SMALL BOAT UNDERDECK FURLER 477, 493, 478
Contents
1. the correct size 477 493 478 Small Boat underdeck furling 11 12 This page intentionally left blank 477 493 478 Small Boat underdeck furling 478 Small Boat Underdeck Furler Deck Drill Template Hole Saw Size Recommendations Read Before Drilling 110 mm 41 s Requires some beveling of bottom edge of deck hole to provide a good fit Alternatively a smaller hole may be used to fashion a socket in deck to conform to ball shape This may improve appearance and reduce amount of water that enters 115 mm 4 1 2 Use if no beveling to underside of deck is desired 31 75 mm 1 86 mm 3 3 8 M BOW Hole saw size m 70 mm 27 7 see above D 110 mm 4 Ka EN Hole saw size see above 115 mm 4 em 478 Small Boat deck drill template IMPORTANT If you print this template from a computer file measure to confirm that template is the correct size 5 9 150 mm 208 mm 8 130 mm 5 1 8 STERN 163 mm 6 7 16 477 498 478 Small Boat underdeck furling 13 14 This page intentionally left blank 477 493 478 Small Boat underdeck furling Appendix Sailmaker Instructions Consult specifications for swivel and drum pin to pin lengths to determine luff length deductions If using optional hoistable halyard swivel make sure to deduct for this Standard Upper Swivel Only sailmaker will often install a 1 x 19 stainles2. 3 93 Fax 48 22 839 22 75 Web harken pl e Email polska harken pl Harken Sweden AB Main Office and Harken Brandstore Vastmannagatan 81B SE 113 26 Stockholm Sweden Telephone 46 0303 61875 Fax 46 0303 61876 Mailing address Harken Sweden AB Box 64 SE 440 30 Marstrand Web harken se e Email harken harken se Harken UK Lid Bearing House Ampress Lane Lymington Hampshire 041 8LW England Telephone 44 01590 6891 22 Fax 44 01590 610274 Web harken co uk e Email enquiries harken co uk Please visit http Awww harken com locator aspx to locate Harken dealers and distributors Printed in USA 4428 5 15
3. SMALL BOAT UNDERDECK FURLER 477 493 478 Installation and User Manual Intended for specialized personnel or expert users 4428 5 15 Preassembly Safety precautions terms general information 2 Parts descriptions specifications 3 Planning Installation Hoistable halyard swivel 4 Tools 4 Furler requires drained compartment D Assembly Stay loading 5 Stay angle 5 Deck plate 6 Commissioning Furling line Upper swivel 8 Operation Unfurling furling 8 Maintenance Clean 9 Inspect S Maintenance 8 Deck Drill Templates 477 Small Boat underdeck furler 9 10 493 Medium underdeck furler 11 12 478 Small Boat underdeck furler 13 14 Appendix Sailmaker instructions 15 Addresses 16 Please read these instructions carefully before installing servicing or operating the equipment This manual may be modified without notice See www harken com manuals for updated versions PLEASE SAVE THESE INSTRUCTIONS Safety Precautions Terms General Information Introduction This manual gives technical information on installation and service This information is destined exclusively tor specialized personnel or expert users Installation disassembling and reassembling by personnel who are not experts can cause serious damage to property or injury to users and those in the vicinity of the product If you do not understand an instruction contact Harken The user must have appropriate training in order to use this product Harken
4. accepts no responsibility for damage or harm caused by not observing the safety requirements and instructions in this manual oee limited warranty general warnings and instructions at www harken com manuals Purpose Harken jib furling is designed to roll sails on sailboats so wind has little effect on the sail Use of this product for other than normal sailboat applications is not covered by the limited warranty Safety Precautions WARNING Strictly follow all instructions to avoid potential hazards that can kill or hurt you and others See www harken com manuals for general warnings and instructions Deck plate ball Q Deck plate d Bullseye Swivel assembly Spool Drum assembly Bridge Clevis pin Maximum Line working load Furler Description in mm Ib k in mm 477 Underdeck furler small 1 4 6 950 431 Va 5 32 3 4 493 Underdeck furler medium 5 16 8 2000 907 5 32 3 16 4 5 478 Underdeck furler large 6 11 3000 1361 3 16 1 4 5 6 2 477 498 478 Small Boat underdeck furling Parts Descriptions and Specifications A B C D E F G H l Furler in mm in mm in mm in mm in mm in mm in mm in mm in mm 477 45 118 45 16 147 19 16 40 55 8 143 63 16 157 69 16 166 21 2 64 3 16 8 3 76 493 511 16 144 55 46 135 113 16 45 d 179 73 8 188 718 16 198 4 102 3 3 9 5 4 100 478 7 177 53 4 147 27 16 61 93 8 238 81 2 215 91 2 240 43 4 121 The 11 5 51 2 140 gt H Componen
5. eat Add length indicated below Part Line Measure distance from furler to cleat and add No in mm ft m 477 1 5 5 32 3 4 10 3 493 5 30 3 16 4 5 13 4 478 3 16 1 4 5 6 15 4 5 Determine Fairlead Location The fairlead location determines furling direction The furler is shipped with fairlead mounted on side of bridge Refer to chart below to determine if port fairlead mounting will work If necessary remove fairlead and assemble on starboard side Fairlead side Furling direction Charge spool by rotatin Suncover if used on Port Counterclockwise Clockwise Starboard Starboard Clockwise Counterclockwise Port Fairlead L Switch fairlead for opposite furling rotation Set up lead block so furling line runs perpendicular to drum when line leaves bullseye The bullseye can correct small differences in line angle Lead line aft using ball bearing blocks where line makes a turn more than 30 Install cleat Feed line through bullseye and into nearest opening 477 493 478 Small Boat underdeck furling Commissioning Upper Swivel 1 Run line out of hole in bottom of spool and tie a single overhand knot Note On 493 deadend hole is in hub 2 Pull knot back up to seat at hole 493 deadend hole 477 478 deadend hole Counterclockwise furling direction Clockwise furling direction Rotate drum clockwise to charge spool Rotate drum counterclockwise to charge spool Wind 10 15 3 4 5
6. hole than listed may be used to fashion a socket in the deck to conform to the ball shape This Add deck thickness to this measurement 4 can improve appearance and reduce amount of sealant required See drilling template in appendix 477 493 478 Small Boat underdeck furling Planning Installation Furler Requires Drained Compartment The drum assembly is designed to keep much of the water from entering the compartment Water will drip through furler during rain or when sailing in heavy weather IMPORTANT Furling compartment must drain Assembly Stay Loading The drum assembly is designed for either transferring headstay loads to deck or for transferring the loads to an underdeck chainplate If securing to deck only make sure deck is strong enough and designed for this purpose A cored deck will not provide adequate strength Use stay attachment belowdeck A turnbuckle is used to connect chainplate to bridge on furler It must be carefully tensioned as mast is tensioned to neutralize load on deck e Bridge Zz Turnbuckle to bridge Stay Angle The Harken deck plate angle matches a stay angle of 72 when compared to deck Stay angle can vary between 71 and 73 IMPORTANT If stay angle does not fall between 71 to 73 furler will be difficult to furl and can create excessive force on deck and furler To correct problem change mast rake or make shims using structural epoxy 11 3 477 493 478 Smal
7. l Boat underdeck furling Assembly Deck Plate Carefully locate center point in deck to locate deck plate Line from mast to underdeck chainplate must intersect this center point Mark center fore aft and athwartships lines Line up template Mark four outer holes and center pilot hole Make sure closer pair of holes is for ward Mark center hole for drilling large hole If using an interior chainplate check hole position by drilling pilot hole and running a low stretch line from masthead to chainplate Tip After pilot drill bit clears deck drill final hole from bottom using pilot hole to line up hole drilled from top This will prevent glass from chipping Tip Run line through fairlead and deadend line into spool before mounting lower unit Make sure hole is just large enough so deck plate bears against deck It is better to make hole slightly smaller and file opening larger to fit Use template to mark large hole and bolt holes Once hole is located in line with chainplate and required shimming is done drill hole 90 to deck Use screws washers and deck sealant to fasten lower unit to deck see chart at right Minimum thread Note Make sure there is sufficient thread Furler in deck plate engagement into deck plate 41 493 emm __ 478 3 10 mm Deadend line before mounting 477 498 478 Small Boat underdeck furling Commissioning Furling Line To figure line length measure distance from furler to furling cl
8. ls work along with standard Harken Small Boat furler IMPORTANT Hoistable halyard swivel must be loaded on stay before terminals are made Make sure the end with circlip is facing up When using hoistable halyard swivel adapter tangs provide a Y attachment to connect both stay and sail tack to lower unit A sailmaker eye may also be used The eye consists of a swage marine eye with a hole designed for lashing or shackling the tack to terminal Sail tack securing points Sailmaker eye 1 Hole saw 5 Deck sealant 2 Center punch 6 File for bevelin 3 Scissors 7 Wrench for deck plate bolts 4 Rigging or black tape 8 Power drill drill bit for pilot holes Hoistable Halyard Swivel A Upper swivel a Hoistable swivel Circlip End of halyard Swivel with circlip faces up Tools Parts You Will Need W W Hole Saw Size Refer to information below and choose hole saw for deck plate Deck Plate Ball 4 Recommended Hole Saw 0 A B Requires some beveling Requires no beveling Fasteners for Mounting Unit to Deck Not Supplied Unit in mm in mm in mm in mm Unit FastenerO C deck plate thickness 477 2 6 X 66 27 685 25orsmaler 650rsmaler 275 70 417 9 mm va 6 mm 493 3 76 325 D 3orsmaller 750rsmaller 325 85 493 va 6 mm 4 8 425 108 45 114 4250rsmallr _110 or smaller 4 5 115 478 6 mm 10 mm A smaller
9. m of line on spool Wind 10 15 3 4 5 m of line on spool Commissioning Upper Swivel Attach upper swivel to jib halyard Fasten head of unfurled jib to upper swivel and attach tack to top of drum Hoist sail with halyard snug up and cleat When using hoistable swivel attach head of sail to shackle Operation Unfurling Furling To furl jib pull furling line to roll sail up around its own luff To unfurl uncleat furling line and pull jib sheet Maintenance Inspect Clean 1 Unit for signs of chafe wear or damage 2 Rigging components for signs of stress corrosion 4 Turnbuckle below drum or inside torque tube for signs of loosening 9 Headstay tension for signs of loosening 6 All clevis pins locking rings and cotter pings to make sure they are secure 7 Wire for signs of wear or unraveling CO 477 493 478 Small Boat underdeck furling 477 Small Boat Underdeck Furler Deck Drill Template Keep unit clean When washing boat flush unit with soap and fresh water Occasionally lower sail and flush halyard swivel with soap and fresh water To clean drum bearings squirt mild detergent and water solution into small gap between plastic ball and spool extension as shown at right Spin drum and let soak Follow with one minute flushing with hose Clean drum bearings 477 Small Boat Underdeck Furler Deck Drill Template Hole Saw Size Recommendations Read before drilling 65 mm 21 2 Requires so
10. me beveling of bottom edge of deck hole to provide a good fit Alternatively a smaller hole may be used to fashion a socket in deck to conform to ball shape This may improve appearance and reduce amount of water that enters 70 mm 23 4 Use if no beveling to underside of deck is desired 39 mm 15 Q 2 2 Hole saw size BOW see above mm 2 Hole saw size 107 mm see above DN 70 mm 2 h 471 Sm all Boat deck drill template e STERN 83 mm 3 2 S 7 S IMPORTANT When printing this template from a computer file measure to confirm template is correct size 477 493 478 Small Boat underdeck furling 0 10 This page intentionally left blank 477 493 478 Small Boat underdeck furling 493 Medium Underdeck Furler Deck Drill Template Hole Saw Size Recommendations Read Before Drilling 75 mm 3 Requires some beveling of bottom edge of deck hole to provide a good fit Alternatively a smaller hole may be used to fashion a socket in deck to conform to ball shape This can improve appearance and reduce amount of water that enters 85 mm 3 Use if no beveling to underside of deck is desired 31 75 mm 1 Hole saw size see above BOW 75 mm 3 Hole saw size see above 85 mm 3 4 140 5 mm 517 32 STERN v Ei 95 mm 33 4 IMPORTANT When printing this template from a computer file measure to confirm that template is
11. rlead Starboard fairlead Counterclockwise furling Counterclockwise furling direction GRY Secure sail direction here Attach furler Wire should tighten to this hole Wire should tighten when sail puts a clockwise load on the strands Outside of roll is on starboard when sail puts a counterclockwise load on the strands Outside of roll is on port 477 493 478 Small Boat underdeck furling HARKEN Corporate Headquarters N15W24983 Bluemound Rd Pewaukee WI 53072 USA Telephone 262 691 3320 Fax 262 701 5780 Web www harken com e Email harken harken com Harken Australia Ply Ltd 1B Green Street Brookvale N S W 2100 Australia Telephone 61 2 8978 8666 Fax 61 2 8978 8667 Web harken com au e Email info harken com au 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 harken fr e Email info 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 harken it Email info harken it Harken New Zealand Ltd 158 Beaumont Street Unit 11 Orams Marine Centre Westhaven Aukland 1010 New Zealand Telephone 64 9 303 3744 Fax 64 9 307 7987 Web harken co nz e Email harken harken co nz Harken Polska SP ZOO ul Rydygiera 8 budynek 3A lokal 101 pietro 01 793 Warszawa Poland Tel 48 22 561 9
12. s steel wire sewn into the luff with thimbles that are secured to the tack and head so they will not turn while furling In this case the luff wire becomes the headstay The jib remains on the boat in its furled position when it is not in use and a cover protects the sail from UV exposure Alternatively a temporary mast assist line is used Direction of Wire Lay All Installations When installing wire coordinate the lay of wire with direction of furling so twist in strands are tightening when sail is pulling aft as it is furled The furler may be set up to work in either direction Consult the chart below and note load direction on the wire strands Fairlead side Spool charged Sail rolled Load on wire strands Port Clockwise Counterclockwise Clockwise Starboard Counterclockwise Clockwise Counterclockwise Note The outside of the roll will be on starboard See diagram below Circlip Hoistable Halyard Swivel If a hoistable halyard swivel is used the sailmaker will use a luff sleeve or small snap straps SO sail can be hoisted onto a permanent stay End of halyard and removed with the headstay left in place Make sure head and tack thimbles are swivel with secured to sail to handle furling loads circlip faces up IMPORTANT Load hoistable halyard swivel onto stay before terminals are assembled Use tangs to provide a sail attachment to lower furler A sailmaker eye may also be used Attach headstay to upper hole Port fai
13. ts Upper Hoistable Weight swivel swivel Drum Upper swivel Hoistable swivel Drum Furler Part No PartNo PartNo 07 02 02 477 164 464 HC9226 2 6 74 2 9 82 24 680 PartNo in umi 493 207 465 10893 9 2 261 8 9 252 42 6 1201 464 4556 124 478 HCP141 482 HC9976 15 431 16 8 477 81 2296 465 516 144 Hoistable halyard swivels 464 465 482 are not included with 477 493 or 478 402 719 32 193 Tangs for Attaching Sail to Lower Unit Tack Pin to pin Wire Clevis pin adapter tang length Weight Furler Part No in mm in mm in mm 02 0 Ib kg 477 HCP649 3 4 19 1 3 3 u 6 493 489 13 8 JO 5 32 4 5 16 GR 478 479 11 2 38 5 32 4 5 16 M 9 2 147 3000 1361 478 480 11 2 38 3 16 3 g 10 9 2 147 3000 1361 478 481 1 2 38 1 4 6 tg a ke 5 2 147 3000 1361 See parts required below Upper tang hole pin size listed following parts must be ordered with the Upper HCP649 E 4 adapter tang on Part No Qty Description hole 479 HCP650 2 Neoprene O ring RK J e 480 er a pin 1 16 X 500 18 8 4j 481 evis pin 1 4 X 672 SS HCP649 tang M d 489 477 493 478 Small Boat underdeck furling 3 Planning Installation An optional hoistable ball bearing halyard swivel can be installed on headstay to raise or lower the sail without removing headstay Hoistable halyard swivels are independent of headstay allowing luff to be tensioned separately from mast rake Hoistable swive
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