Cruising Jib Reefing & Furling Installation Manual Unit 1, 2

Cruising
Jib Reefing & Furling
Installation Manual
Unit 1, 2
WARNING! Strictly follow all instructions to avoid an
accident, damage to your vessel, personal injury, or death.
See www.harken.com for additional safety information.
Table of Contents
Preassembly
Operation
Parts4–5
Tools
6
Dimensions/Sailmaker's Instructions
7
Toggle Deductions, Stay Into Foil Options
8
Top Foil Length Worksheet—Unit 1
9
Top Foil Length Worksheet—Unit 2
10
Short Top Foil 11
Foil Length
12
Halyard/Headstay Tension
Raise Sails
Furl/Reef
Secure Sail
24
25
23–24
26
Maintenance
Clean27
Inspect
27
Replace Line
27
Storage
27
Remove Furler
27
Assembly
Foils/Connectors13–15
Halyard Swivel
13
Drum Assembly
13
Rod Rigging
14
Adjust Turnbuckle
17
Toggle
17–18
Final
17–18
Troubleshooting
Warranty
Parts
Commissioning
Turnbuckle20
Line to Cockpit
21
Halyard Swivel Height/Angle
22–23
Halyard Restrainer/Tension
7
21
6
5
3
4
1
Parts Descriptions
1) Toggle Assembly
2) Crosspin
3) Shackle
4) Drum Assembly
2
2
5) Foil Clamp Screws
6) 2' (610 mm) Bottom Foil
7) Connector Isolator
8) Connector
Unit 1, 2 Cruising
9) 7' (2.13 m) Foil
10) Connector Screws
11) Halyard Swivel
12) Trim Cap
13) Trim Cap Screws
08/23/10
Preassembly
Sizing Check
13
12
11
Size Check
10
Check headstay and clevis pin dimensions in chart below.
9
7
8
WARNING! Harken does not recommend drilling boat's chainplate
or toggle as this may result in rig failure which will cause an accident,
damage to your vessel, personal injury, or death. See www.harken.
com for additional safety information.
Will drum fit on bow? See page 7. If necessary use an additional toggle
to slightly raise the unit. To clear anchor use Harken Long Link Plates,
which can be cut to various lengths.
UniPart No.
Description
7311.10
Cruising Unit 1
Toggle Part No.
7411.20 1/2
7311.20 1/2
7311.20 5/8
7311.21 1/2
7311.21 5/8
Part No.
Description
Eye/jaw reversible
Jaw/jaw
Stud/jaw
Long link plate w/toggle
Long link plate w/toggle
Description
7312.10
Cruising Unit 2
Toggle Part No.
7412.20 5/8
7312.20 5/8
7312.20 3/4
7312.21 5/8
7312.21 3/4
Description
Eye/jaw reversible
Jaw/jaw
Stud/jaw
Long link plate w/toggle
Long link plate w/toggle
Wire Ø
UNIT 2
UNIT 1
1/4", 9/32", 5/16"
6 mm, 7 mm, 8 mm
Rod Ø
-8, -10
5.72 mm, 6.35 mm
Chainplate Clevis Ø
1/2"
12.7 mm
1/2"
12.7 mm
5/8"
15.9 mm
1/2"
12.7 mm
5/8"
15.9 mm
Wire Ø
Chainplate Clevis Pin
5/16", 3/8", 7/16" 8 mm, 10 mm, 11 mm, 12 mm*
Rod Ø
-12, -17, -22
7.14 mm, 8.38 mm, 9.53 mm
Chainplate Clevis Pin Ø
5/8"
15.9 mm
5/8"
15.9 mm
3/4"
19.1 mm
5/8"
15.9 mm
3/4"
19.1 mm
*7/16", 11 mm and 12 mm requires large bore H-41009 isolators. They have a “12” stamped on
the outside. H-41009 Isolators are shipped with 7412.20 3/4 stud jaw toggle and 7312.21 3/4
long link plate assembly
08/23/10
Unit 1, 2 Cruising
3
Parts
Bottom Foil
w/Feeder
Foils
Halyard Swivel
Line
Drum Assembly
Main Components
Description
Part No.
Qty
Drum Assembly
HFG146
1
2'(610 mm) Bottom foil
7311.33
1
7311.30
6
7'(2.13 m) Foil
Unit
1
Halyard Swivel
H-36596C
1
7mm Double braid polyester line
HFG233
70'(21.3 m)
Drum Assembly
HFG188
1
7312.33
1
7312.30
8
2'(610 mm) Bottom foil
7'(2.13 m) Foil
Halyard Swivel
8mm Double braid polyester line
4
2
H-37317C
1
HFG235
100' (30.4 m)
Unit 1, 2 Cruising
08/23/10
Parts
Red Loctite®
Blue Loctite®
Trim Cap Set
Trim Cap
Screw Set
Connector Isolators
Connector Screw Set
Connectors
Foil Clamp
Screw Set
Other Components
Description
Unit
Part No.
Qty
Size
HFG182
1
—
Trim cap screw set
HFS1127
3
—
Red Loctite® (foil screws)
HFG739
2
—
Trim cap set
(H-37443B/H-37444B)
833
1
—
7311.31F
6
6" (152 mm)
H-41008
6
—
HFG149
1
—
Foil clamp screw set
H-41153
3
—
Bow shackles
2110
HFG197
3
6 mm
1
—
Trim cap screw set
HFS1127
3
—
Red Loctite (foil screws)
HFG739
2
—
833
1
—
7312.31F
8
9" (229 mm)
Blue Loctite® (foil clamp screws)
Connectors
Connector isolators
1
Connector screw set
(30 - HFS980)
Trim cap set
(H-37445B/H-37446B)
®
Blue Loctite® (foil clamp screws)
Connectors
H-37330C
8
—
Connector isolator for 7/16", 11 mm, 12 mm Wire*
H-41009
9
—
Connector screw set
HFG196
1
—
H-41154
3
—
Connector isolators
2
Bow Shackles
Allen Wrenches
Allen Wrenches (Supplied)
Unit
Qty
1
1 Each
2117
M3, M4, M6
2
Bow shackles
3
8 mm
*H-41009 Connectors are shipped with 7312.20 3/4 stud/jaw toggle and 7312.21 3/4 long link plate w/toggle for use with 7/16", 11 mm or 12 mm wire.
1 Each
Foil clamp screw set
10/19/10
(38 - HFS1060)
Unit 1, 2 Cruising
Description
M2.5, M4, M5
5
Preassembly
Rigging Parts Check/Tools
WARNING! Headstay condition should be
1. Harken toggle assembly required. Sold separately.
checked by a professional rigger before
2. Mating turnbuckle components must be purchased separately.
reusing. Wire that is old or damaged
3. Headstay may require cutting and shortening to fit Harken
may break suddenly causing an accident,
toggle. Headstay may remain uncut by replacing lower stud
damage to your vessel, personal injury,
of turnbuckle with stud/eye thus eliminating extra toggle.
or death. See www.harken.com for
4. Rod rigging requires Harken rod adapter stud.
additional safety information.
5. Order Harken 7404 Lead Block Kit and one additional 7403 if necessary. Fits 1" (25 mm) stanchions.
ROD RIGGING
Harken Rod Adapter
Stud Required
(Sold Separately)
ALL UNITS
Harken Toggle (Sold Separately)
Stud/Jaw Toggle
Unit
1
Part No.
7311.20 5/8
5/8"
2
7312.20 3/4*
3/4"
Thread Ø
- 18LH
- 16LH
Jaw/Jaw Toggle
Eye/Jaw Toggle
Unit
1
Unit
1
Part No.
7311.20 1/2
2
7312.20 5/8
2
7404 Lead Block Kit
(Sold Separately)
Long Link
Plate w/Toggle
Part No.
7411.20 1/2
Unit
7412.20 5/8
1
*Includes 9 H-41009 large bore connector isolators
for use with 7/16", 11 mm or 12 mm wire.
** Requires drum assembly with four threaded holes
in base. See page 16.
Part No.
7311.21 1/2
7311.21 5/8
7312.21 5/8
2
7312.21 3/4*
Unit
1
1&2
2
Rod Adapter Stud
Part No.
7422 -8
1/2"
Thread Ø
- 20RH
7423 -10
1/2"
- 20RH
7424 -12
5/8"
- 18RH
7425 -17
5/8"
- 18RH
7426 -22
3/4"
- 16RH
Includes 3 x 7403; 1 x 7401;
1 x 7402; 1 Horn Cleat
Tools You Will Need
5
2
3
12
1
6
4
7
8
9
10
11
1. Long tape measure
6. Side cutters
11. Center punch
2. Short tape measure
7. Rat-tail file
12. Rigging or black tape
3. Drill bit – 1/8" (3 mm)
8. Allen wrenches (provided)
13. Hammer
4. Power drill
9. Phillips screwdriver
5. Hacksaw
10. Needle-nose pliers
6
Unit 1, 2 Cruising
13
10/19/10
Preassembly
Sailmaker's Instructions
C
B
A
Luff Length
Note offsets above and below sail.
A shorter luff may be required if a halyard restrainer is necessary
(page 23) 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, make sure a pendant must be added. (See page 22).
Tack Setback
Note setback for tack shackle and cut the sail accordingly.
Luff Tape Size
Both units require #6 (6/32" or 5 mm) luff tape.
Luff Tape Length
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:
E
Unit
1
A
11/16" (27 mm)
1/2"
2
13/4" (44 mm)
11/16"
A
B
(13 mm)
(17 mm)
B
Suncover
Suncovers may be installed on either side of 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.
D
I
G
Unit 2 Unit 1
H
F
1/2" (12.7 mm) Clevis Pin
Add 131/2" to 65/8" (343 mm to 168 mm)
5/8" (15.9 mm) Clevis Pin
Add 111/4" to 43/8" (286 mm to 111 mm)
5/8" (15.9 mm) Clevis Pin
Add 161/8" to 81/4" (410 mm to 210 mm)
3/4" (19.1 mm) Clevis Pin
Add 139/16" to 511/16" (344 mm to 144 mm)
J
Unit
A
B
C Max
D
E
F
G
H
I
J
Toggle Used
1
*1/2" (12.7 mm)
35/8"
6"
12"
13/8" Min 331/2" (851 mm) Min 91/2" (241 mm) Min 81/2"( 216 mm)
31/16" Min 27/8" (71 mm)*
65/8"
92 mm 152 mm 305 mm 35 mm Max 407/16" (1027 mm) Max 117/8" (302 mm) Max 1013/16" (275 mm) 167 mm 78 mm Max 51/16" (129 mm)** **5/8" (15.9 mm)
2
*5/8" (15.9 mm)
41/2"
8"
16"
111/16" Min 427/16"(1078 mm) Min 113/4" (298 mm) Min 103/8" (264 mm) 83/16" 313/16" Min 33/8" (86 mm)*
114 mm 203 mm 406 mm 42 mm Max 503/4"(1289 mm) Max 147/8" (378 mm) Max 131/2" (343 mm) 208 mm 97 mm Max 61/2" (165 mm)** **3/4" (19.1 mm)
11/01/10
Unit 1, 2 Cruising
7
Preassembly
Toggle Deductions/Stay Into Foil Options
Use dimensions of the 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 allows fine tune adjustment of mast rake.
Unit
1
5/8" - 18LH
2
3/4" - 16LH
Unit 1
37/8" (98 mm)
Unit 2
51/4" (133 mm)
Thread
Unit 1
87/8" (225 mm)
Unit 2
115/8" (295 mm)
Eye/Jaw Reversible Toggle
Crosspin
Crosspin
Fork
Attachment
Tang
Attachment
For tang-down
installations,
switch plugs
to this position.
Unit 1
31/4" (83 mm)
Unit 2
4" (102 mm)
Stud/Jaw
Unit
1
1/2" (12.7 mm)
2
5/8" (15.9 mm)
3/4" (19.1 mm)
2
5/8" (15.9 mm)
Make sure your
toggle looks like this!
Eye/Jaw Reversible
Unit
1
Clevis Pin
Clevis Pin
Unit 1
*25/16" (59 mm)
11
**2 /16" (68 mm)
Unit 2
*25/8" (67 mm)
1
**3 /4" (83 mm)
Unit 1
3" (76 mm)
Unit 2
39/16" (90 mm)
Long Link
Plate w/Toggle
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 that crosspin
will be 90 degrees to main clevis pin.
Jaw/Jaw
Unit
1
Clevis Pin
1/2" (12.7 mm)
2
5/8" (15.9 mm)
Make sure your
toggle looks like this!
Unit
1
2
Clevis Pin
1/2" (12.7 mm)*
5/8" (15.9 mm)**
5/8" (15.9 mm)*
3/4" (19.1 mm)**
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. When using smaller wires, marine eye may fit. See page 14.
4. Rod adapter nosepiece for Harken rod adapter stud.
WARNING! Using a threaded nosepiece with only
adhesive at the upper rod eye terminal may result
in headstay system failure which can cause an
accident, damage to your vessel, personal injury,
or death. See www.harken.com for additional
safety information.
8
Unit 1, 2 Cruising
10/11/10
Preparation for Assembly
Top Foil Length Worksheet
Measure A and add to this chart
and “length chart” below
Inches
mm
A
B
.5
13
E
24.0
610
F
16.4
416
Make sure upper
measurement points
of A and pin-to-pin
are the same.
Alternate
Measurement
Point
A
A
Pin
to
Pin
B
C
G
UNIT 1
Total A+B+E+F+G
1
Pin-to-Pin Length
2
Subtract ABEFG
3
Result (Pin-to-Pin – ABEFG)
–
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 = 10668.0
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 12,000 mm “D” = 10,668 mm
Result (C) Top Foil Length
5
Pin
to
Pin
If top foil length is
63/4" (171 mm) or
less, go to page 11
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.
Pin-to-Pin Length Worksheet
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
24.0
16.4
610
416
E
Pin-to-Pin Length
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.
08/23/10
Unit 1 Cruising
F
G
9
Preparation for Assembly
Top Foil Length Worksheet
Measure A and add to this chart
and “length chart” below
Inches
mm
A
B
.7
18
E
24.0
610
F
19.1
484
Make sure upper
measurement points
of A and pin-to-pin
are the same.
Alternate
Measurement
Point
A
A
Pin
to
Pin
B
C
G
UNIT 2
Total A+B+E+F+G
1
Pin-to-Pin Length
2
Subtract ABEFG
3
Result (Pin-to-Pin – ABEFG)
–
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
4 x 2133.6 = 8534.4
4 X 84 = 336
5 x 2133.6 = 10668.0
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
8 x 2133.6 = 1920.4
9 x 84 = 756
D
Example–If result from Step 3 is:
500 inches “D” = 420 inches 12,000 mm “D” = 10,668 mm
Result (C) Top Foil Length
5
Pin
to
Pin
If top foil length is
91/8" (232 mm) or
less, go to page 11
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.
Pin-to-Pin Length Worksheet
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
.7
18
24.0
19.1
610
484
E
Pin-to-Pin Length
G Toggle Distance from Lower Clevis Pin to Crosspin Hole
Toggle Part No.
7412.20 5/8
7312.20 5/8
7312.20 3/4
7312.21 5/8
7312.21 3/4
Type
Eye/Jaw Reversible
Jaw/Jaw
Stud/Jaw
Long Link Plate w/Toggle
Long Link Plate w/Toggle
Clevis Pin
G Distance
15.9 mm 2.00" 51 mm
5/8"
15.9 mm 2.00" 51 mm
3/4"
19.1 mm 5.10" 130 mm
5/8"
15.9 mm 18.10" 460 mm
3/4"
19.1 mm 18.75" 476 mm
5/8"
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.
10
Unit 2 Cruising
F
G
08/23/10
Preassembly
Short Top Foil
Use one of the following special techniques for short foils to ensure sufficient bearing surface for foil in area of
halyard swivel.
Cut-Offs
Do Not Use
Unit 1
Top foil length from worksheet:
63/4" (171 mm)
No change necessary.
Unit 2
91/8" (232 mm)
Unit 1
Unit 2
Top foil length from worksheet:
31/2" - 11/2" (89 - 38 mm) 51/2" – 21/2" (89 - 64 mm)
Actual Top Foil
4" (102 mm)
53/4" (146 mm)
Do not cut top foil to length from worksheet. Cut top
foil to 4" (102 mm) or 53/4" (146 mm) and shorten trim
cap as shown in middle photo above. Shorten bottom
foil per chart below.
Cut-Offs
Do Not Use
Unit 1
Unit 2
Top foil length from worksheet:
61/2" – 4" (165 – 102 mm) 9" - 53/4" (229 - 146 mm)
Cut top trim cap as shown above.
UNIT 2
UNIT 1
Cut top
trim cap
Shorten bottom of
bottom foil by this
amount
in
mm
Top foil length
from worksheet
in
mm
Actual top foil
in
mm
31/2
89
4
102
0
0
3
76
4
102
1
25
21/2
64
4
102
11/2
38
2
51
4
102
2
51
11/2
64
38
4
102
21/2
51/2
140
53/4
146
0
0
5
127
53/4
146
1
25
41/2
114
53/4
146
11/2
38
4
102
53/4
146
2
51
31/2
89
53/4
146
21/2
64
3
76
53/4
146
3
76
21/2
64
53/4
146
31/2
89
Unit 1
Unit 2
Top foil length from worksheet:
2" - 1/2" (51 – 13 mm)
1" - 1/2" (25 – 13 mm)
Do not use short top foil. Use full length foil and
clamp foil higher in drum assembly.
08/23/10
Unit 1, 2 Cruising
11
Preassembly
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. 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 clamp screw holes
are lined up with third row of holes as
shown.
Note: Mark top foil so foil with trim cap will
ride 1/2" (12 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. Check length to see
if it matches results from chart on
page 9 (Unit 1) or page 10 (Unit 2).
12
Unit 1, 2 Cruising
08/23/10
Assembly
Cut Top Foil/Slide Foil on Stay/Assemble Trim Cap
Cut foil to length using hacksaw.
Deburr inside edge
using rat-tail file.
Insert trim cap. Use centerpunch to mark
two top foil trim cap holes ½" (12 mm)
down from top of foil on each side of
sail groove.
Remove trim cap. Drill two 1/8" (3 mm)
holes in foil for self-tapping screws.
08/23/10
Unit 1, 2 Cruising
13
Assembly
Assemble Trim Cap
Smaller Wires
Unit
1
2
Larger Wires
Wire Ø
1/4", 6 mm, 9/32", 7 mm
5/16", 8 mm, 3/8", 10 mm
Unit
1
2
Slide foils on stay starting from bottom or top. In most
cases marine eye will fit through foil.
Wire Ø
5/16", 8 mm
7/16", 11 mm, 12 mm
Swage stud fitting or wire end must pass through foil.
Use Norseman-/Sta-Lok-type terminal with wire end.
Place halves of trim cap over wire and
insert into top foil.
Tip: With foil groove up, have
rectangular pieces on the upper half.
Install self-tapping trim cap screws.
Rectangular pieces
Fold halves of plastic isolator over wire.
Note: Use H-41009 Isolators for use
with 7/16", 11 mm or 12 mm wire. Nine
H-41009 isolators are shipped with
3/4"(19mm) Harken Toggles. Look
for “12” molded on the outer side.
14
Unit 1, 2 Cruising
10/19/10
Assembly
Assemble Connector/Assemble Foil/Slide on Halyard Swivel
Place connector over plastic isolator
so tabs on isolator are to side.
Put red Loctite® in screw holes and
assemble. Continue with rest of foils.
Make sure bottom foil with feeder gap
will be at bottom.
Red
Loctite®
Slide halyard swivel onto foils so swivel
portion is towards top of stay.
Tip: Taller “half” will be facing up.
Slide drum assembly onto foils.
7/01/08
Unit 1, 2 Cruising
15
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.
16
Unit 1, 2 Cruising
5/30/08
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. Use a fender
washer to fit large-diameter cruising foil.
Washer
Eye/Jaw Toggle Assembly
Up
Make sure shallow jaw is up.
Down
Eye/Jaw Toggle Assembly
5/30/08
Jaw/Jaw Toggle Assembly
Stud/Jaw Toggle Assembly
Unit 1, 2 Cruising
17
Assembly
Attach Toggle/Long Link Plate
Make sure drum assembly
has four threaded holes
in base.
Determine height of long link
plates to provide anchor
clearance and cut to length.
Cut at scribe mark. Deburr
edges.
Make sure shallow jaw is up.
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.
Fasten second long link plate to drum
assembly and secure to clevis pin 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 causing
an accident, damage to your
vessel, personal injury, or death.
See www.harken.com for
additional safety information.
18
Unit 1, 2 Cruising
08/23/10
Assembly
Attach Foil to Drum Assembly
Slide lower drum assembly over turnbuckle
and attach using long crosspin. Use plastic
washers provided.
Crosspin at 90°
to Clevis Pin
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 causing
an accident, damage to your
vessel, personal injury, or death.
See www.harken.com for
additional safety information.
Clevis Pin
Lift foils so top of foils ride about
½" (12 mm) below upper terminal.
1/2" (12 mm)
Lining these holes
up with top of drum
assembly insures
screws are lined
up with foil holes.
08/23/10
Use blue Loctite® on
screws to secure foils
in a lifted position.
Unit 1, 2 Cruising
19
Commissioning
Adjust Turnbuckle on Boat
Have extra cotter pins on hand to replace used ones at base
of unit and for turnbuckle. Hold foils and remove foil clamp
screws. Lower foils.
Remove crosspin holding lower unit to turnbuckle. Raise
drum assembly and use halyard to hold unit at about
5' (1.5 m) above deck. Raise foils and secure with second
halyard. Allow room above for turnbuckle take up.
WARNING! To avoid injury, make sure drum
assembly and foils are securely lifted using a
halyard before adjusting turnbuckle. Failure to do
so may result in furler dropping suddenly, causing
damage to the furler, or severe injury. See www.
harken.com for additional safety information.
Adjust turnbuckle. Use sidecutters or needlenose pliers to
bend cotter pin. Replace used cotter pins. Lower unit and
install crosspin and new cotter pin.
Lift foils so top is 1/2" (12 mm) below upper terminal.
Use blue Loctite® on foil clamp screws when you replace them.
WARNING! Stay must attach to toggle. Do not attach stay to crosspin at drum assembly because
crosspin and plates may fatigue and break causing
an accident, damage to your vessel, personal
injury, or death. See www.harken.com for
additional safety information.
Crosspin
20
Unit 1, 2 Cruising
08/23/10
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.
WARNING! If line is led through opening
between two enclosed windows it can ride
above lineguard and jam furler. This can
cause an accident, damage to your vessel,
personal injury, or death. See www.harken.
Enclosed
com for additional safety information.
Window
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
08/23/10
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.
Unit 1, 2 Cruising
Drum Full
(sail unfurled)
Drum Empty
(sail furled)
21
Commissioning
Halyard Wraps
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/unfurling and may cause serious damage to the unit and halyard.
WARNING! In severe cases, a halyard wrap can cause loss of
control of boat and/or headstay can break suddenly which can
cause an accident, damage to your vessel, personal injury, or
death. See www.harken.com for additional safety information.
To prevent wraps, the halyard must exert a slight pull to the rear. This
allows the foils to turn while halyard remains stationary.
Prevent Halyard Wraps
WARNING! Sail must be fitted to foil length before using to
prevent headstay loss which will cause an accident, damage
to your vessel, personal injury, or death. See www.harken.com
for additional safety information.
1. Halyard swivel should be within top 4" (100 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.
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 going aloft and freeing halyard.
If sail will not furl or unfurl, try to remove jib sheets and manually
wrap sail around headstay.
Testing at dock does not indicate halyard angle is correct. In wave
action, halyard may wrap if lead angle is not correct. The 8–10°
diverging angle shown at right is critical.
8–10°
Pendants
If the your sail luff is not long enough to position the halyard swivel
properly, you must add a pendant. Pendants should be made of plasticcoated wire and be permanently attached so the sail height will be
correct. Adjustable length pendants are not acceptable as they
might not be adjusted correctly during a sail change.
Installing a Pendant
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 a pendant of this length to head of sail.
8. Repeat this procedure for every jib in your sail inventory.
22
Unit 1, 2 Cruising
08/23/10
Commissioning
Halyard Restrainer
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 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 restrainer, use Harken part 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 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.
5/30/08
Unit 1, 2 Cruising
23
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 which can cause an accident, damage
to your vessel, personal injury, or death. See
www.harken.com for additional safety
information.
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. It may be necessary to shorten foil slightly to prevent this.
24
Unit 1, 2 Cruising
08/23/10
Operation
Sail: Raise/Storm/Reef
Raise Sails
1)
2)
3)
4)
5)
6)
Shackle tack of sail to drum. Install shackle so screw pin head is on same
side as suncover.
Secure genoa sheets to clew of sail.
Attach genoa halyard to halyard swivel.
Pass luff tape through 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 at feeder 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 multipurpose 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 22.
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 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 28. Do not use a winch to force a system to turn.
You may use a winch to make furling easier, if you are certain that system is operating properly.
08/23/10
Unit 1, 2 Cruising
25
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 while entering or leaving harbors.
Secure Sail
When furling prior to leaving your boat in slip or
on mooring, be sure that you get a tight furl and
continue furling system until sheets wrap around
rolled sail two or three times. Some people secure
sail with shock cord or sail ties. Be sure to securely
cleat furling line to a standard horn cleat.
You may also lock your system by aligning holes
in bottom of drum and basket and then using a
line to secure drum.
Be sure that mooring lines are not placed across
furling line where they may cause chafe.
26
Unit 1, 2 Cruising
5/30/08
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
WARNING! Periodically inspect items listed
below and any others as necessary. Failure to scrap of luff tape may be run up foil to scrub inside the
inspect can cause an accident, damage to your grooves. Foils may be sprayed with McLube® spray to
reduce friction during sail changes.
vessel, personal injury, or death. See www.
harken.com for additional safety information.
Inspect
1) Unit for signs of chafe, wear or damage.
2) Foil clamp screws for signs of loosening. Check headstay tension
for signs of loosening.
3) Swage fitting and lower toggle for signs of stress corrosion.
4) Norseman/Sta-Lok® terminal/rod terminal for signs of loosening.
5) All screws on unit to be sure they have not loosened.
6) Foil to make sure that it has not dropped into drum assembly.
7) Wire for signs of wear or unraveling.
Replace Line — Unit 1
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.
Replace Line — Unit 2
Use HFG235 furling line or source a good quality line with good wear characteristics. Use 5/16" (8 mm) line with
break strength exceeding 3740 lbs (1700 kg). Smaller boats or smaller sails may allow 3/8" (8 mm) line.
Replace Line — Both
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.
Remove Furler
Foils can lock against upper stay terminal when backstay is released. To prevent this loosen foil clamp screws and
lower foil before loosening backstay.
08/23/10
Unit 1, 2 Cruising
27
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 20.
Foils too high, binding on swage eye.
Lower foils until clear. See adjusting turnbuckle on page 20.
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 fresh water and lubricate with dry spray lubricant such as McLube®
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 foil 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 corretly.
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 20.
Foils too high, binding on swage eye.
Lower foils. See adjusting turnbuckle on page 20.
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.
Warranty online at www.harken.com or call, write, email or fax Harken, Inc., Pewaukee, WI USA
28
Unit 1, 2 Cruising
08/23/10
HFG688
HFG687
HFG686
Cruising Unit 1
Parts
HFS980 H-35665D
HFS980 1
1
H-35600C
2
H-35199E
3
4
2
Description
Top Cover Assembly w/Screws
Top Cover
Top Cover Screw
Bottom Flange Assembly w/Screws
Flange
Bottom Flange Screw
Guard Assembly
Guard
Guard Screw
Torque Tube Screws
Hub
Ball Plugs
Delrin Ball Bearing
Igus Crosspin Bushing
Order
1
2
2
1
2
2
1
2
2
2
Part No
HFG686
H-35665D
HFS980
HFG687
H-35600C
HFS980
HFG688
H-35199E
HFS1052
H-41153
1
3
72
2
HFG145
H-35144A
HBB152
H-36636A
HFS1052 HFG145
H-41153
3
4
HBB152 (24)
H-35144A
HBB152 (24)
H-35144A
H-35144A
HBB152 (24)
H-36636A
1/06/10
Unit 1 Cruising
29
Cruising Unit 1
Parts
HFS1127
5
HFG182
HCP728
H-36602A
HBB14
H-36596C
H-36602A
HBB14
H-36602A
7311.30
7311.10 FOILSET
Description
Trim Cap Set
Trim Cap Screw
Halyard Swivel
Clip/Smally Ring
Clip/Smally Ring for liners
Liner/Igus
Torlon Ball Bearings
Foil Set (6)
Foil (7'/2.13 m Luff)
Foil (2'/610 mm) Bottom w/Feeder
Connector Set (6)
Connector
Connector Screw Set (30)
Connector Screw
Connector Isolator
Connector w/isolator
Order
Part No.
1
HFG182
2
HFS1127
1
H-36596C
1
HCP728
2
H-36602A
3
H-36604A
42
HBB14
1
7311.10 FOILSET
6
7311.30
1
7311.33
1
HFG937
6
7311.31F
1
HFG149
30
HFS980
6
H-41008
7311.31
HFS980
HFG149
5
7311.33
7311.31F
HFG937
H-41008
7311.31
6
4414
MKIV
Jib Reefing & Furling
Installation Manual
Unit 0
WARNING!: Strictly follow all instructions
to avoid an accident, damage to your vessel,
personal injury or death. See www.harken.com
for additional safety information.
2110
HFG739
833
HFG233
M5
M4
M2.5
30
7404
6
7
944
884
Unit 1 Cruising
7
Description
Instruction Manual
Shackle
Red Loctite®
Blue Loctite®
7mm Double Braid Polyester (70', 21.3 m)
Allen Wrenches
M2.5
M4
M5
Order
1
3
2
1
1
Part No
4414
2110
HFG739
833
HFG233
1
1
1
HCP1387
HFG640
HFG642
Description
Lead Block Kit
29 mm Outboard Lead Assembly
57 mm Carbo Ratchet Assembly
40 mm Carbo Assembly
Horn Cleat
Halyard Restrainer
Sheave/SS Inner Race Only
Clevis Pin (1/4" x 1.0625" 18-8)
Bracket-Large
Cotter Pin (1/16" x .500" 18-8)
Snap Shackle
Order
1
3
1
1
1
1
1
1
1
1
1
Part No
7404
7403
7402
7401
HCP168
944
944A
HFG467
HCP393
HFS118
884
10/11/10
Cruising Unit 1
Parts
8
2
3
7422 -8
7423 -10
7424 -12
8
1
4
No.
Description
Rod Adapter Stud w/Nosepiece
1 Stud (Main Body)
2 Nosepiece
3 Cotter Pin
No.
Description
Rod Adapter Stud w/Nosepiece
1 Stud (Main Body)
2 Nosepiece
3 Cotter Pin
Part No
Part No
7422 -8
7423 -10
H-41536
H-41536
H-41534
H-41535
HFG193
HFG193
Part No
7424 -12
H-41531
H-41527
HFG193
3
1
6
6
2
7311.20 1/2
5
9
2
3
9
4
1
3
7
7411.20 1/2
4
6
5
8
8
5
5
8
10
8
4
7311.21 1/2
7311.21 5/8
7311.20 5/8
7
7
6
Order
1
1
1
2
Order
1
1
1
2
2
10
2
11
2
5
3
1
5
3
7
3
1
6
4
10/11/10
No.
Description
Long Link Plate w/Toggle
1 Jaw Jaw Toggle
2 Link Plate Straps
3 Cross Pin
4 Lower Clevis Pin
5 Isolator
6 Cotter Pin
7 Nylock Nut (M12)
8 Allen Cap Screws (M6 x 1 x 12mm)
11
6
Unit 1 Cruising
No.
Description
Jaw/Jaw Toggle
1 Toggle
2 Crosspin
3 Clevis Pin
4 Cotter Pin
5 Cotter Pin
6 Nylon Washer
Eye/Jaw Toggle Reversible
1 Toggle
2 Crosspin
3 Nylon Washer
4 Cross Hole Plug
5 Clevis Pin
6 Cotter Pin
7 Cotter Pin
Stud/Jaw Toggle
1 Jaw Jaw Toggle
2 Crosspin
3 Clevis Pin
4 Stud
5 Cotter Pin
6 Cotter Pin
7 Nylon Washer
Order
1
2
1
1
2
2
2
4
Order
Part No
1
7311.20 1/2
1
H-42336
1
H-42396
2
H-42395
2
HFS220
1
HFS181
2
HFS1109
1
7411.20 1/2
1
H-37675C
1
H-42396
2
HFS1109
2
H-42049
1
h-42395
1
HFS220
1
HFS181
1
7311.20 5/8
1
H-41300
1
H-42396
2
H-42397
1
H-43207
3
HFS220
1
HFS181
2
HFS1109
Part No
7311.21 1/2
H-42159
H-42178
H-42170
H-42395
H-42182
HFS220
HFS846
HFS876
Part No
7311.21 5/8
H-41300
H-42178
H-42171
H-42397
H-42182
HFS203
HFS846
HFS876
31
HFG691
HFG690
HFG689
Cruising Unit 2
Parts
HFS1060 H-35025D
HFS1060 1
1
H-35465C
2
H-33758E
3
4
2
Description
Top Cover Assembly w/Screws
Top Cover
Top Cover Screw
Bottom Flange Assembly w/Screws
Flange
Bottom Flange Screw
Guard Assembly
Guard
Guard Screw
Torque Tube Screws
Hub Assembly
Ball Plugs
Delrin Ball Bearing
Igus Crosspin Bushing
Order
1
2
2
1
2
2
1
2
2
2
Part No
HFG689
H-35025D
HFS1060
HFG690
H-35465C
HFS1060
HFG691
H-33758E
HFS873
H-41154
1
3
75
2
HFG183
H-33860A
HBB153
HCP1707
HFS873 HFG183
H-41154
3
4
HBB153 (25)
H-33860A
HBB153 (25)
H-33860A
H-33860A
HBB153 (25)
HCP1707
32
Unit 2 Cruising
1/06/10
Cruising Unit 2
Parts
HFS1127
5
HFG197
H-38028A
H-38027A
HBB7
H-37317C
H-38029A
HBB7
H-38027A
7312.30
7312.10 FOILSET
Description
Trim Cap Set w/o Screws
Trim Cap Screw
Halyard Swivel
Clip/Smally Ring
Clip/Smally Ring for liners
Liner/Igus
Torlon Ball Bearings
Foil Set (8)
Foil (7'/2.13 m Luff)
Foil (2'/610 mm) Bottom w/Feeder
Connector Set (8)
Connector
Connector Screw Set (30)
Connector Screw
Connector Isolator
Connector Isolator (7/16", 11 mm,
12 mm Wire)
Connector w/H-37330C
Order
Part No.
1
HFG197
2
HFS1127
1
H-37317C
1
H-38028A
2
H-38027A
3
H-38029A
44
HBB7
1
7312.10 FOILSET
8
7312.30
1
7312.33
1
HFG938
8
7312.31F
1
HFG196
30
HFS1060
8
H-37330C
9
H-41009
7312.31
HFS1060
HFG196
5
7312.33
6
7312.31F
HFG938
7
H-37330C
H-41009
7312.31
4414
MKIV
Jib Reefing & Furling
Installation Manual
Unit 0
WARNING!: Strictly follow all instructions
to avoid an accident, damage to your vessel,
personal injury or death. See www.harken.com
for additional safety information.
2117
7404
HFG739
833
HFG235
6
7
945
M6
M4
M3
10/11/10
885
Unit 2 Cruising
7
Description
Instruction Manual
Shackle
Red Loctite®
Blue Loctite®
8mm Double Braid Polyester (100', 30.4 m)
Allen Wrenches
M3
M4
M6
Description
Lead Block Kit
29 mm Outboard Lead Assembly
57 mm Carbo Ratchet Assembly
40 mm Carbo Assembly
Horn Cleat
Halyard Restrainer
Sheave/SS Inner Race Only
Clevis Pin (1/4" x 1.0625" 18-8)
Bracket-Large
Cotter Pin (1/16" x .500" 18-8)
Snap Shackle
Description
Lead Block Kit
29 mm Outboard Lead Assembly
57 mm Carbo Ratchet Assembly
40 mm Carbo Assembly
Horn Cleat
Halyard Restrainer
Sheave/SS Inner Race Only
Clevis Pin (1/4" x 1.0625" 18-8)
Bracket-Large
Cotter Pin (1/16" x .500" 18-8)
Snap Shackle
Order
Part No.
1
3
2
1
1
4414
2117
HFG739
833
HFG235
1
1
1
HCP1089
HFG640
HFG644
Order
Part No.
1
3
1
1
1
1
1
1
1
1
1
7404
7403
7402
7401
HCP168
945
945A
HCP208
HCP394
HFS181
885
Order
Part No.
1
3
1
1
1
1
1
1
1
1
1
7404
7403
7402
7401
HCP168
945
945A
HCP208
HCP394
HFS181
885
33
Cruising Unit 2
Parts
8
7424 -12
7425 -17
7426 -22
8
1
4
No.
Description
Rod Adapter Stud w/Nosepiece
1 Stud (Main Body)
2 Nosepiece
3 Cotter Pin
No.
Description
Rod Adapter Stud w/Nosepiece
1 Stud (Main Body)
2 Nosepiece
3 Cotter Pin
6
6
2
7312.20 5/8
5
9
9
2
3
4
1
3
7
7412.20 5/8
4
6
5
8
8
5
10
8
5
8
8
4
9
7312.20 3/4
7
7
2
10
7312.21 5/8
7312.21 3/4
2
2
5
3
6
1
5
3
11
11
7
3
1
6
4
34
Part No.
7424 -12
H-41531
H-41527
HFG193
Part No.
7425 -17
7426 -22
H-41531
H-41812
H-41526
H-41811
HFG193
HFG319
3
1
6
Order
1
1
1
2
Order
1
1
1
2
Unit 2 Cruising
No.
Description
Jaw/Jaw Toggle
1 Toggle
2 Crosspin
3 Clevis Pin
4 Cotter Pin
5 Cotter Pin
6 Nylon Washer
Eye/Jaw Toggle Reversible
1 Toggle
2 Crosspin
3 Nylon Washer
4 Cross Hole Plug
5 Clevis Pin
6 Cotter Pin
7 Cotter Pin
Stud/Jaw Toggle
1 Jaw JawToggle
2 Crosspin
3 Clevis Pin
4 Stud
5 Cotter Pin
6 Cotter Pin
7 Nylon Washer
8 Large Bore Connector Isolator
Order
Part No.
1
7312.20 5/8
1
H-42316
1
H-42398
2
H-42397
2
HFS203
1
HFS220
2
HFS1005
1
7412.20 5/8
1
H-37647C
1
H-42398
2
HFS1005
2
H-42045
1
H-42397
1
HFS203
1
HFS220
1
7312.20 3/4
1
H-41489
1
H-42398
2
H-42403
1
H-43210
3
HFS203
1
HFS220
2
HFS1005
9
H-41009*
*Large Bore Connector Isolators for 7/16", 11 mm or 12 mm wire
No.
Description
Order
Part No.
Part No.
Long Link Plate w/Toggle
7312.21 5/8 7312.21 3/4
1 Jaw Jaw Toggle
1
H-41300
H-41489
2 Link Plate Straps
2
H-41304
H-41304
3 Cross Pin
1
H-41302
H-41525
4 Lower Clevis Pin
1
H-42397
H-42403
5 Isolator
2
H-41497
H-41497
6 Cotter Pin
2
HFS203*
HFS203**
7 Nylock Nut (M12)
2
HFS937
HFS937
8 Allen Cap Screws (M8x1.25x16 A4 (SH) 4
HFS336
HFS336
9 Large Bore Connector Isolator
9
H-41009***
—
* (5/8" x 11/2" 18-8); **(3/4" x 113/16" 18-8); *** Large Bore Connector Isolators for 7/16", 11 mm
or 12 mm wire
10/19/10
Travelers
Jeanneau Sun Odyssey 52DS — Photo courtesy Jeanneau
Make cruising safer and easier
Add a Harken ball bearing traveler to your boat.
The difference in performance will be night and day.
Harken free-running travelers provide smooth sail
control in all conditions. Wind light? Adjust
the traveler to power up the main. Wind howling?
Safely depower by easing the car to reduce heel
and maintain speed—faster and safer than
releasing and retrimming the sheet.
Harken captive ball traveler cars are modular
with 2:1 to 6:1 purchases so a small crew can play a highly loaded mainsail. Systems can be tailored for end-boom— mounted on bridge decks—or for mid-boom
configurations with risers and high-beam track to move the traveler out of the cockpit.
Tech Tip
To reduce heel: Slack the windward adjuster line so the
traveler car slides to the boat’s low side, depowering the
leech and spilling air from the main. After tacking make the
same adjustment. Mark both lines at the cam for no-guess
trimming when it's windy.
1251 E. Wisconsin Ave., Pewaukee, WI 53072, Tel: 262-691-3320, Fax: 262-691-3008, Email: [email protected], Web: www.harken.com
Corporate Headquarters
1251 East Wisconsin Avenue, Pewaukee, Wisconsin 53072-3755 USA
Telephone: (262) 691-3320 • Fax: (262) 691-3008
Web: www.harken.com • Online Catalog: www.harkenstore.com
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: www.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: www.harken.it • Email: [email protected]
Harken UK, Ltd.
Bearing House, Ampress Lane, Lymington, Hampshire S041 8LW, England
Tel: (44) 01590-689122 • Fax: (44) 01590-610274
Web: www.harken.co.uk • Email: [email protected]
Harken Polska SP ZOO
Ul Lisa Kuli 4 Lok 1, 01-512 Warsaw, Poland
Telephone: +48 22 561 93 93 • Fax: +48 22 839 22 75
Email: [email protected]
Harken Sweden AB
Main Office and Harken Brandstore: Västmannagatan 81B
SE-113 26 Stockholm Sweden
Telephone: +46 303 618 75 • Fax:+46 303 618 76
Mailing address: Harken Sweden AB, Box 64, SE -440 30 Marstrand
Email: [email protected]
Harken Adriatik d.o.o.
Obala 107, 6320 Portoroz, Slovenia
Telephone/Fax: (386) 5-6774122
Web: www.harken.si • 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: www.harken.com.au • 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: www.harken.co.nz • Email: [email protected]
Please visit: http://www.harken.com/dealers/dealers.php
for an up-to-date list of Harken dealers and distributors
0
97653 15322
1
Printed in USA 4414/11-01-10