Carbon Jib Reefing & Furling Installation Manual Unit 2/2.5
Contents
1. May 2002 2 2 5 Carbon Furler SPECIFICATIONS ROD SIZES 12 17 22 7 14mm 8 38mm 9 53mm CLEVIS PIN SIZES Ys 9 4 15 9 mm 19 1 mm LUFF TAPE SIZE 6 9 5mm B RIGGING ATTACHMENT TO LOWER UNIT If no turnbuckle is required attach the rod marine eye directly to the integral toggle on the 2 5 If a turnbuckle is required it must terminate in a marine eye that will fit directly to the integral toggle Use a Navtec C560 turnbuckle or similar for rod with either a Ys 15 9mm pin or 19mm pin diameter RETROFITS FITTING ROD If you plan to reuse the existing rod and turnbuckle Lower End If you are using a standard Navtec turnbuckle with integral toggle the lower body must be replaced with a standard Navtec marine eye body Check to make sure that this eye will mate with the Harken integral toggle Two cross pin sizes are available They are the same size as the clevis pin See above Upper End You must take apart the marine eye so that you are left with a threaded nosepiece Check to see if this is pos sible If necessary contact Navtec or Riggarna for correct pro cedure You will slip carbon foils over this threaded nosepiece If you cannot remove this fitting you will need to cut the rod 4 2 2 5 Carbon Furler TOOLS REQUIRED Sharp Hacksaw Sandpaper Small Triangular File Heat Gun Razor Knives Sandpaper SUPPLIES REQUIRED FOR GLUING FOILS Rigging tape blue masking ta2. WARNING It is critical to have clearance between the top foil and the top rigging fitting when the stay adjuster is in the fully closed position If the fittings touch the unit will jam or in the case of a Sta Lok fitting the terminal may become unscrewed This could cause catastrophic failure to the spar and a life threatening situation It is the responsibility of the rigger to check clearance December 2001 2 2 5 Carbon Furler 11 COMMISSIONING Tying Soft Attachment Lines You must lace line around the furler halyard swivel three times when attaching the sail or halyard Harken recommends us of a Hunter s Bend This knot can be highly tensioned without slipping and like a bowline can be untied afterwards There are other bends and knots that will also work Lace line three times around the torque tube halyard swivel to capture sail or halyard After lacing line tie ends on side opposite sail 1 Form a loop in line that comes from left tunnel Below this form a second loop with line from the right tunnel 2 Twist loop clockwise and arrange ends of line so they are below standing loops as shown 12 2 2 5 Carbon Furler December 2001 COMMISSIONING Tying Soft Attachment Lines 3 Take end that is now running down to right Tuck it down under crossing lines and up through loop towards 4 Pass other end up and over crossing lines and then down into loop away from you 5 Atthis point knot wil
3. Carbon Jib Reefing amp Furling Installation Manual Unit 2 2 5 TABLE OF CONTENTS Parts 8 Pictures and list of all parts ification 4 MEER ClEVIS DID SIZES PUM TANG SIZES MT Rigging attachment to IQWwer unit suse Rennen Preparation for Assembl Foil cut length Warranty of Harken Carbon parts is one year from the time of purchase 2 2 2 5 Carbon Furler December 2001 Cross Smalley Ring CYC Bottom Regular Connectors Top Bushing Clevis pin Feeder i Connector Cotter pin ee Torque Tube Connector Cross pin includes 2 H2912A bushings 36 Connector bushings mce tn AN 33 Feeder 1 Lower Unit 947 Assembly 15 9 H 29364C OOI Bras CHLOE EE H 27385C Grossi nere Ys 15 9mm H 29388A Grossi 19mm H 27407A GOL yen or roe HFG344 Se e EET 15 9mm HCP1352 SmaleyiRindS 19mm HCP1062 CMS PIN eer 15 9 H 29385A dk RIESCO 9 19mm H 29386A Boftomi keedeniConnectorp CETTE H 27448BF REGUIANCONECIO SERRE 1096F TOP 27508 Torque Tube WANG H 27902BF Connector Bushings 36 H 27495A H 27904B Fede H 29238B 4 ENERO SMIMG RR H 29662C 5 Mer H 27374EF Lacing Lines 3 1 4 6mm Spectra eT M HFG6907
4. sure swivel side is towards top of stay Slide trim cap over threaded nosepiece Heat cap in hot water to help it slide over nosepiece Attach trim cap using Superglue Make sure foils are straight and grooves are facing up Inspect lower unit to make sure that feeder and bottom foil are aligned correctly Allow to cure undisturbed overnight After curing overnight remove splint Use a small triangular file to clean excess epoxy while tape remains in place Remove tape and use a razor knife to carefully remove any excess epoxy Make sure halyard swivel passes all points Install top rod eye using red Loctite on locking screw or with upset as per manufacturer s instructions Remove eight socket head cap screws located on underside of lower unit and remove lower cap Remove three set screws located at top of torque tube 10 2 2 5 Carbon Furler ASSEMBLY Slide lower unit onto bottom foil Assemble turnbuckle Attach turnbuckle eye to toggle using cross pin with tapered ends Secure Cross Pin using Circlip Smalley Rings supplied Note Make sure the end of the toggle with the long slot is towards the bottom Bring the lower unit down so that Cross Pin seats in the housing Install cap using Blue Threadlocker on the eight screws E FOIL HEIGHT Check the clearance between the top of the foil and top terminal TIP Check clearance when the unit is on the ground before raising the headstay into position
5. an it up using the acid brush Use excess to coat feeder area of connector Clean up the end of the foil using paper towel wetted with acetone taking care that no epoxy is in the sail grooves 8 2 2 5 Carbon Furler May 2002 Lightly coat feeder area of connector and slip feeder into place Use glue brush to coat inside of foil for one or two inches Coat half the outside of connector with epoxy and slowly insert connector into foil Work connector in and out as you insert to adhere epoxy without dry spots on inside of foil As excess epoxy comes off connector clean up using acid brush Clean up end of foil using paper towel wetted with acetone taking care that no epoxy is in sail grooves Coat the remaining half of connector with epoxy and insert into foil as described above cleaning up excess epoxy Take special care to clean epoxy from sail grooves May 2002 2 2 5 Carbon Furler Lay plastic against foil and place splint against foil Tightly wrap clear packaging tape around splint near both ends Insert wood alignment stick between foil and feeder and inspect to make sure that foil feeder are aligned Coat bottom foil reinforcement torque tube connector with epoxy and insert into foil as directed above Insert plastic bushings in top connector as directed above Coat outside of connector with epoxy as directed above and insert into top foil Clean up excess epoxy Slide halyard swivel onto foils Make
6. ength so halyard tension is required only to shape sails not to support them Use only enough halyard tension to remove some wrinkles along the luff Do not tension the halyard enough to cause vertical wrinkles in the luff Use halyard tension to adjust draft position of the sail to suit sailing conditions Your halyard should be firm but not tight If in doubt release halyard tension To protect the sail ease the halyard when the boat is not in use December 2001 2 2 5 Carbon Furler 17 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 Marco Biagi 14 22070 Limido Comasco CO Italy Telephone 39 031 3523511 Fax 39 031 3520031 Web www harken it Email info harken 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 lkeki
7. f in socket on either side of connector grooved side up Bring connector up on rod and place other bushing half on rod and rotate bushing so seam is at top and bushing assembly stays in place Place foil on bench with grooves facing up and supported on wood blocks June 2002 2 2 5 Carbon Furler B 7 Cool Weather Temperature should be higher than 60 F 15 C If you glue at a lower temperature You must follow four step gently warm joints with a hair dryer to no more than 100 F 38 C a temperature at which you can still ivi hold the foil comfortably in your hand mixing Instructions shown If glued in temperature less than 60 F 15 C allow glued below exactly or the foil foils to cure undisturbed for 48 hours before moving connector bond will fail Warm Weather Surfaces must be dry Adhesive Working pee dui 85 F 29 C 45 minutes Allow glued foils to cure undisturbed for 24 hours Remove plastic clip from Hysol adhesive pack 1 Mix for five minutes in bag 2 Pour entire contents into cup 3 Squeegee remaining epoxy into cup 4 Continue to thoroughly stir epoxy in cup Use glue brush to coat the inside of the foil for one or two inches Coat 1 2 of the outside of the connector with epoxy and slowly insert the connector into the foil Work the con nector in and out as you insert it to adhere the epoxy without dry spots on the inside of the foil As excess epoxy comes off the connector cle
8. f sail 5 Repeat this procedure for every jib TIP Pendants are used at head of sail Short pendants may be added at tack to improve visibility under genoa but remember that visibility is already improved by shackling to tack swivel Tack pendants increase heeling moment by raising sailplan You may install pendants at both head and tack of sail HALYARD RESTRAINER To prevent wraps the jib halyard must pull slightly to the rear On some boats the halyard sheaves are located too close to the headstay and a halyard restrainer must be used Use halyard restrainers only when required by the masthead geometry Restrainers tend to limit sail luff length and may cause problems if not properly installed Mount the restrainer as high as possible on the face of the mast Position the restrainer so the foils will not hit it when under load The restrainer should deflect the halyard 8 10 If the angle is more than 10 you may experience difficulty in tensioning the sail luff friction in furling and possible damage to the foils To decrease deflection angles shorten the luff of the sail TIP Boats used in charter service should consider using a halyard restrainer regardless of masthead geometry 16 2 2 5 Carbon Furler December 2001 COMMISSIONING Halyard Tension HALYARD TENSION The jib halyard should be firm but not too tight TIP The luff foil system supports the sail along its entire l
9. l not look anything like the finished bend Set knot by gently pulling on bitter ends and then standing parts until it looks like Drawing 6 December 2001 2 2 5 Carbon Furler 13 COMMISSIONING Tying Soft Attachment Lines Aij dw KA N Tl h 7 Finished bend drawn up and set If your bend does not look like this untie and repeat the process 9 If furler is installed under deck lace tack pendant as pictured Rigging a pendant directly from carbon tunnels will damage unit 8 It is important to keep tack luff as close to torque tube and as low as possible A tack line that is too long will angle up too far and damage the carbon tunnels When sail is bent on check to make sure tack line is not pulling up against the carbon tunnels 14 2 2 5 Carbon Furler December 2001 COMMISSIONING Halyard Wraps Prevent Halyard Wraps HALYARD WRAPS The most serious problem with furling systems occurs when the jib halyard wraps around the headstay foil Halyard wraps will prevent furling or unfurling and may cause serious dam age to the unit and the halyard In severe cases halyard wraps may cause loss of the headstay To prevent wraps the halyard must exert a slight pull to the rear This allows the foils to turn while the halyard remains stationary B PREVENT HALYARD WRAPS WARNING The sail must be fitted to foils before operation 1 Halyard swivel should be within top 4 100mm of foil 2 Halyard must
10. lsgatan 6 Box 64 440 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 www harken com dealers dealers php for an up to date list of Harken dealers and distributors 4362 9 08
11. om of rod terminal to allow for turnbuckle adjustment As turnbuckle is adjusted terminal is pulled down towards top of rod If no turnbuckle is used there only needs to be minimal space Y2 12mm between the carbon foil and rod terminal We have put 4 100mm as a starting point This may need to be adjusted based upon how turnbuckle was set when headstay was measured If there is less than 4 100mm take up less space can be left and vice versa The space between foil trim cap and bottom of turnbuckle must be more than take up on turnbuckle 4 Add A B E and subtract from total pin to pin headstay length SUM 5 Choose the number from foil multiplier below closest to but not greater than sum from step 4 Fill in D length 6 72 432 6 1828 8 10972 8 7 72 504 7x1828 8mm 12801 6 8 72 576_ 8 1828 8mm 14630 4 9 x 72 648 9 1828 8 164592 10 x 72 720 10x1828 8mm 18288 0 11 x 72 792 11x1828 8mm 20116 8 5 Add A B D E Subtract from pin to pin length for C top foil length WORKSHEET DETERMINE TOP FOIL LENGTH Dimensions Inches A Center of PIN to bottom of terminal B Bottom of terminal to top of foil C Top foil Foils below 8 203mm see next page D x 72 1828 8mm foils E Top of feeder to center of clevis pin Total pin to pin headstay length IF YOU HAVE SHORT TOP FOIL If top foil is less than 8 203mm do not use a recessed top connector The to
12. p foil must be at least 4 101mm If it is less shorten the upper 72 1 83m foil to make the upper foil 4 101mm CUTTING TOP FOIL Once you have checked the top foil length by laying foils alongside the rod use a sharp hacksaw to cut top foil Tape foil and cut along tape Sand bottom end of the foil so it is square and to remove any carbon burrs Lightly sand inside of foil where it will be bonded with 220 grit to remove any grease or mold release agent June 2002 2 2 5 Carbon Furler 5 PREPARATION FOR ASSEMBLY Tape outside ends of all foils using blue masking tape To make sure tape edge lines up with end of foil extend the tape over foil end Use a sharp razor knife to trim tape even with foil Coat rod with mold release agent or wax to keep epoxy from adhering Heat rod terminal and remove threaded screw and threaded nosepiece If rod terminal has been upset peened follow Navtec or Riggarna procedures for removing peening Tape threads of nosepiece and tape nosepiece so it will not slip down foil when pushing it back out 6 2 2 5 Carbon Furler December 2001 Assuming that installation is done from the top slide bottom foil onto rod so end with holes is at bottom end of foil Slide feeder over so so rounded sail groove corners will be at the bottom end of foil Slide full length 72 1 83m foils onto the rod Assemble connectors onto rod in preparation for glueing Place one bushing hal
13. pe 9430 Hysol Epoxy supplied Scissors mixing cup mixing stick glue brushes acetone paper towels cut into quarters plastic to cover splint area clear packaging tape wood alignment stick and placemat sized table covering Alignment Splints Use 90 angle extrusion to make splints Sides to be about 19mm Cut extrusion into 8 203mm lengths and remove burrs from cutting HEADSTAY LENGTH Note When cutting rod to length or making up new rod make sure that you can take apart the rod terminal usually the top eye so that you are left with a threaded nosepiece Make up the rod headstay or adjust the turnbuckle so the Harken toggle fits below the rod terminal eye The pin to pin distance of the Harken toggle is 3 4 83mm Note The 2 5 Carbon furler has an integral toggle No additional toggle is required below the furler May 2002 PREPARATION FOR ASSEMBLY Foil Cut Length Top Foil Cut Length Short Top Foil Cutting Top Foil FOIL CUT LENGTH i The Carbon 2 5 furler has an integral toggle No additional toggle is required below the unit A To check the foil length lay foils alongside the stay before cutting top foil Make sure 1 that turnbuckle is set to desired length FOIL CUT LENGTH Instructions for worksheet below 1 Fill in total pin to pin headstay length 2 Fill in A length 3 Adjust B length if necessary Note There must be enough space between top of carbon foils and bott
14. pull slightly to rear 8 10 3 Halyard must be snug but not too tight If a halyard wraps do not force unit to turn Attempt to open sail by alternately furling and unfurling sail slightly If the sail can be unfurled lower sail by releasing jib halyard Severe halyard wraps can only be cleared by going aloft and freeing halyard If the sail will not furl or unfurl it may be possible to remove jib sheets and manually wrap unwrap the sail around from the headstay Important Testing at the dock does not indicate halyard angle is correct In wave action halyard may wrap if lead angle is not correct The diverging 8 10 angle mentioned above is critical December 2001 2 2 5 Carbon Furler 15 COMMISSIONING Pendants Halyard Restrainer PENDANTS If your sail is not long enough to position halyard swivel properly you must add a pendant to sail Pendants should be plastic coated wire permanently attached to the head of sail so height will be correct Adjustable length pendants are not acceptable as they might not be adjusted correctly during a sail change B INSTALL A PENDANT 1 Raise sail but do not attach tack shackle 2 Position halyard swivel correctly near top of headstay and secure halyard 3 Secure a piece of rope to sail tack Lead line through tack shackle on furling drum and tension sail 4 Measure distance from tack shackle to sail tack and have a pendant of this length permanently attached to head o
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