Cruising Jib Reefing & Furling Installation Manual Unit 1, 2
Contents
1. 42 Unit 2 44 2110 2117 YY ar np JU 7311 30 7312 30 HFS980 HFG149 HFS1060 HFG196 9 7311 33 7312 33 Unit 1 HFG937 PSI t t tul tul tu tuj 7312 31 Unit 2 HFG938 H 41008 Unit 2 H 41008 i l XXXX NI y 9 fi gu HFG235 SR SCR SQ 944 p M6 945 M4 Se M3 ay 884 ny M2 5 CS 885 Unit 1 2 Cruising Parts List Description Order Unit 1 Unit 2 Trim Cap Set w o Screws 1 HFG182 HFG197 Trim Cap Screw Set 2 HFS1127 1127 Trim Cap Screws 1 Halyard Swivel w o Shackles 1 H 36596C H 37317C Bow Shackle 2 2110 211f Torlon Ball Bearings 42 HBB14 44 HBB7 Clip Smalley Ring 2 H 36602A H 38028A Foil Set 6 Luff 1 Bottom 8 Luff 1 Bottom 1 HFS100 HFS101 Foil 7 2 13 m Luff 1 7311 30 7312 30 Foil 2 610 mm Bottom w Feeder 1 Lal 7312 33 Connector Set Unit 1 6 Unit 2 8 1 HFG937 HFG938 Connector w lsolator 1 7311 31 1312 31 Connector Screw Set 1 30 2 38 1 HFG149 HFS196 Connector Screw 1 HFS980 1060 Connector Isolator Set Unit 1 6 Unit 2 8 1 H 41008 37330 Connector Isolator for 7 16 11mm 12 mm Wire i Description Order Unit 1 Unit 2 Instruction Manual 1 Red Loctite 2 HFG739 HFG739 Blue Loctite 1 833 833 Allen Wrenches M2 5 1 HCP1387 M3 1 HCP1089 M4 1 HFG640 HFG640 M5 1 HFG642 M6 1 HFG644 7mm Double Braid Polyester 70 21 3 m 1 HFG233 8mm Double Braid Polyester 100 30 4 m 1 HFG235 Description2. 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 harken harken co nz Please visit http Awww harken com dealers dealers php for an up to date list of Harken dealers and distributors Printed in the USA 07 09
3. Line jams between Line is not led through windows Pull line through enclosed window guard and plastic spool plate Warranty Online at www harken com or call write email or fax Harken Inc Pewaukee WI USA 28 Unit 1 2 Cruising 5 30 08 Cruising Unit 1 2 HFS980 Description HFS1060 Top Cover Assembly w Screws Top Cover CES H 356650 Top Cover Screw H 350250 Bottom Flange Assembly w Screws HFS980 Flange HFS1060 Bottom Flange Screw H 356600C Guard Assembly H 350250 Guard Set Guard Screw Torque Tube Screw Set H 35199E Torque Tube Screw H 33758E Hub Assembly Ball Plugs Delrin Ball Bearing HFS1052 Shackle HFS873 H 41153 H 41154 HFG146 HFS183 2110 2117 Delrin Balls 24 Delrin Balls 25 Delrin Balls 24 Delrin Balls 25 Delrin Balls 24 Delrin Balls 25 A See Page 31 06 18 09 Unit 1 2 Cruising Order 1 NO rS NN Unit 1 HFG686 H 356650 HFS980 HFG687 H 35600C HFS980 HFG688 H 35199E HFS1052 H 41153 HFS HFG146 H 35144A 72 HBB152 2110 Parts List Unit 2 HFG689 H 350250 HFS1060 HFG690 H 35465C HFS1060 HFG691 H 33758E HFS873 H 41154 HFS HFG183 H 33860A 75 HBB153 2117 29 Cruising Unit 1 2 T HFG182 HFS1127 HF6197 2110 2117 H 36596C Torlon Ball Bearings H 37317C Unit 1
4. 9 6 Side cutters 7 Rat tail file 8 Allen wrenches provided 9 Phillips screwdriver 10 Needle nose pliers Unit 1 2 Cruising 7423 10 7424 12 7425 17 7426 22 11 Center punch 12 Rigging or black tape 13 Hammer Includes 3 x 7403 1 x 7401 1 x 7402 1 Horn Cleat 05 19 09 Preassembly Sailmaker s Instructions Luff Length Note offsets above and below sail C 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 head stay 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 6 682 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 Unt A B 1 11 6 27mm 1 2 13mm 2 13 4 44mm 11 16 17mm 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
5. zin Install 7403 Outboard Stanchion Blocks so line is OUTBOARD outside stanchions Number and placement leads depends on boat length and number configuration of stanchions i 7402 Ratchet Stanchion Block Mount 7402 Ratchet Stanchion Block as furthest aft m lead to prevent line overrides in drum when unfurling STANCHION 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 SEO Tip Make sure ratchet switch is in ON position If there is STANCHION no clicking sound lead line through block in opposite direction SEDEM Lead line to Furling Line Cleat in cockpit HCP168 Furling Line Cleat Install so line is angled as shown 7402 Use 10 5 mm fasteners RATCHET 1 STANCHION Drum Full BLOCK Note As furling line lead changes make sure line Jk sail unfurled doesn t chafe against line guard Rotate line guard if necessary sail furled STERN 5 30 08 Unit 1 2 Cruising Commissioning 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
6. 9 8 x 11 2 18 8 No Toggle Plates Upper Clevis Pin Custom Lower Clevis Pin Isolator Cotter Pin Nylock Nut M12 Allen Cap Screws M6 x 1 x 12mm S 4 x 113 16 18 8 Description Long Link Plate w Toggle 1 Go PO 8 9 8 x 11 2 18 8 Toggle Plates Upper Clevis Pin Custom Lower Clevis Pin Isolator Cotter Pin Nylock Nut M12 Allen Cap Screws M8x1 25x16 A4 SH 3 4 x 113 16 18 8 Order 1 ND 1 ND J ND IND SS N IND IND mS Order Order ect Parts List Unit 1 7422 8 7423 10 H 41536 H 41536 H 41534 H 41535 HFG193 HFG193 Unit 1 amp 2 1424 12 H 41531 H 41527 HFG193 Unit 2 1425 17 1426 22 H 41531 H 41812 H 41526 H 41811 HFG193 HFG319 Unit 1 Unit 2 1311 20 1 2 7312 20 5 8 H 42336 H 42316 H 42396 H 42398 H 42395 H 42397 HFS220 HFS203 HFS181 HFS220 HFS1109 HFS1005 7411 20 1 2 7412 20 5 8 H 37675C 37647 H 42396 H 42398 H 42397 HFS1005 H 43207 H 42045 HFS220 H 42397 HFS181 HFS203 HFS1109 HFS220 7311 20 5 8 7312 20 3 4 H 41300 H 41489 H 42396 H 42398 H 42397 H 42403 H 42307 H 43210 HFS220 HFS203 HFS181 HFS220 HFS1109 HFS1005 Unit 1 7311 21 1 2 7311 21 5 8 H 42159 H 41300 H 42178 H 42178 H 42170 H 42171 H 42395 H 42397 H 42182 H 42182 HFS220 HFS203 HFS846 HFS846 HFS876 HFS876 Unit 2 7312 21 5 8 7312 21 3 4 41300 41489 41304 41304 413
7. 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 5 30 08 Operation Sail Raise Storm Reef Raise Sails 1 Shackle tack of sail to drum Install shackle so screw pin head is on same side
8. reverse eye jaw Tm Ur om toggle so eye is down 1 uz 127mm Important Remove black plastic 2 15 8 15 9mm Eve Jaw Reversible Unit Clevis Pin 1 2 12 7mm 2 5 8 15 9mm For tang down Make sure your caps and install them so that crosspin toggle looks like this will be 90 degrees to main Clevis pin 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 21 16 53mm 211 16 68mm 29 8 67mm 31 4 83mm Toggle Deductions Stay Into Foil Options Unit 1 Unit 2 Long Link Plate w Toggle Unit ck 05 19 09 Preparation for Assembly Top Foil Length Worksheet Measure A and add to this chart and length chart below Make sure upper Alternate measurement points Measurement A of and Pin to Pin Point are the same elle 0 Pin Pin to Pin Length 2 Subtract ABEFG Result Pin to Pin ABEFG To find D pick number from
9. Order Unit 1 Unit 2 Lead Block Kit 1404 1404 29 mm Outboard Lead Assembly 1 7403 7403 5 mm Carbo Ratchet Assembly 1 7402 7402 40 mm Carbo Assembly 1 7401 7401 Horn Cleat 1 HCP168 HCP168 Halyard Restrainer 1 944 945 Sheave SS Inner Race Only 1 944A 945A Clevis Pin 1 4 x 1 0625 18 8 1 HFG467 HCP208 Bracket Large 1 HCP393 HCP394 Cotter Pin 1 16 x 500 18 8 1 HFS118 HFS181 Snap Shackle 1 884 885 07 20 09 Cruising Unit 1 2 3 7311205 8 7312 20 3 4 07 20 09 7422 8 7423 10 7424 12 7425 17 7426 22 411 20 1 2 412 20 5 8 Vide Al 312 20 5 8 TES LU TSN A 56 7312 21 5 8 7312 21 3 4 Unit 1 2 Cruising No Description Rod Adapter Stud w Nosepiece 1 Stud Main Body 2 3 Nosepiece Cotter Pin 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 No Description Jaw Jaw Toggle O CO 6 Toggle Crosspin Clevis Pin Cotter Pin Cotter Pin Nylon Washer Eye Jaw Toggle Reversible 1 PSION 7 Toggle Crosspin Nylon Washer Cross Hole Plug Clevis Pin Cotter Pin Cotter Pin Stud Jaw Toggle 1 NI GD amp Go PO No Toggle Crosspin Clevis Pin Stud Cotter Pin Cotter Pin Nylon Washer Description Long Link Plate w Toggle 1 NI 01 amp GO PO 8
10. Pin Point are the same elle 0 Pin Pin to Pin Length 2 Subtract ABEFG Result Pin to Pin ABEFG find D pick number from chart below that is closest to but not greater than total from step 3 Inches mm 4 X 84 336 4 x 2133 6 8534 4 5 X 04 420 5 X 2133 6 10668 0 6 x 84 504 6 x 2133 6 12801 6 X 84 588 x 2133 6 14935 2 8 x 04 672 0 x 2133 6 1 068 8 9 x 84 56 8 x 2133 6 1920 4 Example If result from Step 3 is 500 inches D 420 inches 12 000mm D 10 668mm Result C Top Foil Length If top foil length is Pin Length Check 91 8 232mm or allle After completing worksheet above fill in A C D and G below Add less go to Page 11 through G to confirm total equals your pin to pin measurement Length Worksheet i Dimensions Center of Pin to Bottom of Terminal L o T TopFollengh y F Bottom of Foil to Crosspin G Crosspin to Clevis Pin Pin to Pin Length G Toggle Distance from Lower Clevis Pin to Crosspin Hole Toggle Part No _ Type ClevisPin G Distance 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 G 10 Unit 2 Cruising 12 30 08 Preassembly Short
11. as suncover Secure genoa sheets to clew of sail 3 Attach genoa halyard to halyard swivel Passluff tape through feeder into foil groove Attach head of sail or pendant at head of sail to halyard swivel 6 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 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 oee 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 the
12. 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 Uc 3 4 TES Clevis Pin Unit A B CMax E F G H J Toggle Used 39 8 6 12 13 8 Min 331 4 845mm Min 91 4 235mm Min 81 4 210mm 65 8 31 46 Min 21 2 64mm ie 12 7mm 92mm 152mm 305mm 35mm 40 16 1027mm Max 11 8 302mm Max 1013 16 275mm 167mm 78mm 5 16 129mm 5 e 15 9mm 4pm eg 16 111 16 Min 427 16 1078mm Min 113 4 298mm Min 103 2 264mm 83 16 31 16 33 e 86mm 5 8 15 9mm 114mm 203mm 406mm 42mm 503 4 1289mm 14 8 378mm 13 2 343mm 208mm 97mm 61 2 165mm 3 4 19 1mm 06 16 09 Unit 1 2 Cruising 7 Preassembly Use dimensions of the 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 allows fine tune adjustment of mast rake Unit Thread _ 1 5 8 18LH Unit 2 EN Unit 1 amp 878 225mm 7 E Eye Jaw Reversible Toggle T B3 iis e M on Unit 2 ET 295mm e lf lt Crosspin E JY Fork Tang Attachment Attachment Cy Make sure your E toggle looks like this installations Unit 1 switch plugs K 23 4 70mm to this position M Most boats have a chainplate with a single tang If boat has two plates WT forming a jaw
13. chart below that is closest to but not greater than total from step 3 Inches mm 3 X 84 252 3 X 2133 6 6400 8 4 X 84 336 4 x 2133 6 8534 4 5 X 84 420 5 x 2133 6 10668 0 6 x 84 504 6 x 2133 6 12801 6 x 84 588 x 2133 6 14935 2 8 x 04 672 0 x 2133 6 1 068 8 Example if result from Step 3 is 500 inches D 420 inches 12 000mm D 10 668mm Result C Top Foil Length lo If top foil length is Pin Length Check 63 2 171mm or After completing worksheet above fill in A C D and G below Add 695 0010 Page P A through G to confirm total equals your pin to pin measurement Length Worksheet a Dimensions 0 Center of Pin to Bottom of Terminal L o T TopFoillength y o F Bottom of Foil to Crosspin G Crosspin to Clevis Pin Pin to Pin Length G Toggle Distance from Lower Clevis Pin to Crosspin Hole Toggle Part No ClevisPin G Distance 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 12 30 08 Unit 1 Cruising 9 Preparation for Assembly Top Foil Length Worksheet Measure A and add to this chart and length chart below Make sure upper Alternate measurement points Measurement A of and Pin to
14. sure shallow jaw is up Jaw Jaw Toggle Assembly Stud Jaw Toggle Assembly Eye Jaw Toggle Assembly 5 30 08 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 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 A 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 Unit 1 2 Cruising 7 30 09 Assembly Attach Foil to Drum Assembly Slide lower drum assembly over turnbuckle and attach using long crosspin Use plastic __ Crosspin at 90 to Clevis Pin washers provided WARNING Crosspin must be 90 degrees to clevis pin that C levis Pin attaches unit to boat If pins run same direction toggle will fatigue b and could break suddenly causing an accident damage to your vessel personal injury or death See ww
15. 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 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 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 plastic coated 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 sa
16. 02 41525 42397 42403 41497 41497 HFS203 HFS203 HFS937 HFS937 HFS336 HFS336 31 HARKEN 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 harken harken com 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 harken harken fr Harken Italy S P A Via Della Cerca 12 14 22070 Lurago Marinone Como Italy Telephone 39 031 3523511 Fax 39 031 3520031 Web www harken it Email info harken it Harken UK Lid Bearing House Ampress Lane Lymington Hampshire S041 8LW England Telephone 44 01590 6891 22 Fax 44 01590 610274 Web www harken co uk Email enquiries harken co uk Harken Poland ul Lisa Kuli 4 Lok 1 01 512 Warszawa Polska Telephone 48 607 979 747 Web www harken com Email polska harken com Harken Sweden Mj lkekilsgatan 8 Box 64 5 440 30 Marstrand Sweden Telephone 46 303 618 75 Fax 46 303 618 76 Web www harken se Email harken harken se Harken Adriatik d 0 0 Obala 107 6320 Portoroz Slovenia Telephone Fax 5 6 74122 Web www harken si Email info harken si Harken Australia Pty Lid 1B Green Street Brookvale N S W 2100 Australia Telephone 61 2 8978 8666
17. H 37317C 1 8mm Double braid polyester line HFG235 100 30 4m 4 Unit 1 2 Cruising 12 30 08 Parts Trim Cap Set Trim Cap Screw Set ta Other Components Description Trim cap set Trim cap screw set Red Loctite foil screws Blue Loctite foil clamp screws Connectors Connector isolators Connector screw set Foil clamp screw set Bow shackles Trim cap set Trim cap screw set Red Loctite foil screws Blue Loctite foil clamp screws Connectors Connector isolators Connector isolator for 7 16 11mm 12mm Wire Connector screw set Foil clamp screw set Bow shackles we e j Red Loctite Connector Isolators ime w k Connectors Foil Clamp Screw Set el Unit Part No Qty Size HFG182 H 37443B H 37444B HFS1127 HFG739 033 7311 31F H 41008 HFG149 30 HFS980 H 41153 2110 HFG197 H 37445B H 37446B HFS1127 HFG739 833 7312 31F 2 H 37330C H 41009 Allen Wrenches Supplied HFG196 38 HFS1060 Te Description H 41154 3 2117 9 Bow Shackles OH SH FS ce Allen Wrenches cO CO CO PO lt rN rN cO M2 5 M4 M5 M3 M4 M6 8mm H 41009 Connectors are shipped with 7312 20 3 4 stud jaw toggle and 7312 21 3 4 long link plate w toggle 12 30 08 Unit 1 2 Cruising 5 Rigging Parts Check Tools WARNING Headstay condition should be checked b
18. HARKEN Cruising Jib Reeting amp 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 Parts 4 5 Halyard Headstay Tension 24 Tools 6 Raise Sails 25 Dimensions Sailmaker s Instructions T Furl Reef 23 24 Toggle Deductions Stay Into Foil Options 8 secure Sail 26 Top Foil Length Worksheet Unit 1 9 Maintenance Top Foil Length Worksheet Unit 2 10 cisean 27 Short Top Foil 11 inpet 97 HOED 3i Replace Line 27 Assembly Storage 27 Foils Connectors 13 15 Remove Furler 2 Halyard Swivel B Troubleshooting Drum Assembly 13 Warranty Rod Rigging 14 Adjust Turnbuckle 17 Toggle 17 18 Final 17 18 Commissioning Turnbuckle 20 Line to Cockpit 21 Halyard Swivel Height Angle 22 23 Halyard Restrainer Tension 21 Parts Descriptions 1 Toggle Assembly 5 Foil Clamp Screws 9 7 2 13m Foil 13 Trim Cap Screws 2 Crosspin 6 2 610mm Bottom Foil 10 Connector Screws 3 Shackle 7 Connector Isolator 11 Halyard Swivel 4 Drum Assembly 8 Connector 12 Trim Cap 2 Unit 1 2 Cruising 5 30 08 Preassembly Sizing Check Size Check Check headstay and clevis pin dimensions in chart below damage to your vessel personal injury or death See www harken to slightly raise the unit To clear anchor use Harken Long Lin
19. 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 Top foil length from worksheet 31 2 11 2 89 38mm 51 2 21 2 89 64mm Top foil length from worksheet Actual Top Foil 63 4 171mm 91 232mm 4 102mm 53 4 146mm Do not cut top foil to length from worksheet Cut top foil to 4 102mm or 52 4 146mm and shorten trim cap as shown in middle photo above Shorten bottom foil per chart below Shorten bottom of Top foil length bottom foil by this Cut top m from worksheet Actual top foil amount trim cap in mm in mm in mm 102 0 102 25 Do Not Use m 102 21 2 64 Top foil length from worksheet 53 4 146 0 0 612 4 165 102mm 9 53 4 229 146mm ut top trim cap as snown above ma E 89 53 4 146 76 59 4 146 64 53 4 146 Top foil length from worksheet 7 15 08 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 mea
20. al halyard angle It may be necessary angle between mast and and halyard is too shallow to mount a halyard restrainer on front of your mast to hold halyard to rear Jib halyard is wrapping around the headstay See installation instructions regarding optimal halyard swivel height A wire pendant because halyard swivel is too low may be needed at head of sail to raise halyard swivel to proper height Jib halyard is too tight Foils riding on turnbuckle Foils too high binding on swage eye Spare halyard is wrapping in sail as it furls Sail will not furl or iS difficult to furl Salt or dirt in bearings maintain proper drag on line while unfurling Stop knot catching Sail full of wind 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 or will not unfurl angle between mast and halyard is too shallow mount a halyard restrainer on front of your mast to hold halyard to rear because the halyard swivel is too low Furling line is not free Free furling line Sail will not furl Insufficient furling line on drum Remove sheets Rotate stay wrapping as much furling line on drum as possible completely 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 dru
21. ate 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 A apply a dry spray lubricant such as McLube WARNING Periodically inspect items listed Foils may be cleaned by washing with soap and water A below any others as necessary Failure to scrap of luff tape may be run up foil to scrub inside the A inspect can cause an accident damage to your grooves Foils may be sprayed with McLube spray to vessel personal injury or death See www reduce friction during sail changes 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 swage fitting and lower toggle for signs of stress corrosion Norseman Sta Lok terminal rod terminal for signs of loosening All screws on unit to be sure they have not loosened Foil to make sure that it has not dropped into drum assembly 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 7mm line with break strength exceeding 2500 Ibs 1130 kg Smaller boats or smaller sails may al
22. ates may fatigue and break causing an accident damage to your vessel personal injury or death See www harken com for additional safety information 20 Unit 1 2 Cruising 1 01 08 Commissioning Lead Line to Cockpit wa 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 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 _ tT 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 1401 Forward Stanchion Block 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 7401 Correct block position is critical to even FORWARD line spooling and ease of furling STANCHION BLOCK BOW A 7403 Outboard Stanchion Blocks
23. il 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 to your vessel personal injury or death See www harken com Halyard Wraps 5 30 08 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 sa
24. il 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 ten sion 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
25. k Plates 7311 10 Chainplate Clevis Pin 7411 20 1 2 Eye jaw reversible 7311 21 1 2 Long link plate w toggle WARNING Harken does not recommend drilling boat s chainplate or toggle as this may result in rig failure which will cause an accident com for additional safety information Will drum fit on bow See page 7 If necessary use an additional toggle which can be cut to various lengths Description 1 4 9 32 5 16 5 2mm 6 35mm Toggle Part No Description Chainplate Clevis 7311 20 1 2 7311 20 5 8 Stud jaw 7311 21 5 8 Long link plate w toggle Part No Description Wire 5 16 3 8 7 16 8mm 10mm 11mm 12mm 7312 10 12 17 22 7 14mm 8 38mm 9 53mm Toggle Part No Description Chainplate Clevis Pin 0 Eye jaw reversible 7 16 14mm and 12mm requires large bore 41009 isolators They have a 12 stamped on the outside 41009 Isolators are shipped with 7412 20 3 4 stud jaw toggle and 7312 21 3 4 long link plate assembly 6 24 08 Unit 1 2 Cruising 3 Parts s Tie Tie Bottom Foil w Feeder Foils Halyard Swivel Drum Assembly Main Components Description Part No Drum Assembly HFG146 1 2 610mm Bottom foil 7311 33 1 7 2 13m Foil 7311 30 6 Halyard Swivel H 36596C 1 7mm Double braid polyester line HFG233 70 21 3m Drum Assembly HFG188 1 2 610mm Bottom foil 731233 1 7 2 13m Foil 7312 30 8 Halyard Swivel
26. low 9 16 amm line Replace Line Unit 2 Use HFG235 furling line or source a good quality line with good wear characteristics Use 5 16 8mm line with break strength exceeding 3740 105 1700 kg Smaller boats or smaller sails may allow 3 8 8mm 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 5 30 08 Unit 1 2 Cruising 27 3 4 9 6 S Troubleshoot Problem Probable Cause Solution Jib halyard is wrapping around headstay because See installation instructions regarding optim
27. m opare halyard catching in sail as it furls Move halyards away from furling headsail as above Headstay rotates in Insufficient tension on headstay Tighten headstay and or backstay to eliminate sag in headstay jerks or elliptically Sail does not stay Sail not furled tightly on stay furled Furling line not secure Sail will not go up Luff tape will not go into groove Maintain drag on sheets while furling Secure furling line Check luff tape for fraying Check luff tape size Sail catching at prefeeder Flake sail more loosely on deck Sail will not raise Halyard swivel is hitting end stop Luff of sail is too long and must be recut ee or luff Angle between halyard and mast is too sharp Halyard must be routed from a point higher on mast This may require that any halyard WI TOL and halyard is pulling too much to the rear turning blocks aloft be replaced or sail shortened Sail will not Halyard is wrapping on headstay Angle between headstay and halyard is too shallow and must be optimized per installation instructions come down Halyard swivel off foil Sail luff too long or foil is too short or low and must be lengthened or raised Ultravoilet cover rolls 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 up inside of sail drum in opposite direction Line guard and cowling alignment may need to be adjusted
28. r pieces Fold halves of plastic isolator over wire 14 Unit 1 2 Cruising 12 28 08 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 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 RIO 00 RIC 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 Unit 1 2 Cruising Rod Rigging Rod Adapter Stud 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 Make
29. re 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 5 30 08 Unit 1 2 Cruising 25 Operation Reef Secure Sail 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 Lubric
30. suring 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 12mm 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 7 01 08 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 12mm down from top of foil on each side of Sail groove Remove trim cap Drill two 1 8 8mm holes in foil for self tapping screws 06 22 09 Unit 1 2 Cruising 13 Assembly Assemble Trim Cap Smaller Wires Unit Wire 0 1 1 4 6mm 9 32 7mm Unit Wire 0 L wa 5 16 8mm 2 516 8mm 3 8 10mm S 7 16 11mm 12mm olide foils on stay starting from bottom or top In most Swage stud fitting or wire end must pass through foil cases marine eye will fit 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 Rectangula
31. w harken com for additional safety information Lift foils so top of foils ride about v2 12mm below upper terminal 1 2 12mm Lining these holes up with top of drum assembly insures Screws are lined up with foil holes Use blue Loctite on screws to secure foils in a lifted position es nw 2 5 30 08 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 9 1 5m 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 12mm 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 pl
32. y a professional rigger before Preassembly 1 Harken toggle assembly required Sold separately 2 Mating turnbuckle components must be purchased separately 3 Headstay may require cutting and shortening to fit Harken toggle Headstay may remain uncut by replacing lower stud of turnbuckle with stud eye thus eliminating extra toggle 4 Rod rigging requires Harken rod adapter stud 5 Order Harken 7404 Lead Block Kit and one additional 7403 if necessary Fits 1 25mm stanchions reusing Wire that is old or damaged A may break suddenly causing an accident damage to your vessel personal injury or death See www harken com for additional safety information ALL UNITS E dien p arken no ater OIN IUE SOUE epee Stud Required 7404 Lead Block Kit Sold Separately Sold Separately Jib Reeting amp Mos d Load Block Kit Stud Jaw Toggle Part No Unit ft 7 j 13 Long Link Jaw Jaw Toggle Eye Jaw Toggle Plate w Toggle Rod Adapter Stud Unit Part No Unit Part No Unit Part No Part No Thread 7311 20 1 2 7411 20 1 2 2 73122058 2 7412 205 8 Includes 9 H 41009 large bore connector isolators Requires drum assembly with four threaded holes in base See page 16 Tools You Will Need 6 1 Long tape measure 2 Short tape measure 3 Drill bit 1 8 3mm 4 Power drill 9 Hacksaw 6 1911 21 1 2 7311 21 5 8 9122155 7312 21 3 4
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