MKIV Jib Reefing & Furling Installation Manual Unit 3

MKIV Jib Reefing & Furling Installation Manual Unit 3
MKIV
Jib Reefing & Furling
Installation Manual
Unit 3
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
Parts
Tools
Dimensions/Sailmaker's Instructions
Toggle Deductions/Stay Into Foil Options
Top Foil Length
Short Top Foil Foil Length 4-5
5
6
7
8
9
10
Foils/Connectors
Halyard Swivel
Drum Assembly
Rod Rigging
Turnbuckle
Toggle
Final
28
29
29 - 30
30
31
Maintenance
Assembly
Halyard/Headstay Tension
Raise Sails
Furl/Reef
Secure Sail
Race Conversion
11 - 17
17
18
19
20
20 - 21
22 - 23
Clean
Inspect
Replace Line
Storage
Remove Furler
32
32
32
32
32
Troubleshooting
Warranty
Commissioning
Turnbuckle
Line to Cockpit
Halyard Swivel Height/Angle
Halyard Restrainer/Tension
24
25
26 - 27
27
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' (610mm) Bottom Foil
7) Feeder
8) Connector Bushing
MKIV Unit 3
9) Bottom Connector
10) 7' (2.13m) Foil
11) Connector Screws
12) Connector Wedge
13) Connector
14) Halyard Swivel
15) Trim Cap
16) Trim Cap Screws
5/30/07
Preassembly
Sizing Check
16
14
15
12
13
11
10
9
Size Check
1. Check headstay and clevis pin dimensions in chart below.
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.
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.
Sizing Check
Unit Part No.
Description
Wire Sizes
7/16", 1/2""
7413.10
MKIV Unit 3
Rod Sizes
-22, -30
Toggle Part No.
7/14/08
Description
11mm, 12mm
9.53mm, 11.10mm
Chainplate Clevis Pin Size
7413.20 3/4
Eye/jaw reversible
3/4"
19.1mm
7413.20 7/8
Eye/jaw reversible
7/8"
22.2mm
7313.21 3/4
Long link plate w/toggle
3/4"
19.1mm
7313.21 7/8
Long link plate w/toggle
7/8"
22.2mm
MKIV Unit 3
Chainplate Clevis Pin
3
Preassembly
Parts
7' (2.13m)
Foils
2' (610mm)
Bottom Foil
Connector Bushings
Plastic
Connector
Wedges
Trim Cap
Foil Screws
Connectors
Bottom
Connector
Trim Cap Screws
Bow Shackles
Feeder
Prefeeder
Halyard Swivel
3,4, 6, 10mm
Allen Wrenches
Drum Assembly
Injector
Main Components
Other Components
Part No.
Quantity
Part No.
Quantity
HFG293
1
Drum assembly with clamp
7413.31
9
9.75" (248mm) Connector
H-39392
1
Halyard swivel
7413.32
1
14" (356mm) Bottom connector
HFG297
1
Connector bushing set (20 each H-42073/H-42074)
HFG324
1
Plastic connector wedge set (22 39487)
HFG349
1
Foil screw set (46 HFS1106)
HFG682
1
Trim cap set (H-39751/H-39752)
HFG672
1
Trim cap screw set (3-HFS1127)
947
1
Prefeeder
H-39756
1
Feeder with screw and tab
2124
3
10mm Bow shackle
HFG725
1
Injector, 1 oz. 5200 Adhesive (HFG722)
Description
Foils (Standard Package)
Part No.
Quantity
Description
7413.30
10
7'(2.13m) Foil
7413.33
1
2'(610mm) Botton foil (shipped in drum box)
Tools
Quantity
1 Each
4
5200
Adhesive
Description
Description
3, 4, 6, 10mm Allen wrenches
MKIV Unit 3
8/15/07
Preassembly
Rigging Parts Check/Tools
Line Diameter/Length
Furling line is not included with furling unit. Purchase 7/16" (12mm) low stretch
Dacron double braid. The length of the line should be equal to the length of the boat plus the length of the foot of the largest genoa plus 6' (2m).
Line Not Included
Toggles
ROD RIGGING
Harken Rod Adapter
Stud Required
(Sold Separately)
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.
ALL UNITS
Harken Toggle
(Sold Separately)
WARNING!: Headstay condition should be
checked by a professional rigger before
reusing. Wire that is old or damaged may
break suddenly causing an accident,
damage to your vessel, personal injury or
death. See www.harken.com for additional
safety information.
Eye/Jaw Toggle Long Link Plate w/Toggle*
7313.21 3/4
7413.20 3/4
7313.21 7/8
7413.20 7/8
7426 -22
7427 -30
Rod Adapter Stud
*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 70 F (22C) with 50% humidity.
Do not apply at temperatures below 40 F
(5C) and above 100F (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. Allen wrenches (provided)
13. Scissors
4. Drill bit – 5/32" (4mm)
9. Slotted/phillips screwdrivers
14. Metal straight edge
5. Hacksaw
10. Needle-nose pliers
15. Hammer
8/14/08
MKIV Unit 3
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
18"*
(457mm)*
115/8"
(296mm)
75/16"
(186mm)
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).
Tack Setback
Note setback for tack shackle and cut sail accordingly.
Luff Tape Size
Unit 3 requires #6 (6/32" or 5mm) luff tape.
*Less with
Sta-Lok®/Norseman
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: (A) 17/8" (48mm)
(B) 13/16" (21mm)
A
B
Sun cover
Sun covers may be installed on either side of sail. Be sure to match other sails in the customer's inventory.
Min
541/8" (1357mm)
Max
567/8" (1445mm)
37/16"
(88mm)
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.
3/4" (19.1mm) Clevis Pin
Add 199/16" to 1011/16" (497mm to 271mm)
7/8" (22.2mm) Clevis Pin
Add 197/8" to 11" (505mm to 279mm)
111/16"
(280mm)
163/16"*
(411mm)
167/16"**
(418mm)
43/16" (106mm)*
47/16" (113mm)**
6
Toggle Used
*3/4" (19.1mm)
**7/8" (22.2mm)
MKIV Unit 3
8/15/07
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 2/3 open to allow shortening for new wire stretch and for fine-tuning mast rake.
Clevis Pin
3/4" (19.1mm)
7/8" (22.2mm)
Crosspin
Fork Attachment
Pin-to-Pin
Length
5" (127mm)
51/2"
(140mm)
Crosspin
5"
(127mm)
or
51/2"
(140mm)
Tang
Attachment
For tang-down installations,
switch plugs to this position.
*31/4" (83mm)
**37/8" (98mm)
Most boats have a chainplate with 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.
Long Link Plate w/Toggle
*3/4" (19.1mm) Clevis Pin)
**7/8" (22.2mm) 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 of 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 which
can cause an accident, damage to your vessel, personal injury or
death. See www.harken.com for additional safety information.
7/14/08 MKIV Unit 3
7
Preassembly
Top Foil Length
Make sure upper
measurement points
of A and Pin-to-Pin
are the same.
Measure A and add to this chart
and length chart below
Inches
mm
B
1
25
E
24
610
F
31
787
A
Alternate
Measurement
Point
A
A
Pin
to
Pin
TOP FOIL LENGTH WORKSHEET
B
C
G
Total A+B+E+F+G
Pin-to-Pin Length
1
Subtract ABEFG –
2
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
  7 x 2133.6 = 14935.2
7 x 84 = 588
8 x 84 = 672
  8 x 2133.6 = 17068.8
9 x 84 = 756
  9 x 2133.6 = 19202.4
10 x 84 = 840
10 x 2133.6 = 21336
11 x 84 = 924
11 x 2133.6 = 23470
D
Example–If result from Step 3 is:
800 inches “D” = 756 inches 20,000mm “D” = 19,202mm
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
Inches
mm
1
25
24
31
610
787
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" (2133.6mm)
E Bottom Foil
F Bottom of Foil to Crosspin
G Crosspin to Clevis Pin
E
Pin-to-Pin Length
G Toggle Distance from Lower Clevis Pin to Crosspin Hole
Toggle Part No.
7413.20 3/4
7313.20 7/8
7313.21 3/4
7313.21 7/8
Type
Eye/Jaw Reversible
Eye/Jaw Reversible
Long Link Plate w/Toggle
Long Link Plate w/Toggle
Clevis Pin
19.1mm
7/8"
22.2mm
3/4"
19.1mm
7/8"
22.2mm
3/4"
G Distance
2.5" 63.5mm
2.75"
70mm
22"
559mm
225/8" 575mm
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 3
F
G
5/30/07
Preassembly
Short Top Foil
31/2" (89mm)
3" (76mm)
21/2" (64mm)
2" (51mm)
11/2" (38mm)
93/4" (248mm)
If top foil is shorter than 93/4" (248mm), 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
95/8" - 71/8" (244 - 181mm)
93/4" (248mm) No special treatment required.
31/2" - 11/2" (89 – 38mm) 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
–
(244 – 181mm) Do not use plastic bushing above top connector.
71/8"
53/8" - 4" (137 - 102mm)
3"
(76mm)
61/16"
(154mm)
21/2"
(64mm)
Cut-Offs – Do Not Use
53/8" - 4" (137 – 102mm) 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.
MKIV Unit 3
5. Shorten
trim cap
Length
47/8"
(124mm)
No
41/2"
(114mm)
47/8"
(124mm)
No
69/16"
(167mm)
4"
(102mm)
47/8"
(124mm)
No
2"
(51mm)
51/16"
(129mm)
31/2"
(89mm)
43/8"
(111mm)
Yes
11/2"
(38mm)
49/16"
(116mm)
3"
(76mm)
33/4"
(95mm)
Yes
Cut-Offs
Do Not Use
7" - 51/2" (178 – 140mm) Do not use plastic bushing
above top connector. Shorten top of connector and if
necessary shorten trim cap.
7/15/08
69/16"
(167mm)
4. Shorten
connector
Cut-Off
Do Not Use
*To allow for saw cut, position blade so upper half of
middle hole is preserved.
Under 11/2" (38mm)
7" - 51/2" (178 - 140mm)
95/8"
31/2"
(89mm)
2. Cut through 3. Shorten
middle hole in full length
top foil.*
adjoining
foil by
Resulting Top cutting
through
Foil Length
middle
5"
hole.*
(127mm)
Under 11/2" (38mm) Eliminate top foil and run foil
higher in drum assembly.
9
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. 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" (25mm) 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.
10
MKIV Unit 3
7/15/08
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 cutoff piece and use a flat metal object (i.e. metal ruler) to scribe top line of foil.
5/30/07
MKIV Unit 3
11
Assembly
Top Foil
Cut out template at right. Line up template
with top of foil and scribed line. Tape in
place. Use center punch to mark holes.
Check center punch marks to confirm they are 3/8" (10mm) and 13/8" (35mm) from top of foil.
Foil
Top
!
3/8" (10mm)
13/8" (35mm)
Drill two (2) 5/32" (4mm) holes for trim cap.
Lay top foil in line with others. Slide stay
into top foil and down line of foils or slide
each foil up stay.
12
MKIV Unit 3
5/30/07
Assembly
Top Foil
Install trim cap. Place each side over wire.
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.
5/30/07
MKIV Unit 3
13
Assembly
Top Foil/Connectors
Slip 93/4" (248mm) connector on wire, mating hook of plastic bushing with connector.
Loading Injector with Adhesive
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.
Adhesive in
lower half
14
MKIV Unit 3
5/30/07
Assembly
Foils/Connectors
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.
Put a drop of adhesive into screw holes.
Hold plastic wedge in place with thumb as you insert into foil. Line foil holes with connector screw holes.
5/30/07
MKIV Unit 3
15
Assembly
Foils/Connectors
Inject only a small amount of adhesive into middle hole. Unit 3 will only take 1 to 11/4ml of a graduation mark.
Tip: When you see a small amount of
adhesive enter one screw hole, stop.
You have applied enough adhesive.
Stop when you see a small
amount of adhesive enter
one screw hole.
Use “ml”
marks to
estimate 1
to 11/4ml of
adhesive
Tighten screws into connector holes. Make
sure a drop of adhesive entered each screw
hole. If not, apply to screw.
Use bushings, connector, wedge and adhesive in other screw hole and insert into other foil. Use 1 to 11/4ml of adhesive.
16
MKIV Unit 3
5/30/07
Assembly
Bottom Foil/Connectors/Halyard Swivel
Continue installing connectors and wedges. Make sure to use adhesive in screw holes.
Continue assembly. Use 14" (356mm) bottom connector to assemble bottom foil.
Slide halyard swivel onto foil above feeder
window. Make sure taller “half” is up as
shown.
5/30/07
MKIV Unit 3
17
Assembly
Drum Assembly/Turnbuckle/Harken Toggle
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 3
5/30/07
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.
5/30/07
MKIV Unit 3
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
Eye/Jaw Toggle Assembly
20
MKIV Unit 3
5/30/07
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
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.
7/14/08
MKIV Unit 3
21
Assembly
Final
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.
Important: Crosspin must be at 90 degrees
to clevis pin that attaches unit to boat.
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.
Check foil height at top, set and secure
using Allen wrench.
See tip on next page.
22
MKIV Unit 3
5/30/07
Assembly
Feeder/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.
5/30/07
MKIV Unit 3
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' (1.5m). Raise foils using second halyard and secure. 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
cause an accident, damage to your vessel, personal
injury or death. See www.harken.com for additional
safety information.
Adjust turnbuckle.
Replace used cotter pins. Lower drum assembly and install clevis
pin and new cotter pin.
Lift foils so top is 1" (25mm) below upper terminal.
Important: When reinstalling crosspin, pin must be at
90 degrees to clevis pin that attaches unit to boat.
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.
24
MKIV Unit 3
Crosspin
7/14/08
Commissioning Lead Line to Cockpit
Enclosed Window
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.
com for additional safety information.
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.
2600 Forward Lead Block
BOW
Position 2600 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.
2600 CARBO
FORWARD
LEAD BLOCK
Furling line must enter drum at right
angle to headstay.
2600 57mm Carbo Intermediate Lead Blocks
2660 CARBO
INTERMEDIATE
LEAD BLOCK
Install 2600 Intermediate Lead Blocks so line is inside stanchions.
Number and placement of leads depends on boat
length and number/configuration of stanchions.
2670 75mm Carbo Ratchet Block
2660 CARBO
INTERMEDIATE
LEAD BLOCK
2660 CARBO
INTERMEDIATE
LEAD BLOCK
2670 CARBO
RATCHET BLOCK
STERN
7/14/08
Mount 2670 Carbo Ratchet 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.
Furling line lead changes as amount of
furling line on drum changes.
061 stanchion mount bases provide
an ideal attachment for furling line
lead blocks. Ball joint socket accepts
most small boat swivel blocks, including ratchet blocks.
Furling Line Cleat
Install so line is angled as shown.
Note: As furling line lead changes, make sure line
doesn’t chafe against line guard. Rotate line guard if necessary.
MKIV Unit 3
Drum Full
(sail unfurled)
Drum Empty
(sail furled)
25
Commissioning
Halyard: Swivel Height/Lead Angle
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 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" (100mm) 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 halyard swivel properly,
you must add a pendant. Pendants should be made of plastic-coated wire
and be permanently attached so sail height will be correct. Adjustablelength 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.
26
MKIV Unit 3
7/14/08
Commissioning
Halyard: Restrainer/Tension
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 No. 945 or 1988.
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.
5/30/07
MKIV Unit 3
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 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. To prevent this, it may be necessary to shorten foil slightly.
28
MKIV Unit 3
7/14/08
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 3 should never require use of a winch
to furl. If 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.
5/30/07
MKIV Unit 3
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.
Your system is provided with a “locking” device that
can be used to lock unit while reefed or when leaving
boat unattended at dock or mooring. To lock unit in
reefed or furled configuration, align holes in bottom of
drum and basket, then use a line to secure drum. Use
of lock removes tension from furling line and prevents
accidental release of line which could expose a full
sized genoa to heavy winds.
Use of lock while reefed requires going onto foredeck after reefing and again before sail can be
reefed further or unreefed. Since one purpose of a
reefing system is to allow you to change sail size
while remaining in safety of cockpit, many people
choose not to use locking device. Use of locking
device is not required during reefing.
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 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.
30
MKIV Unit 3
5/30/07
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.
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.
To Remove
Feeder For
Racing
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 10mm Allen wrench provided to
remove 2 screws on bottom of guard
assembly and remove two halves. Be careful—screws are not captive.
3) Use a 3mm Allen wrench to loosen four screws in plastic cover and flange.
5/30/07
MKIV Unit 3
31
Maintenance
Clean/Inspect/Remove Furler
WARNING!: Periodically inspect items listed
below and any others as necessary. Failure
to inspect can cause an accident, damage
to your vessel, personal injury or death.
See www.harken.com for additional
safety information.
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. Foils may be sprayed with McLube® spray to reduce friction during sail changes.
Inspection
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 7/16" (11mm) diameter line. Use double-braid polyester line with good wear characteristics.
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 3
7/14/08
Troubleshoot
Problem
Sail will not furl or is difficult to furl.
Sail will not unfurl or will not unfurl completely.
Sail will not furl 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 with freshwater 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 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.
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
5/30/07
MKIV Unit 3
33
34
MKIV Unit 3
1/02/08
7/14/08
MKIV Unit 3
35
Corporate Headquarters
1251 East Wisconsin Avenue, Pewaukee, Wisconsin 53072 USA
Telephone: (262) 691-3320 • Fax: (262) 691-3008 • Cable: Harken Pewaukee
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
Telephone: (44) 01590-689122 • Fax: (44) 01590-610274
Web: www.harken.co.uk
Email: [email protected]
Harken Poland
ul. Lisa Kuli 4 Lok.1, 01-512 Warszawa, Polska
Telephone: +48 607 979 747
Web: www.harken.com
Email: [email protected]
Harken Sweden
Mjölkekilsgatan 6, Box 64
S-440 30 Marstrand, Sweden
Telephone: (46) 303-618 75 • Fax: (46) 303-618 76
Web: www.harken.se
Email: [email protected]
Harken Adriatik d.o.o.
Obala 107
6320 Portoroz, Slovenia
Telephone/Fax: 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: info.harken.com.au
Harken New Zealand, Ltd.
30-36 Fanshawe Street
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
Printed in USA 4419/9-08
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