MKIV Jib Reefing & Furling Installation Manual Unit 0
Contents
1. 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 0 15 Assembly Foils Connectors Inject only a small amount of adhesive into middle hole Unit 0 will only take 1 4 to 1 3 of a graduation mark Do not press tip of injector into hole Back off slightly while injecting Tip When you see a small amount of adhesive enter one of the screw holes stop You have applied enough 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 4 1 2ml of adhesive 16 MKIV Unit 0 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 10 254mm bot tom 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 0 17 Assembly Drum Assembly Turnbuckle Harken Toggle Loosen foil clamp screws at top of drum assembly Slide drum assembly onto foils pom wr etat Co cL AER Tip Face clamp downward so it cni E o0 CRM clears foil notches during installation 18 MKIV Unit 0 5 30 07 Assembly MOI nili E2. sail furled STERN STERN 24 MKIV Unit 0 5 01 09 Commissioning Halyard Wrap Prevent Halyard Wrap Halyard Wraps 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 A injury or death See www harken com for additional safety information If Halyard Wraps If halyard wraps do not force unit to turn Attempt to open sail by carefully furling in and out a little at a time If sail will unfurl lower it by releasing jib halyard Severe halyard wraps can only be cleared by a professional going aloft and freeing halyard If sail will not furl or unfurl try to remove jib sheets and manually wrap sail around headstay WARNING 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 WARNING Do not go aloft on boat s halyards if there has been a halyard wrap Do not use boat Damage to halyard headstay stay terminals or connections as a result of a halyard wrap may cause these parts to break suddenly causing mast to fall down while person is aloft resulting in severe injury or death Sailing or motoring with boat after a wrap can result in the headstay breaking and mast falling down possibly resulting in severe injury or death Before using boat have a prof
3. G LINGE 9 30 07 Apply a few drops of red Loctite to threads of nosepiece Screw main threaded stud portion onto bronze nosepiece until flats align with two cotter pin holes in terminal body Tip Turn nosepiece completely into threaded stud portion Flats will be close and may only require a small half turn to align with cotter pin holes Insert two cotter pins and spread Clean excess Loctite from terminal body using Special care to ensure that there is no red Loctite on threaded stud MKIV Unit 0 Rod Rigging Rod Adapter Stud Assembly Assemble turnbuckle and attach Harken toggle Note If using Sta Lok or Norseman Stud you must use a washer above Stud as shown below Eye Jaw Toggle Assembly 20 MKIV Unit 0 Attach Turnbuckle Toggle 4 13 09 Assembly Final If stay length is set use side cutters or needle nose pliers to bend cotter pin to secure turnbuckle J ML Amm m s E i R gt 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 A WARNING Crosspin must be JE o 90 degrees to clevis pin that uu attaches unit to boat If pins x Ta run same direction toggle will fatigue and could break suddenly causing an accident damage to c y your vessel personal inj
4. HCP393 HFS118 884 05 27 09 Tame your main with Harken Battcar Mainsail 5 om a LL 224 D au simple low cost solution that lets you raise reef and douse your mainsail at any wind angle Why choose Battcars instead of in hoom or in mast furling No hidden costs A basic in boom or in mast furling system costs 4 6 times as much as a top of the line Battcar system With ball bearing Battcars you don t need a new boom mast mainsail or professional installation and you ll never need an electric winch as long as you can hoist the weight of the sail Proven reliability Battcars have a simple robust design that withstands years of extreme mainsail loads Top solo circumnavigators trust these systems to take them around the world Sail efficiency In boom and in mast furlers generally require smaller and flatter custom designed sails Battcars let you keep the performance of your existing sail Fits boats 21 42 ft TECH TIP 2 When reefing or dousing the sail use a Harken Lazy Jack SF system to flake the main on the boom p INNOVATIVE SAILING SOLUTIONS For the Top 10 Q amp A on Battcars see www harken com usa 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 Ha
5. O1 amp GO PO No Description Rod Adapter Stud 4 w Nosepiece 1 Stud Main Body 2 Nosepiece 4 3 Cotter Pin 3 32 x 3 4 18 8 Rod Adapter Stud 6 w Nosepiece 1 Stud Main Body 2 Nosepiece 6 Cotter Pin 3 32 x 3 4 18 8 Parts List Order 1 BO PO Order Order OT 104 1 Order 1 M eek PI Order PD PD a Part No HFG683 H 38817 HFS980 HFG684 H 38818 HFS980 Part No HFG685 H 38293 HFS1052 Part No HFG695 H 42959 HFS1102 7410 10Base H 36865 HSB17 HSB242 2110 Part No 1410 20 3 8 H 37687C H 42401 HFS1108 H 42050 H 42400 HFS181 1410 20 7 16 H 37686C H 42401 HFS1108 H 42050 H 42399 HFS181 Part No 7420 4 H 41707 H 41708 HFS181 7421 6 H 41705 H 41706 HFS181 33 MKIV Unit 0 e 8 S HFG629 HFS1126 c5 LL 2110 Q c 96 Torlon Ball Bearings 2110 N HFS1126 lS 7410 30 z 9999 816 216 Vd Velie oa HFG28 CEL Ses 7410 33 T 2 zr d HFG341 8 mE ce 7410 31 EL Mm oc e HFGSYY 7410 32 515 Ld d IS H 42067 34 4416 HFG 722 947 HFG200 HFG201 HFG594 HCP1387 HCP1089 HFG642 H 42068 39625 H39713 884 MKIV Unit 0 Description Trim Cap Set w o Screws
6. blocks to stanchions See instructions below Tip Start all four screws before tightening 7401 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 BOW 7401 Correct block position is critical to even 4 line spooling and ease of furling BLOCK 7403 Outboard Stanchion Blocks zin Install 7403 Outboard Stanchion Blocks so line is E OUTBOARD outside stanchions STANCHION BLOCK Number and placement of leads depends on boat length and number configuration of stanchions 7402 Ratchet Stanchion Block Mount 7402 Ratchet Stanchion Block as furthest aft 252 lead to prevent line overrides 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 7403 Tip Make sure ratchet switch is in ON position If there is OUTBOARD STANCHION no clicking sound lead line through block in opposite direction a 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 PO RATCHET STANCHION Drum Full BLOCK Note As furling line lead changes make sure line y doesn t chafe against line guard Rotate line guard if necessary
7. 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 WARNING Harken does not recommend drilling boat s chainplate Sizing Check Unit Part No Description Wire Sizes 7410 10 MKIV Unit 0 Rod Sizes 4 3 mm 5 03mm Toggle Part No Description Chainplate Clevis Pin Size 7410 20 3 8 Eye jaw reversible 7410 20 7 16 Eye jaw reversible 7 16 Chainplate Clevis Pin 7 16 08 MKIV Unit 0 Preassembly Parts uw T 2 13m 2 610mm Foils Bottom Foil Connector Bushings Bottom C nnact rs Connector Trim Cap Plastic _ Connector Foil Screws 7 Pp Wedges 3 Trim Cap Screws Halyard Swivel Drum Assembly 2 5 3 Allen Wrenches Line Prefeeder Injector Adhesive Main Components Other Components Part No Quantity Description Part No Quantity Description HFG290 1 Drum assembly with foil clamp 7410 31 4 6 5 165mm Connector H 39923 1 Halyard swivel 7410 32 1 10 254mm Bottom Connector Foils Standard Package HFG294 1 Connector bushing set 10 H 42067 10 H 42068 Part No Quantity Description HFG298 1 Plastic connector wedge set 12 H 39625 7410 30 5 7 2 13m foil HFG341 1 Foil screw set 26 HFS1105
8. not placed across furling line where they may cause chafe 5 30 07 MKIV Unit 0 Reef Secure Sail Operation Race Conversion Race conversion allows use of both grooves Remove Feeder for sail changes and tacking genoas on deck for use of maximum luff length genoas 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 To Remove Serious racers may want to remove the pacing halyard swivel Note It is not possible to remove halyard ND swivel on a unit with a Norseman Sta Lok or rod adapter stud unless you disassemble Q terminal stud Make sure you use a new 2 1 L Norseman Sta Lok wedge to reassemble 1 a Norseman Sta Lok fitting 2 Slide screw up Remove feeder 3 Lower halyard swivel RETO drum assembly Carefully remove feeder bottom end first 2 Rig a secure temporary headstay Don t drop the feeder overboard 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 23 Remove turnbuckle body and lower unit and slide off halyard swivel 6 Reattach headstay to boat Remove Drum 1 Remove sail and unwind line from drum Line can
9. required if a halyard restrainer is necessary page 26 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 25 Tack Setback Note setback for tack shackle and cut sail accordingly Luff Tape Size Unit 0 requires 6 9 2 or 5mm luff tape Luff Tape Length Cut off top of luff tape so it is 18 to 24 450 to 600 mm below head of Sail This allows head to lag behind rest of sail to help flatten sail It will also help head to roll more smoothly Note feeder height and extend bottom of luff tape downward so it is below feeder This will prevent luff tape from catching in feeder as sail is lowered Tack and Head Shackles Make sure tack and head shackles fit sail rings Minimum inside dimensions of standard head and tack shackles are 1 46 27mm gt 13mm Sun cover lt B gt sun covers may be installed on either side of the sail Be sure to match other sails in customer s inventory MKIV Unit 0 9 29 09 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 f GlevisPin _Pin to Pin Length 3e 9 5mm 25 6 66 5mm 2 p Fork Tang Attachment Attachment T A M fm 3 2
10. 5 8 66 5mm For tang down installations 0 t 97 3 7mm 09 Switch plugs to this position P 4 lt 55 a IMP pr Most boats have a chainplate with a single tang M gt If boat has two plates forming a jaw reverse HV eye jaw toggle so eye is down Fork Attachment Tang Attachment Important Remove black plastic caps and install them so crosspin will be 90 degrees to lower 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 4 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 16 08 MKIV Unit 0 7 Preassembly Top Foil Length Measure A and add to this chart Make sure Upper Alternate FG and length chart below measurement points Measurement of A and Pin to Pin Point i are the same Total EE 5 25 Pin to Pin Length EI Subtract ABEFG Result Pin to Pin ABEFG af Subtract To find D pick number from chart below that
11. 7410 33 1 2 610 Botton foil HFG679 1 Trim cap set H 37335 H 37336 HFG629 1 Trim cap screw set 3 HFS1126 Line Standard Package o 947 1 Prefeeder su H 39713 1 Feeder with screw and tab HFG594 95 16 7m 7mm Single braid polyester 2110 3 m Tools HFG725 1 Injector 1 oz 5200 Adhesive HFG722 Quantity Description 1 Each 2 5 3 Allen wrenches 4 MKIV Unit 0 6 06 08 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 Fits 1 25mm stanchions ALL UNITS ROD RIGGING Harken Toggle Harken Rod Adapter Sold Separately Stud Required Sold Separately r Tools You Will Need ui 1 Long tape measure 2 Short tape measure 3 Power drill 4 Drill bit 1 8 3mm 9 Hacksaw 7 16 08 7420 4 Eye Jaw Toggle 7410 20 3 8 7421 6 7410 20 7 16 Rod Adapter Stud 9 6 Side cutters 7 Rat tail file 8 Allen wrenches provided 9 Slotted phillips screwdrivers 10 Needle nose pliers 11 Center punch 12 Rigging or black tape 13 Scissors 14 Metal straight edge 15 Hammer MKIV Unit 0 Rigging Parts Check Tools WARN
12. HARKEN MKIV Jib Reefing amp Furling Installation Manual 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 Tools 5 Raise Sails Dimensions Sailmaker s Instructions 6 Furl Reef Toggle Deductions Stay Into Foil Options 7 secure Sail Top Foil Length 8 Race Conversion Short Top Foil 9 Maintenance Foil Length 10 Clean Assembly Inspect Foils Connectors 11 17 Replace Line Halyard Swivel 17 Storage Drum Assembly 18 Remove Furler Rod Rigging 19 Troubleshooting Turnbuckle 20 Warranty Toggle 20 Final 21 22 Commissioning Turnbuckle 23 Line to Cockpit 24 Halyard Wrap Prevent Halyard Wrap 25 Pendants Halyard Restrainer Tension 26 27 28 26 29 29 30 29 29 29 29 29 Parts Descriptions 1 Toggle Assembly 9 Foil Clamp 9 Bottom Connector 2 Crosspin 6 2 610mm Bottom Foil 10 7 2 13m Foil 3 Shackles 7 Feeder 11 Connector Screws 4 Drum Assembly 8 Connector Bushing 12 Connector Wedge 2 MKIV Unit 0 13 14 15 16 Connector Halyard Swivel Trim Cap Trim Cap Screws 7 16 08 Preassembly Sizing Check A a ps 10 Size Check 1 Check headstay and clevis pin dimensions in chart below or toggle as this may result in rig failure which will cause an accident damage to your vessel personal
13. ING 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 7404 Lead Block Kit Sold Separately Jib Reefing I amp dera bp Lead Block Kit Includes 3 x 7403 1 x 7401 1 x 7402 1 Horn Cleat 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 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 Preassembly Dimensions Sailmaker s Instructions Min 391 2 1003mm Luft Length Note offsets above and below sail A shorter luff may be
14. Trim Cap Screw Set 3 Trim Cap Screw Halyard Swivel w o Shackles shackle Torlon Ball Bearings Clip Smalley Ring Foil Set 5 Luff 1 Bottom Foil 7 2 13 m Luff Foil Screw Set 26 Foil Screw Foil 2 610 mm Bottom Connector Set w o Bushings 4 x 6 5 165mm 1 x10 254 mm Connector w Bushings Connector Bottom w Bushings Connector Bushing Set 10 Connector Bushing w Hook Connector Bushing Connector Wedge Set 12 Connector Wedge Feeder Set Feeder Feeder Screw Tab Description Instruction Manual Prefeeder 5200 Adhesive Set 5200 Marine Adhesive Sealant Injector Allen Wrenches 2 5 mm 3mm 7mm Single Braid Polyester 55 16 7m 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 Small Cotter Pin 1 16 x 500 18 8 Snap Shackle Parts List Order 1 1 1 1 2 96 mak NS all Order Order Ol Part No HFG679 HFG629 HFS1126 H 39923 2110 HSB17 HCP1199 HFG286 7410 30 HFG341 HFS1105 7410 33 HFG599 7410 31 7410 32 HFG294 H 42067 H 42068 HFG298 H 39625 H 39713 H 37272B HFS1128 H 3 282A Part No 4416 947 HFG725 HFG722 HFG200 HFG201 HCP1387 HCP1089 HFG642 HFG594 Part No 1404 7403 7402 7401 HCP168 944 944A HFG467
15. ation instructions regarding optimal 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 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 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 all
16. d if necessary shorten trim cap e Cut Offs Do Not Use 33 3 25 8 86 67mm 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 0 p PS ETETE 958455 Y Sin TT E ANETTE Cut Offs Not Use 21 2 1 2 63 13mm 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 4 Shorten connector 2 Cut through middle hole in top foil 1 Initial top foil cut length Top Foil Length from Resulting Top Worksheet Foil Length 21 2 59 8 41 16 63mm 143mm 103mm 2 51 8 39 16 51mm 130mm 90mm 11 2 4 31 16 38mm 117mm 78mm 1 41 8 29 16 25mm 105mm 65mm 1 2 39 8 21 16 13mm 92mm 52mm Do Not Use To allow for saw cut position blade so upper half of middle hole is preserved E OD T a Ram 3 Under 1 2 13mm Eliminate top foil and run foil higher in drum assembly 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
17. essional rigger inspect and replace parts as necessary using following methods A professional rigger must carefully inspect the masthead area using a secure hoisting method Inform rigger that there has been a halyard wrap so they can avoid an accident by relying on standing rigging or halyards Inspection must be done while rigger is suspended from a separate crane or mast must be lowered to perform inspection Some professionals may rig a new line through internal masthead sheaves to serve as a temporary headstay to hold mast in place Wire rod rigging terminals toggles clevis pins or cotter pins must be inspected and replaced if they show any signs of damage Prevent Halyard Wraps To prevent wraps the halyard must exert a slight pull to the rear This allows the foils to turn while halyard remains stationary A 1 Halyard swivel should be within top 4 6 100 152mm of foil unless a halyard restrainer is used 2 Halyard must pull slightly to rear 8 10 3 Halyard must be snug but not too tight Test furler at dock but if water is smooth an incorrect lead angle may not be apparent Halyard wraps usually occur in wave action when lead angle is not correct The 8 10 angle shown at right is critical 8 25 09 MKIV Unit 0 WARNING Sail must be fitted to foil length before using to prevent halyard wraps and possible headstay loss which will cause an accident damage to your vessel personal injury or death See www harken com fo
18. h 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 23 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 adjust er 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 9 30 07 MKIV Unit 0 2f Operation Sail Raise Storm Reef Raise Sails 1 Install prefeeder by securely tying end of
19. 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 6 x 84 504 6 x 2133 6 12801 6 result from Step 3 is 500 inches D 420 inches 12 000mm D 10 668mm Result Top Foil Length Length Check After completing worksheet above fill in A C D and G below Add A through to confirm total equals your pin to pin measurement Length Chart inches Center of Pin to Bottom of Terminal Bottom of Terminal to Top of Foil 224 Top Foil Length D Number of Foils x84 2133 6 mm D E Bottom Foil F Bottom of Foil to Crosspin 16 25 G Crosspin to Clevis Pin MN EMEN G Toggle Distance from Lower Clevis Pin to Crosspin Hole Toggle Part No Type ClevsPin GDistance 7410 20 3 8 Eye Jaw 7410 20 7 16 Eye Jaw 8 MKIV Unit 0 9 30 07 9 30 07 Preassembly Short Top Foil If top foil is shorter than 7 177 8mm 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 61 4 45 8 159 117mm not use plastic bush ing above top connector Cut Offs Do Not Use 1 2 31 2 114 89mm 41 2 31 2 114 89mm not use plastic bushing above top connector Shorten top of connector an
20. line to a deck fitting or to toggle below furler so it is 2 610mm below feeder 2 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 4 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 7 Holst 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 Siorm 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 25 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 a
21. ment may need to be adjusted 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 32 MKIV Unit 0 5 30 07 MKIV Unit 0 HFG683 HFG685 HFG684 HFG695 Torlon Balls 26 HFS980 H 38817 HFS980 H 38818 H 38293 HFS1052 H 42959 HFS1102 WEES Delrin Balls 26 2110 Delrin Balls 26 Delrin Balls 26 Delrin Balls 26 05 27 09 MKIV Unit 0 Description Top Cover Assembly w Screws Top Cover Top Cover Screw Bottom Flange Assembly w Screws Flange Bottom Flange Screw Description Guard Assembly Guard Set Guard Screw No Description Clamp with Screws Clamp Clamp Screw Hub Assembly Ball Plugs Torlon Ball Bearing Delrin Ball Bearing Shackle No Description Eye Jaw Toggle 3 8 9 5 mm Pin 1 Toggle 2 Crosspin 3 Nylon Washer Set 2 4 Cross Hole Plug Set 2 5 Olevis Pin 6 Cotter Pin 3 32 x 3 4 18 8 Eye Jaw Toggle 7 16 11 1 mm Pin 1 Toggle Crosspin Nylon Washer Set 2 Cross Hole Plug Set 2 Clevis Pin Cotter Pin 3 32 x 3 4 18 8 OD
22. mount of force required is related to amount of wind but a Unit 0 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 32 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 20 MKIV Unit 0 5 30 07 Operation A sail may be partially furled before you resume Sailing This is known as reefing Many sailors find it helpful to place marks on foot of sail so that they can reef to a variety of predetermined jib sizes This allows marks to be placed on jib lead tracks or toe rail so that lead block position can be changed to correspond to reefed jib sails are generally reefed to balance boat and to reduce heeling moment Sails may also be reefed to improve visibility or to slow boat while sailing in congested areas or entering or leaving harbors Secure Sail When furling 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
23. oosening 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 9 32 7mm diameter line Use either Harken replacement or double braid polyester line Storage Mast Down In areas where it freezes do not store system where water can accumulate in foils When water freezes it will rupture aluminum Store foils under cover with grooves facing down or on an angle so water will run out Storage Transporting Do not store or transport system with drum assembly extending beyond mast Remove masthead clevis pin and shift furler up so drum assembly can be strapped securely to mast Some people remove drum assembly and halyard swivel for storage and transport After Storage or Transport After storing or transporting unit clean thoroughly including ball bearings See instructions above Loosen Foil Clamp Before Slacking Backstay In order to prevent foils from locking against upper stay terminal when backstay is released loosen foil clamp screws and lower foil before loosening backstay 7 16 08 MKIV Unit 0 31 Troubleshoot Problem Probable Cause Solution Jib halyard is wrapping around headstay because See install
24. or slide each foil up stay 8 or 13 16 20mm MKIV Unit 0 5 30 07 Assembly Ton 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 0 13 Assembly Top Foil Connectors slip 6 5 165mm connector on wire mating hook of plastic bushing with connector 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 ING lower half 14 MKIV Unit 0 5 30 07 Assembly Foils Connectors otart 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
25. ow line to roll evenly on drum 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 Gheck luff tape for fraying Gheck 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 ENST 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 align
26. r 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 3 8 10mm below upper terminal WARNING Stay must attach to toggle Do not attach stay to crosspin at drum assembly because crosspin and plates may fatigue and break causing an accident damage to your vessel personal injury or death See www harken com for additional safety information MM gt 2 2 gt gt P HETTE 16 LT TT n EN 7 16 08 MKIV Unit 0 Commissioning Lead Line to Cockpit i 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 122246 personal injury or death See www harken P FER Enclosed Window 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 Remove four screws on stanchion blocks Clamp
27. r additional safety information Commissioning Pendant Halyard Restrainer Tension Pendants If the your sail luff is not long enough to position halyard swivel high enough to create an 8 10 angle as shown you must add a pendant Pendants should be made of plastic coated wire and be permanently attached so sail height will be correct Adjustable length pendants are not acceptable as they might not be adjusted correctly during a sail change 1 Raise sail but do not attach tack shackle 2 Position halyard swivel correctly near top of headstay 3 Secure halyard 4 Tie a piece of rope to sail tack 5 Lead line through tack shackle on furling drum 6 Tension sail 7 Measure distance from tack shackle to sail tack and permanently attach pendant of this length to head of sail 9 Repeat procedure for every jib in your sail inventory 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 No 945 or 1988 Restrainer should be mounted as high as possible on face of mast Po
28. remain attached to drum 2 Use 5mm 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 2 5mm Allen wrench to loosen four screws in plastic cover and flange 30 MKIV Unit 0 5 30 07 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 scrap of luff tape may be run up foil to scrub inside WARNING Periodically inspect items listed 9 00ves Foils may be sprayed with McLube spray below and any others as necessary Failure to reduce friction during sail changes to inspect can cause an accident damage to your vessel personal injury or death See www harken com for additional safety information t Y by nd A a 4 a 22 1 me 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 l
29. rken 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 harkenQharken fr 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 infoQharken it 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 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 6774122 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 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 O I Io for an up to date list of Harken dealers and distrib
30. sition 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 26 MKIV Unit 0 8 21 09 Operation Halyards Headstay Tension Spinnaker Halyards spinnaker halyards occasionally cause problems with furling 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 wit
31. 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 7 16 11mm 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 muni e a 10 MKIV Unit 0 5 30 07 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 0 11 Assembly Top Foil Cut out template at right Line up template with top of foil and scribed line Tape in place Use a center punch to mark holes Check center punch marks to confirm they are 3 16 5mm and 8 or 13 16 20mm from top of foil Drill two 2 1 8 3 2mm holes for trim cap Lay top foil in line with others Slide stay into top foil and down line of foils
32. ury or Clevis Pin death See www harken com for gv additional safety information Crosspin at 90 to Clevis Pin Check foil height at top set and secure using Allen wrench See tip on next page 7 16 08 MKIV Unit 0 21 Assembly 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 22 MKIV Unit 0 Feeder Final 5 30 07 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 1 9m Raise foils using second halyard and secure Allow room above for turnbuckle take up WARNING To avoid injury make sure drum as sembly 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 fo
33. utors 7653118348118 Printed in USA 4416 8 09
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