing
surface for the foil in the area of the halyard swivel.
Cut-Offs
Do Not Use
6"–5" (150–130 mm)
7" (178 mm) No special treatment required.
21/2"–1" (64–25 mm) Shorten top foil and adjoining
full length foil so two screws are used to assemble joint
instead of four. Do not use plastic bushings above top
connector.
1. Initial
top foil
cut length
Top Foil
Length from
Worksheet
Cut-Offs
Do Not Use
41/2"–4" (115–100 mm)
6"–5" (152–130 mm) Do not use plastic bushing above
top connector.
57/8"
(149 mm)
41/8"
(105 mm)
2"
(51 mm)
53/8"
(137 mm)
11/2"
38 mm)
1"
(25 mm)
3. Shorten
full length
adjoining
foil by
cutting
through
middle
hole.*
4. Shorten
connector
5. Shorten
trim cap
Length
31/2"
(89 mm)
No
35/8"
(92 mm)
31/2"
(89 mm)
No
47/8"
(124 mm)
31/8"
(79 mm)
31/2"
(89 mm)
Yes
43/8"
(111 mm)
25/8"
(67 mm)
31/4"
(83 mm)
Yes
Cut-Offs
Do Not Use
*To allow for saw cut, position blade so upper half of
middle hole is preserved.
Under 1" (25 mm)
31/2"–3" (90–75 mm)
Cut-Offs – Do Not Use
31/2"–3" (90–75 mm) Do not use plastic bushing above
top connector. Cut connector right at cross formed by
glue dispersion channels. Use single foil screw in top
foil only.
Resulting Top
Foil Length
21/2"
(64 mm)
Cut-Offs
Do Not Use
41/2"–4" (115–102 mm) Do not use plastic bushing
above top connector. Shorten top of connector and if
necessary shorten trim cap.
2. Cut through
middle hole in
top foil.*
MKIV Unit 1
Under 1" (25 mm) Eliminate top foil and run foil higher
in drum assembly.
9
Preassembly
Confirm Foil Length
Confirm foil length by laying foils alongside
stay with turnbuckle components.
Pull stay out so it is straight. Attach Harken
toggle to bottom of stay. Make sure toggle
straps are straight. Adjust turnbuckle so
that length of stay with Harken toggle will
fit boat. Ideally, turnbuckle will be half to
two-thirds open to allow for rig adjustment.
Line up drum assembly so holes below
drum line up with holes in Harken toggle.
Make sure toggle is tensioned when
measuring.
Line up bottom foil so foil clamp is just
above or below center of notches in
bottom foil.
Note: Position top foil so that with top
cap the foil will ride 1/2" (13 mm) below
terminal. If wire fitting at top of stay is
swage, foil must ride just below shoulder
of swage. Mark cut line on foil. Wrap tape
around foil as a guide so cut is straight.
If 7302 Halyard Deflector is used, add 1" (25 mm)
10
MKIV Unit 1
Assembly
Top Foil
Cut foil to length using hacksaw.
Deburr inside edge using rat-tail file.
Prepare top foil for drilling.
Tip: Mark top foil to distinguish
from cutoff piece.
Scribe line on top of foil to mark drill
holes. Lay top foil alongside cut-off
piece and use a flat metal object
(i.e. metal ruler) to scribe top
line of foil.
MKIV Unit 1
11
Assembly
Top Foil
Cut out template at right. Line up template
with top of foil and scribed line. Tape in
place. Use a center punch to mark holes.
Check center punch marks to confirm
they are 3/16" (5 mm) and 1" (25 mm)
from top of foil.
Foil
Top
!
3/16" (5 mm)
Drill two (2) 1/8" (3.2 mm) holes for
trim cap.
Lay top foil in line with others. Slide stay
into top foil and down the line of foils or
slide each foil up stay.
12
MKIV Unit 1
1" (25 mm)
Assembly
Top Foil
Install trim cap. Place each side over wire.
Assemble Halyard Deflector if used.
Halyard Deflector
Red Loctite®
Push trim cap into foil to start, then tap
in using hammer.
Install trim cap screws.
Place halves of plastic bushings on stay so
hooked part of longer section faces out.
Tip: With foil screw holes up as shown
below, place longer half of bushing
with hook on upper half.
MKIV Unit 1
13
Assembly
Top Foil/Connectors
Slip 7" (177.8 mm) connector on wire,
mating hook of plastic bushing with
connector.
Put a drop of red Loctite® into screw holes.
14
MKIV Unit 1
AssemblyFoils/Connectors
Hold plastic wedge in place with thumb
as you insert into foil. Line foil holes
with connector screw holes.
Tip: In cooler weather, keep sealed
adhesive in pocket to keep warm. Use
instructions below to fill injector less
than half way; you will only use a small
amount of adhesive. Refill if needed
but do not keep open sealant for long
periods. Use adhesive within 3 hours.
Use cap of adhesive to break seal. Remove
injector tip cap and plunger. Hold injector
at an angle with applicator tip facing down.
Squeeze adhesive into tube so lower half
of injector is full as shown. Keep tip free
of sealant to let air inside.
Loading Injector with Adhesive
Adhesive in
lower half
Start plunger into injector and immediately
hold upright so plunger is down and
applicator tip is up.
As sealant runs down towards plunger an
air pocket will form near tip. Push plunger
to evacuate air. You are now ready to begin
injecting adhesive.
MKIV Unit 1
15
AssemblyFoils/Connectors
Inject only a small amount of adhesive into
middle hole. Unit 1 will only take 1/3–1/2
of a graduation mark.
Tip: When you see a small amount of
adhesive enter one of the screw holes,
stop. You have applied enough adhesive.
Stop when you see a small
amount of adhesive enter
one of the screw holes.
Tighten screws into connector holes. Make
sure a drop of red Loctite® entered each
screw hole. If not, apply to screw.
Red Loctite®
Use bushings, connector, wedge and
adhesive in other screw hole and
insert into other foil. Use 1/3–1/2 ml
of adhesive.
16
MKIV Unit 1
Use “ml”
marks to
estimate
1/3 to 1/2 ml
of adhesive
Assembly
Bottom Foil/Connectors/Halyard Swivel
Continue installing connectors and wedges.
Make sure to use red Loctite® in screw
holes.
Red Loctite®
Continue assembly. Use 10.75" (273 mm)
bottom connector to assemble bottom foil.
Slide halyard swivel onto foil above feeder
window. Make sure taller “half” is up as
shown.
MKIV Unit 1
17
Assembly
Drum Assembly
Loosen foil clamp screws at top of
drum assembly.
Slide drum assembly onto foils.
Tip: Face clamp downward so it
clears foil notches during installation.
18
MKIV Unit 1
Assembly
Rod Rigging: Rod Adapter Stud
ROD RIGGING
Apply a few drops of red
Loctite® to threads of nosepiece.
Screw main threaded stud
portion onto bronze nosepiece
until flats align with two cotter
pin holes in terminal body.
Tip: Turn nosepiece completely
into threaded stud portion.
Flats will be close and may
only require a small half turn
to align with cotter pin holes.
Insert two cotter pins and
spread. Clean excess Loctite®
from terminal body using
special care to ensure that
there is no red Loctite® on
threaded stud.
MKIV Unit 1
19
Assembly
Attach Turnbuckle/Toggle
Assemble turnbuckle and attach Harken
toggle.
Note: If using Sta-Lok® or Norseman®
stud, you must use a washer above
stud as shown below.
Washer
Turnbuckle
Clevis Pin
Crosspin
Up
Make sure shallow jaw is up.
Down
Jaw/Jaw Toggle Assembly
Eye/Jaw Toggle Assembly
20
Stud/Jaw Toggle Assembly
MKIV Unit 1
Toggle
Clevis Pin
Assembly
Attach Toggle/Long Link Plate
Make sure drum assembly
has four threaded holes in
base.
Determine height of link
plates to provide anchor
clearance and cut to length.
Cut at scribe mark. Deburr
edges.
Connect eye to toggle jaw
using special clevis pin.
Secure using cotter pin.
Toggle For Long Link Plates
Apply Isolator.
Fasten one long link plate to drum assembly
using fasteners. Use blue Loctite® on screws.
Blue Loctite®
Fasten second long link plate to drum
assembly and secure to toggle using
locknuts.
WARNING! Stay must attach
to toggle. Do not attach stay
to crosspin at drum assembly
because crosspin and plates
may fatigue and break.
MKIV Unit 1
21
AssemblyFinal
If stay length is set, use side cutters or
needle-nose pliers to bend cotter pin
to secure turnbuckle.
Slide lower drum assembly over turnbuckle
and attach using long crosspin.
Use plastic washers provided.
WARNING! Crosspin must be
90 degrees to clevis pin that
attaches unit to boat. If pins run
same direction toggle will fatigue
and could break suddenly.
Clevis Pin
Crosspin at 90°
to Clevis Pin
Check foil height at top, set, and secure
using hex key.
See tip on next page.
22
MKIV Unit 1
AssemblyFeeder/Final
Tip: Do not remove foil clamp screws
to adjust foil. Loosen screws, hold foils
and bring clamp away from foils. Adjust
and reclamp.
Slide halyard swivel above feeder. Place
feeder in foil recess. Push screw down
so tab catches under foil. Tighten screw.
Note: Screw will turn with some difficulty.
It is plastic coated to prevent loosening
due to vibration.
Important! When removing screw, loosen
no more than one full turn. Slide screw
up and remove feeder.
MKIV Unit 1
23
Commissioning
Turnbuckle on Boat
Have extra cotter pins on hand to replace used ones at base of
unit and for turnbuckle.
Hold foils and loosen drum assembly screws until you can pull
clamp out to lower foils.
Lower foils.
Remove crosspin holding drum assembly to turnbuckle.
Raise drum assembly and use halyard to lift and hold it about
5' (1.5 m). Raise foils using second halyard and secure. Allow
room above for turnbuckle take up.
CAUTION! Foils can drop suddenly causing injury to
hands. Make sure drum assembly and foils are securely
lifted using a halyard before adjusting turnbuckle.
Adjust turnbuckle.
Replace used cotter pins. Lower drum assembly and install clevis
pin and new cotter pin.
Lift foils so top is 5/8" (16 mm) below upper terminal.
WARNING! Stay must attach to toggle. Do not
attach stay to crosspin at drum assembly because
crosspin and plates may fatigue and break.
Crosspin
24
MKIV Unit 1
Commissioning Lead Line to Cockpit
Run line through enclosed window in guard and into hole
in bottom plate of spool. Tie a small overhand knot and
pull it up under drum assembly.
Enclosed Window
WARNING! Lead line through enclosed window. If
line is led through opening between two enclosed
windows it can ride above lineguard and jam
furler which can cause loss of control of boat.
Note location of sun cover. Charge system by rotating furler to wrap line on drum.
Tip: Sun cover to starboard—turn clockwise to charge. Sun cover to port—turn counter-clockwise.
Tension line while charging.
Mount Lead Blocks
Furling line can be led down either side of boat. If boat is in slip, consider mounting opposite dock.
Remove four screws on stanchion blocks. Clamp blocks to stanchions. See instructions below.
Tip: Start all four screws before tightening.
7401 Forward Stanchion Block
BOW
Position 7401 Forward Stanchion Block so line enters
drum at right angles to headstay and centers vertically
in opening. Install so line is inside stanchion.
Correct block position is critical to even line
spooling and ease of furling.
7401
FORWARD
STANCHION
BLOCK
7403 Outboard Stanchion Blocks
7403
OUTBOARD
STANCHION
BLOCK
Install 7403 Outboard Stanchion Blocks so line is
outside stanchions.
Number and placement of leads depends on boat
length and number/configuration of stanchions.
7402 Ratchet Stanchion Block
7403
OUTBOARD
STANCHION
BLOCK
7403
OUTBOARD
STANCHION
BLOCK
Mount 7402 Ratchet Stanchion Block as furthest-aft
lead to prevent line overrides in drum when unfurling.
Position ratchet block so line turns at least 90°.
Install so line is inside stanchion.
Lead line through block so ratchet makes
clicking sound when pulling line to furl sail.
Tip: Make sure ratchet switch is in “ON” position. If there is
no clicking sound, lead line through block in opposite direction.
Lead line to Furling Line Cleat in cockpit.
HCP168 Furling Line Cleat
7402
RATCHET
STANCHION
BLOCK
STERN
Install so line is angled as shown.
Use #10 (5 mm) fasteners.
Note: As furling line lead changes, make sure line
doesn’t chafe against line guard. Rotate line guard
if necessary.
MKIV Unit 1
Drum Full
(sail unfurled)
Drum Empty
(sail furled)
25
Commissioning
Halyard Wrap/Prevent Halyard Wrap
Halyard Wrap
The most serious problem with furling systems occurs when the jib halyard
wraps around the headstay foil. Halyard wraps will keep you from furling or
unfurling and may cause serious damage to the unit and the halyard.
WARNING! In severe cases, a halyard wrap can cause loss
of control of boat and/or headstay can break suddenly. Make
sure halyard is clear of top foil before using system.
If Halyard Wraps
If halyard wraps, do not force unit to turn. Attempt to open sail by carefully
furling in and out a little at a time. If sail will unfurl, lower it by releasing jib
halyard. Severe halyard wraps can only be cleared by a professional going
aloft and freeing halyard.
If sail will not furl or unfurl, try to remove jib sheets and manually wrap
sail around headstay.
WARNING! Do not go aloft on boat’s halyards if there has been a halyard wrap. Do not use boat. Damage
to halyard, headstay, stay terminals, or connections as a result of a halyard wrap may cause these parts to
break suddenly causing mast to fall down while person is aloft. Sailing or motoring with boat after a wrap
can result in the headstay breaking and mast falling down. Before using boat, have a professional rigger
inspect and replace parts as necessary using following methods.
A professional rigger must carefully inspect the masthead area using a secure hoisting method. Inform rigger that
there has been a halyard wrap so they can avoid an accident by relying on standing rigging or halyards. Inspection
must be done while rigger is suspended from a separate crane or mast must be lowered to perform inspection. Some
professionals may rig a new line through internal masthead sheaves to serve as a temporary headstay to hold mast in
place. Wire, rod rigging, terminals, toggles, clevis pins, or cotter pins must be inspected and replaced if they show any
signs of damage.
Prevent Halyard Wrap
To prevent wraps, the halyard must exert a slight pull to the rear. This allows
the foils to turn while halyard remains stationary.
WARNING! Sail must be fitted to foil length before using
to prevent halyard wraps and possible headstay loss.
1. Halyard swivel should be within top 4–6" (100–152 mm) of foil unless
a halyard restrainer is used.
2. Halyard must pull slightly to rear (8–10°).
3. Halyard must be snug, but not too tight.
Test furler at dock, but if water is smooth an incorrect lead angle may not
be apparent. Halyard wraps usually occur in wave action when lead angle
is not correct. The 8–10° angle shown at right is critical.
26
MKIV Unit 1
8–10°
CommissioningPendant/Halyard: Restrainer/Tension
Pendants
If the your sail luff is not long enough to position halyard swivel high
enough to create an 8–10° angle as shown, you must add a pendant.
Pendants should be made of plastic-coated wire and be permanently
attached so sail height will be correct. Adjustable- length pendants
are not acceptable, as they might not be adjusted
correctly during a sail change.
1. Raise sail, but do not attach tack shackle.
2. Position halyard swivel correctly near top of headstay.
3. Secure halyard.
4. Tie a piece of rope to sail tack.
5. Lead line through tack shackle on furling drum.
6. Tension sail.
7. Measure distance from tack shackle to sail tack and permanently
attach pendant of this length to head of sail.
8. Repeat procedure for every jib in your sail inventory.
Halyard Deflector/Halyard Restrainer
To prevent wraps, jib halyard must pull slightly to rear. On most boats,
halyard lead angle is acceptable if halyard swivel is raised to top of foil.
On some boats halyard sheaves are located too close to headstay and
a Halyard Deflector or Halyard Restrainer must be used.
Halyard restrainers should be used only when required by masthead
geometry. Restrainers tend to limit sail luff length and may cause
problems if not installed properly.
If your boat needs a Halyard Deflector, use Part No. 7302 or a Halyard
Restrainer, use Harken Part No. 944.
Restrainer should be mounted as high as possible on face of mast.
Position restrainer so that foils will not hit it when under load.
The restrainer should deflect halyard as little as possible or you may
experience difficulty in tensioning sail luff, friction when furling, and
possible damage to foils. To decrease deflection angles, shorten sail luff.
Tip: Boats used in charter service should have a halyard restrainer,
regardless of masthead geometry.
Halyard Deflector
Halyard Tension
The jib halyard should be firm, but not too tight.
Tip: The luff foil system supports sail along its length so halyard
tension is used only to shape sails, not to support them. Use enough
halyard tension to remove some wrinkles along luff of sail. Do not
tension halyard enough to cause vertical wrinkles in luff of sail.
Tension to adjust position of draft in sail to suit sailing conditions.
Halyard should be firm but not tight. If in doubt, release halyard
tension. To protect sail, ease halyard when boat is not in use.
Halyard Restrainer
MKIV Unit 1
27
Operation
Halyards/Headstay Tension
Spinnaker Halyards
Spinnaker halyards occasionally cause problems
with furling.
WARNING! In severe cases, spinnaker
halyards can jam furler causing loss of
control of boat. Make sure halyards are
clear of top of foils and halyard swivel.
On many boats it will not be possible to attach
spinnaker halyard to bow pulpit or it may be
"sucked" into jib when furling.
On some boats the spinnaker halyard lays across
headstay and will catch on halyard swivel, foils or
jib halyard. To prevent problems it may be necessary
to install a masthead bail to move spinnaker halyard
block forward and to one side.
Boats with external halyards may find it necessary to
flip both ends of spinnaker halyard behind spreaders
to prevent fouling with furling system.
Headstay Tension
A furling system will work best if headstay is tight.
A loose headstay is difficult to rotate and can cause
unusual wear on foil joints.
To adjust headstay tension, remove sail and furling line
from unit and follow instructions on page 24.
Tip: Before adjusting headstay tension, slack
mainsheet and vang.
Backstay Adjusters
Backstay adjusters allow headstay tension to be varied to change sail shape to
match conditions. They permit a very tight headstay to be eased when boat is not
in use. For best performance, consider adding a backstay adjuster; either a block
and tackle, a mechanical adjuster like those offered by Harken, or a hydraulic adjuster.
Remember to keep headstay tight for best performance when furling or reefing.
If your boat is fitted with an adjuster be sure that it is tensioned before the halyard
is tensioned. If not, backstay adjuster may increase halyard tension and could
damage the sail or furling system.
Racing boats often slack the headstay completely when sailing downwind. Check
to be sure that foil does not jam against upper headstay terminal when backstay
is released. To prevent this, it may be necessary to shorten foil slightly.
28
MKIV Unit 1
Operation
Sail: Raise/Storm/Reef
Raise Sails
1)
2)
3)
4)
5)
6)
7)
Install prefeeder by securely tying end of line to a deck fitting or to toggle
below furler so it is 2' (610 mm) below feeder.
Shackle tack of sail to drum. Install shackle so screw pin head is on same
side as sun cover.
Secure genoa sheets to clew of sail.
Attach genoa halyard to halyard swivel.
Pass luff tape through prefeeder and feeder into foil groove.
Attach head of sail or pendant at head of sail to halyard swivel.
Hoist sail.
Tip: New sails are often stiff and may hang up on prefeeder during raising.
Do not force sail when it hangs up—lower and remove twist. Sails "break
in" with use and will become easier to raise.
Storm Sails
Most people will use one multi-purpose genoa for all their sailing, but it is not good seamanship to go offshore
without storm sails.
Heavy-air working jibs and storm sails may be used with your unit. These sails need to have luff tape added to allow
them to be raised in headstay foils.
These sails will generally require pendants to ensure that halyard swivel is properly positioned at top of headstay.
See page 26.
Remember that heavy-air working jibs and storm jibs may be reefed and furled like any other sail.
Furl and Reef
To furl or reef, ease the jib sheets and pull
furling line.
In very light air, it may be necessary to place
some tension on jib sheet to insure a tight furl.
In a breeze, you must completely luff sail by
totally slacking jib sheets before furling.
The furling line should pull readily. The amount
of force required is related to amount of wind,
but a Unit 1 should never require use of a winch
to furl. If the sail will not furl, or if furling requires
a great deal of effort, there is a problem with system. Consult the Troubleshooting
Guide on Page 33. Do not use a winch to force a system to turn. If you are certain
that the system is operating properly, you may use a winch to make furling easier.
MKIV Unit 1
29
Operation
Reef/Secure Sail
Reef
A sail may be partially furled before you resume
sailing. This is known as reefing.
Many sailors find it helpful to place marks on
foot of sail so that they can reef to a variety of
predetermined jib sizes. This allows marks to be
placed on jib lead tracks or toe rail so that lead
block position can be changed to correspond
to reefed jib.
Sails are generally reefed to balance boat and to
reduce heeling moment. Sails may also be reefed
to improve visibility or to slow boat while sailing
in congested areas or entering or leaving harbors.
Secure Sail
When furling the sail completely, make sure sheets and furling line are
secured. Check amount of line on the spool compared to the furled sail
a. 2–3 wraps
before using the system.
A furled sail must have:
a. Two to three wraps of jib sheet wrapped around sail.
b. Two wraps minimum of line wound on spool.
c. Furling line securely cleated.
d. Jib sheets securely wrapped on winch and held in self-tailing jaws.
Furl at dock with tension on sheets to duplicate furling in high wind.
Remember sails furled in light wind and left loosely secured can be a problem
if wind increases.
IMPORTANT! Remove sail from furler if extreme winds are predicted,
especially if boat is left unattended.
IMPORTANT! Check all points above—a, b, c, and d—when leaving boat to
avoid damage to furler or boat.
A loosely rolled sail can catch wind in a storm. Sheets or furling lines can
loosen as winds increase and allow furler to unroll. If no wraps of line are
on spool, the line deadend can break the drum when the boat motors
through waves.
Be sure mooring lines are not placed across furling line where they may
cause chafe.
If you want to:
Add more wraps of
jibsheet on furled sail. Untie jib sheets and keep sail
completely rolled. Secure with
Add more wraps of line
sail tie.
on spool.
30
Turn spool to unroll a
couple of wraps of line.
Turn spool to add a
couple of wraps of line.
MKIV Unit 1
Retie sheets.
b. 2–3 wraps
Operation
Race conversion allows use of both grooves
for sail changes and tacking genoas on deck
for use of maximum luff length genoas.
Race Conversion
Remove Feeder
Halyard Swivel Below Feeder
Use halyard to lift halyard swivel up, away
from feeder. Loosen screw one revolution
only. Slide screw up and hold. Remove
feeder carefully—bottom end first. Don’t
lose the feeder overboard! Lower swivel
onto drum assembly. Replace feeder.
Halyard Swivel Off Furler
Loosen screw one revolution only.
To Remove
Feeder For
Racing
Serious racers may want to remove the
halyard swivel.
Note: It is not possible to remove halyard
swivel on a unit with a Norseman/Sta-Lok®
or rod adapter stud unless you disassemble
terminal stud. Make sure you use a new
Norseman/Sta-Lok® wedge to reassemble
Norseman/Sta-Lok® fitting.
1) Remove drum assembly.
2) Rig a secure, temporary headstay.
3) Loosen backstay, mainsheet and vang
so that headstay goes slack.
4) Remove clevis pin holding furling unit
to chainplate.
5) See adjusting turnbuckle on page 24.
Remove turnbuckle body and lower
unit and slide off halyard swivel.
6) Reattach headstay to boat.
Slide screw up and hold.
1.
2.
1. Loosen screw
one revolution only.
2. Slide screw up.
Remove feeder.
3. Lower halyard
swivel.
Carefully remove feeder–bottom end first.
Don't drop the feeder overboard!
Remove Drum
1) Remove sail and unwind line from drum.
Line can remain attached to drum.
2) Use 5 mm hex key provided to remove
2 screws on bottom of guard assembly
and remove two halves. Be careful—
screws are not captive.
3) Use a 2.5 mm hex key to loosen four
screws in plastic cover and flange.
MKIV Unit 1
31
Maintenance
Clean/Inspect/Remove Furler
Clean and Lubricate
Keep unit clean. When you wash boat, flush unit with
soap and fresh water. Occasionally lower sail and flush
halyard swivel with soap and fresh water.
At least twice a year unit should be cleaned more
thoroughly by removing line (first note direction of
spool) and flushing bearings with soap and fresh water.
After unit has dried, apply a dry spray lubricant such as
McLube®.
Foils may be cleaned by washing with soap and water.
A scrap of luff tape may be run up foil to scrub inside
grooves. If lubrication is required, spray a thin coat of
McLube® SailKote on sail luff tapes away from boat deck.
WARNING! Periodically inspect items listed
below and any others as necessary. Failure
to inspect can cause an accident.
WARNING! Do not spray foil on boat. McLube®
will cause slippery decks which may result in
loss of footing, falling overboard.
Inspect
Inspect unit for signs of chafe, wear, or damage.
Inspect clevis and cotter pins below and inside drum assembly for
signs of loosening. Check headstay tension for signs of loosening.
Inspect swage fitting and lower toggle for signs of stress
corrosion.
Inspect Norseman or Sta-Lok terminal or rod terminal for
signs of loosening.
Inspect all screws on unit to be sure they have not loosened.
Inspect foil to make sure that it has not dropped into drum
assembly. Periodically inspect wire for signs of wear or unraveling.
Replace Line
Use HFG233 furling line or source a good quality line with good wear characteristics. Use 9/32" (7 mm) line with
break strength exceeding 2500 lbs (1130 kg). Smaller boats or smaller sails may allow 5/16" (8 mm) line. If a larger
diameter line is desired, consult with a rigger about using tapered line with a high strength core and cover removed
in forward part of line.
Storage – Mast Down
In areas where it freezes, do not store system where water can accumulate in foils. When water freezes it will rupture
aluminum. Store foils under cover, with grooves facing down or on an angle so water will run out.
Storage/Transporting
Do not store or transport system with drum assembly extending beyond mast. Remove masthead clevis pin and shift
furler up so drum assembly can be strapped securely to mast. Some people remove drum assembly and halyard swivel
for storage and transport.
After Storage or Transport
After storing or transporting unit, clean thoroughly including ball bearings. See instructions above.
Loosen Foil Clamp Before Slacking Backstay
In order to prevent foils from locking against upper stay terminal when backstay is released, loosen foil clamp screws and
lower foil before loosening backstay.
32
MKIV Unit 1
Troubleshoot
Problem
Sail will not furl or
is difficult to furl.
Sail will not unfurl
or will not unfurl
completely.
Probable Cause
Solution
Jib halyard is wrapping around headstay because
angle between mast and and halyard is too shallow
See installation instructions regarding optimal halyard angle. It may be necessary
to mount a halyard restrainer on front of your mast to hold halyard to rear.
Jib halyard is wrapping around the headstay
because halyard swivel is too low.
See installation instructions regarding optimal halyard swivel height. A wire pendant
may be needed at head of sail to raise halyard swivel to proper height.
Jib halyard is too tight.
Ease jib halyard.
Foils riding on turnbuckle.
Raise foils. See adjusting turnbuckle on page 24.
Foils too high, binding on swage eye.
Lower foils until clear. See adjusting turnbuckle on page 24.
Spare halyard is wrapping in sail as it furls.
Secure spare halyards away from furling headstay by flipping them behind spreaders
Salt or dirt in bearings.
Flush bearings frequently with fresh water and a detergent solution.
Furling line tangled in drum.
Overrides are best prevented by using a 7402 ratchet block as the last furling line lead to
maintain proper drag on line while unfurling.
Stop knot catching.
Make sure knot is a single overhand and is pushed up inside drum.
Sail full of wind.
Luff completely before furling or reefing.
Sail flogging too much.
Release a short length of sheet, pull some furling line and repeat.
Jib sheets are not free.
Free jib sheets.
Foil out of drum assembly.
Reinstall foil in drum assembly and tighten clamp screws.
No wraps of furling line on drum.
Remove sheets. Rotate stay wrapping as much furling line on drum as possible.
Lineguard assembly has slipped down.
Tighten line guard assembly screws securely.
Line through 7402 ratchet backwards.
Rerun line.
Halyard swivel installed upside down.
Remount swivel correctly.
Jib halyard is wrapping around headstay because
angle between mast and halyard is too shallow.
See installation instructions regarding optimal halyard angle. It may be necessary to
mount a halyard restrainer on front of your mast to hold halyard to rear.
Jib halyard is wrapping around the headstay
because the halyard swivel is too low.
See installation instructions regarding optimal halyard angle.
Foils riding on turnbuckle.
Raise foils. See adjusting turnbuckle on page 24.
Foils too high, binding on swage eye.
Lower foils. See adjusting turnbuckle on page 24.
Jib halyard is too tight.
Ease jib halyard.
Spare halyard is wrapping in sail as it furls.
Secure spare halyards away from furling headstay by flipping them behind spreaders
Salt or dirt in bearings.
Flush bearings with freshwater and lubricate with dry spray lubricant such as McLube®
Furling line is not free.
Free furling line.
Sail will not furl
completely.
Insufficient furling line on drum.
Remove sheets. Rotate stay, wrapping as much furling line on drum as possible.
Too much line on drum.
Adjust amount of line on drum or change position of forward lead block to allow line
to roll evenly on drum.
Spare halyard catching in sail as it furls.
Move halyards away from furling headsail as above.
Headstay rotates in
jerks or elliptically.
Insufficient tension on headstay.
Tighten headstay and/or backstay to eliminate sag in headstay.
Sail does not stay
furled.
Sail not furled tightly on stay.
Maintain drag on sheets while furling.
Furling line not secure.
Secure furling line.
Sail will not go up.
Luff tape will not go into groove.
Check luff tape for fraying.
Check luff tape size.
Sail catching at prefeeder.
Flake sail more loosely on deck.
Dirt in groove.
Clean groove.
Sail will not raise
completely or luff
will not tension.
Halyard swivel is hitting end stop.
Luff of sail is too long and must be recut.
Angle between halyard and mast is too sharp
and halyard is pulling too much to the rear.
Halyard must be routed from a point higher on mast. This may require that any halyard
turning blocks aloft be replaced or sail shortened.
Sail will not
come down.
Halyard is wrapping on headstay.
Angle between headstay and halyard is too shallow and must be optimized per installation
instructions.
Halyard swivel off foil.
Sail luff too long or foil is too short or low and must be lengthened or raised.
Ultravoilet cover rolls
up inside of sail.
Furling line is wrapped on drum in wrong direction.
Remove sheets. Pull line to remove all furling line from drum. Turn stay to rewind line on
drum in opposite direction. Line guard and cowling alignment may need to be adjusted.
Line jams between guard
and plastic spool plate.
Line is not led through windows.
Pull line through enclosed window.
McLube™ is a registered trademark of McGee Industries, Inc.
Sta-Lok® is a registered trademark of Sta-Lok Terminals, Ltd.
Torlon® is a registered trademark of Solvay Advanced Polymers
Delrin® is a registered trademark of E. I. du Pont de Nemours and Company or its affiliates.
Igus® is a legally registered trademark of Igus® GmbH and/or Igus® Inc.
Loctite® is a trademark of Henkel AG & Company KGaA
Warranty
www.harken.com/manuals
or call, write, email or fax Harken, Inc.,
Pewaukee, WI USA
Online Product Registration
www.harken.com/FurlingWarranty
MKIV Unit 1
33
Parts List
HFG686
MKIV Unit 1
1
HFS980
H-35665D
HFG687
HFS980
1
HFG688
H-35600C
H-35199E
2
HFS1052
HFG696
HFS827
H-42954
2
3
4
5
3
Pin Measurements
4
6
*Grip
Length
7411.10BASE
*Pin measurements
are "Grip Length."
4
MP-129
H-35144A
MP-118
H-35144A
MP-118
H-35144A
H-35144A
MP-118
H-35144A
MP-118
3
2
5
1
7422   -8
7423 -10
7424 -12
H-36636A
8
5
8
5
55
2
3
7412.20 1/2
7411.20
5/8
4
1
4
3
4
6
5
5
5
4
2
5
6
7312.20 1/2
7311.20
5/8
3
1
34
7
1
3
5
7311.20
7312.205/8
3/4
77
7
6
3
4
6
2
2
2
5
3
8
7
7
6
8
6
4
7
7424 -12
7424 -17
3
1
3
7311.21 1/2
7311.21 5/8
6
4
9
MKIV Unit 1
Description
Top Cover Assembly w/Screws
Top Cover
Top Cover Screw (M4 x .7 x 10MM)
Bottom Flange Assembly w/Screws
Flange
Bottom Flange Screw (M4 x .7 x 10MM)
Guard Assembly
Guard Set
Guard Screw (M6 x 1 x 40MM SHCS)
Clamp with Screws
Clamp
Clamp Screw (M5 x .08 x 12MM SHCS)
Hub Assembly
Ball Plugs
Torlon® Ball Bearing
Delrin® Ball Bearing
IGUS® Crosspin Bushing
Order
Part No.
1
HFG686
2
H-35665D
2
HFS980
1
HFG687
2
H-35600C
2
HFS980
1
HFG688
2
H-35199E
2
HFS1052
1
HFG696
1
H-42954
4
HFS827
1
7411.10BASE
5
H-35144A
24
MP-129
96
MP-118
2
H-36636A
No.
Description
Rod Adapter Stud w/Nosepiece (-8)
1 Stud (Main Body)
2 Nosepiece (-8)
3 Cotter Pin (3/32" x 1" 18-8)
Rod Adapter Stud w/Nosepiece (-10)
1 Stud (Main Body)
2 Nosepiece (-10)
3 Cotter Pin (3/32" x 1" 18-8)
Rod Adapter Stud w/Nosepiece (-12)
1 Stud (Main Body)
2 Nosepiece (-12)
3 Cotter Pin (3/32" x 1" 18-8)
Order
1
1
1
2
1
1
1
2
1
1
1
2
Part No.
7422 -8
H-41536
H-41534
HFG193
7423 -10
H-41536
H-41535
HFG193
7424 -12
H-41531
H-41527
HFG193
No.
Description
Eye/Jaw Toggle Reversible
1 Toggle
2 Crosspin (5/16" x 211/16")
3 Nylon Washer
4 Cross Hole Plug
5 Clevis Pin (1/2" x 11/2")
6 Cotter Pin (1/8" x 1" 18-8)
7 Cotter Pin (3/32" x 3/4" 18-8)
Jaw/Jaw Toggle
1 Toggle
2 Crosspin (5/16" x 211/16")
3 Clevis Pin (1/2" x 11/2")
4 Cotter Pin (1/8" x 1" 18-8)
5 Cotter Pin (3/32" x 3/4" 18-8)
6 Nylon Washer
Stud/Jaw Toggle
1 Toggle
2 Crosspin (5/16" x 211/16")
3 Clevis Pin (5/8" x 11/2")
4 Stud
5 Cotter Pin (1/8" x 1" 18-8)
6 Cotter Pin (3/32" x 3/4" 18-8)
7 Nylon Washer
Order
1
1
1
2
2
1
1
1
1
1
1
2
2
1
2
1
1
1
2
1
3
1
2
Part No.
7411.20 1/2
H-37675C
H-42396
HFS1109
H-42049
H-42395
HFS220
HFS181
7311.20 1/2
H-42336
H-42396
H-42395
HFS220
HFS181
HFS1109
7311.20 5/8
H-41300
H-42396
H-42397
H-43207
HFS220
HFS181
HFS1109
No.
Description
Order
Part No.
Long Link Plate w/Toggle
7311.21 1/2
1 Toggle
1
H-42159
2 Strap
2
H-42178
3 Upper Clevis Pin (Custom)
1
H-42170
4 Lower Clevis Pin
1
H-42395
5 Isolator
2
H-42182
6 Cotter Pin
2
HFS220*
7 Nylon Locking Nut (M10)
2
HFS846
8 Allen Cap Screws (M6x1x12MM SHCS)
4
HFS876
9 Loctite® Blue
1
833
* (1/8" x 1" 18-8) **(5/32" x 11/4" 18-8)
Part No.
7311.21 5/8
H-41300
H-42178
H-42171
H-42397
H-42182
HFS203**
HFS846
HFS876
833
MKIV Unit 1
Parts List
HFG680
HFS1126
HFG629
H-36125A
MP-129
8
H-39812
MP-129
HFS1105
7411.30
MP-129
H-36125A
7411.FOIL SET
7411.31
7411.32
HFG343
8
H-42062
H-42063
H-39625
7411.31
7411.32
H-39683
HFG625
7411.33
HFG295
9
HFG299
Description
Trim Cap Set w/o Screws
Trim Cap Screw Set
Trim Cap Screw
Halyard Swivel w/o Shackles
Torlon® Ball Bearings
Clip/Smalley Ring
Foil Set
Foil (7' / 2.13 m) Luff
Foil (2' / 610 mm) Bottom
Foil Screw Set
Foil Screw
Connector Set w/o Bushings
Connector (7" / 178 mm)
Connector Bottom (10.75" / 273 mm)
Connector Bushing Set
Connector Bushing (Curved / Longer)
Connector Bushing (Flat / Shorter)
Connector w/Bushings, Foil Screws, and Wedges
Connector (7" / 178 mm)
Connector Bushing (Curved / Longer)
Connector Bushing (Flat / Shorter)
Foil Screw
Connector Wedge
Connector w/Bushings Bottom
Connector Bottom (10.75" / 273 mm)
Connector Bushing (Curved / Longer)
Connector Bushing (Flat / Shorter)
Connector Wedge Set
Connector Wedge
Feeder Set
Feeder
Feeder Screw
Tab
Description
Instruction Manual
Prefeeder
Loctite® Red
5200 Adhesive Set
5200 Marine Adhesive Sealant
Injector
7 mm Double Braid Polyester (70' / 21.3 m)
MKIV JIB REEFING & FURLING
Unit 2
Installation Manual – Intended for specialized personnel or expert users
4118/12-12-2012
Preassembly
Safety Precautions/Parts Descriptions
Parts Description
Tools
Dimensions/Sailmaker's Instructions
Toggle Deductions/Stay Into Foil Options
Top Foil Length
Short Top Foil
Foil Length
2–3
4–5
5
6
7
8
9
10
4417
10
Assembly
Foils/Connectors
Halyard Swivel
Drum Assembly
Rod Rigging
Turnbuckle
Toggle
Final
11–17
17
18
19
20
20–21
22–23
Commissioning
Turnbuckle
Line to Cockpit
Halyard Wrap/Prevent Halyard Wrap
Pendanta/Halyard: Restrainer/Tension
24
25
26
27
Operation
Halyard/Headstay Tension
Raise Sails
Furl/Reef
Secure Sail
Race Conversion
28
29
29–30
30
31
Maintenance
Clean/Inspect
Replace Line
Storage
Remove Furler
32
32
32
32
Troubleshoot
30
Warranty
30
Appendix
HFG739
7404
Please read these instructions carefully before installing, servicing, or operating the equipment.
This manual may be modified without notice. See: www.harken.com/manuals for updated versions.
PLEASE SAVE THESE INSTRUCTIONS
HFG722
947
HFG200/HFG201
HFG233
9
10
2110
944
7302
HFG643
HFG640
HCP1387
MKIV Unit 1
Description
Lead Block Kit
29 mm Outboard Lead Assembly
57 mm Carbo Ratchet Assembly
40 mm Carbo Assembly
Horn Cleat
Bow Shackle (6 mm)
Halyard Restrainer
Sheave/SS Inner Race Only
Clevis Pin (1/4" x .9" 18-8)
Bracket-Small
Cotter Pin (1/16" x 1/2" 18-8)
Halyard Deflector
Hex Keys
5 mm
4 mm
2.5 mm
Order
1
1
3
1
96
2
1
6
1
1
30
1
5
1
1
12
12
1
1
2
2
4
2
1
1
2
2
1
14
1
1
1
1
Order
1
1
2
1
1
Part No.
HFG680
HFG629
HFS1126
H-39812
MP-129
H-36125A
7411.FOIL SET
7411.30
7411.33
HFG343
HFS1105
HFG625
—
—
HFG295
H-42062
H-42063
7411.31
—
—
—
—
—
7411.32
—
—
—
HFG299
H-39625
H-39683
H-35623B
HFS1129
H-35666A
1
Part No.
4417
947
HFG739
HFG725
HFG722
HFG200
HFG201
HFG233
Order
1
3
1
1
1
3
1
1
1
1
1
1
Part No.
7404
7403
7402
7401
HCP168
2110
944
944ASSY
HFG467
HCP393
HFS118
7302
1
1
1
HFG643
HFG640
HCP1387
1
35
Corporate Headquarters
N15W24983 Bluemound Rd, Pewaukee, WI 53072 USA
Telephone: (262) 691-3320 • Fax: (262) 701-5780
Web: www.harken.com • Online Catalog: www.harkenstore.com
Email: [email protected]
Harken Australia Pty, Ltd.
1B Green Street, Brookvale, N.S.W. 2100, Australia
Telephone: (61) 2-8978-8666 • Fax: (61) 2-8978-8667
Web: harken.com.au • Email: [email protected]
Harken France
ZA Port des Minimes, BP 3064, 17032 La Rochelle Cedex 1, France
Telephone: (33) 05.46.44.51.20 • Fax: (33) 05.46.44.25.70
Web: harken.fr • Email: [email protected]
Harken Italy S.p.A.
Via Marco Biagi, 14, 22070 Limido Comasco (CO) Italy
Telephone: (39) 031.3523511 • Fax: (39) 031.3520031
Web: harken.it • Email: [email protected]
Harken New Zealand, Ltd.
30-36 Fanshawe Street, P.O. Box 1951, Auckland 1001, New Zealand
Telephone: (64) 9-303-3744 • Fax: (64) 9-307-7987
Web: harken.co.nz • Email: [email protected]
Harken Polska SP ZOO
ul. Rydygiera 8, budynek 3A, lokal 101, I piętro, 01-793 Warszawa, Poland
Tel: +48 22 561 93 93 • Fax: +48 22 839 22 75
Web: harken.pl • Email: [email protected]
Harken Sweden AB
Main Office and Harken Brandstore: Västmannagatan 81B
SE-113 26 Stockholm Sweden
Telephone: (46) 0303 61875 • Fax: (46) 0303 61876
Mailing address: Harken Sweden AB, Box 64, SE -440 30 Marstrand
Web: harken.se • Email: [email protected]
Harken UK, Ltd.
Bearing House, Ampress Lane, Lymington, Hampshire S041 8LW, England
Telephone: (44) 01590-689122 • Fax: (44) 01590-610274
Web: harken.co.uk • Email: [email protected]
Please visit: http://www.harken.com/locator.aspx
to locate Harken dealers and distributors
Printed in USA 4417 7/13
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