MKIV Jib Reefing & Furling Installation Manual Unit 3
Contents
1. toggle Note If using Sta Lok or Norseman Stud you must use a washer above Stud as shown below 20 Washer m Min j i NN TEMA UU Eye Jaw Toggle Assembly MKIV Unit 3 5 30 07 Assembly Attach Toggle Long Link Plate Make sure drum assembly has four threaded holes in base Determine height of link plates to provide anchor clearance and cut to length Cut at scribe mark Deburr edges Connect eye to toggle jaw using special clevis pin Secure using cotter pin Toggle For Long Link Plates Fasten one long link plate to drum assem bly using fasteners Use blue Loctite on screws Fasten second long link plate to drum assembly and secure to clevis pin using locknuts WARNING Stay must attach to toggle Do not attach stay to crosspin at drum assembly because crosspin and plates may fatigue and break causing an accident damage to your vessel personal injury or death See www harken com for additional safety information A 7 14 08 MKIV Unit 3 21 Assembly Final If stay length is set use side cutters or needle nose pliers to bend cotter pin to secure turnbuckle hae 4 L7 7 M ttti EH LL Wn y i b olide lower drum assembly over turnbuckle and attach using long crosspin Use plastic washers provided Important Crosspin must be at 90 degrees to clevis pin that attaches unit to boat WARNING Crosspin must be 90 d2. 356mm Bottom connector HFG297 1 Connector bushing set 20 each H 42073 H 42074 HFG324 1 Plastic connector wedge set 22 39487 Foils Standard Package HFG349 1 Foil screw set 46 HFS1106 Part No Quantity Description HFG682 1 Trim cap set H 39751 H 39752 7413 30 10 7 2 13m Foil HFG672 1 Trimcap screw set 3 HFS1127 1413 33 1 2 610mm Botton foil shipped in drum box 947 1 Prefeeder H 39756 1 Feeder with screw and tab Tools 2124 3 10mm Bow shackle Quantity Description HFG725 1 Injector 1 oz 5200 Adhesive HFG722 1 Each 3 4 6 10mm Allen wrenches 4 MKIV Unit 3 8 15 07 Preassembly Line Diameter Length Furling line is not included with furling unit Purchase 7 16 12mm low stretch Dacron double braid The length of the line should be equal to the length of the boat plus the length of the foot of the largest genoa plus 6 2m Toggles ROD RIGGING 1 Harken toggle assembly required Sold separately al 2 Mating turnbuckle components must be purchased Sold Separately Separately ALL UNITS 3 Headstay may require cutting and shortening to fit Harken Toggle Harken toggle Headstay may remain uncut by Sold Separately replacing lower stud of turnbuckle with stud eye thus eliminating extra toggle 4 Rod rigging requires Harken rod adapter stud WARNING Headstay condition should be 3 checked by a professional rigger before y reusing Wire that is old or damaged may break suddenly causing an
3. accident J damage to your vessel personal injury or E death See www harken com for additional Eye Jaw Toggle Long Link Plate w Toggle 7426 22 safety information 7413 20 3 4 7313 21 3 4 7427 30 1413 20 7 8 1313 21 7 8 Rod Adapter Stud Requires drum assembly with four threaded holes in base See page 21 Tools You Will Need 1 Long tape measure 2 Short tape measure 3 Power drill 4 Drill bit 5 32 4mm 9 Hacksaw 8 14 08 6 4 Long tape measure 6 Side cutters 11 Center punch 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 3 Rigging Parts Check Tools Line Not Included 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 ad
4. block to allow 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 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 a
5. 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 up to date list of Harken dealers and distributors 765371834 Printed in USA 4419 9 08
6. marks to be placed on jib lead tracks or toe rail so that lead block position can be changed to correspond to reefed jib Your system is provided with a locking device that can be used to lock unit while reefed or when leaving boat unattended at dock or mooring To lock unit in reefed or furled configuration align holes in bottom of drum and basket then use a line to secure drum Use of lock removes tension from furling line and prevents accidental release of line which could expose a full sized genoa to heavy winds Use of lock while reefed requires going onto foredeck after reefing and again before sail can be reefed further or unreefed Since one purpose of a reefing system is to allow you to change sail size while remaining in safety of cockpit many people choose not to use locking device Use of locking device is not required during reefing sails are generally reefed to balance boat and to reduce heeling moment Sails may also be reefed to improve visibility or to slow boat while sailing in congested areas or entering or leaving harbors Secure Sail When furling prior to leaving your boat in slip or on mooring be sure that you get a tight furl and continue furling system until sheets wrap around rolled sail two or three times Some people secure Sail with shock cord or sail ties Be sure to securely cleat furling line to a standard horn cleat You may also lock your system by aligning holes in bottom of drum and
7. 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 halyard swivel properly you must add a pendant Pendants should be made of plastic coated wire and be permanently attached so sail height will be correct 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 8 Repeat procedure for every jib in your sail inventory 26 MKIV Unit 3 Halyard Swivel Height Lead Angle 7 14 08 Commissioning Halyard Restrainer Tension To preve
8. when boat is not in use 5 30 07 MKIV Unit 3 2f Operation Halyards Headstay Tension Spinnaker Halyards opinnaker 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 ac cident damage to your vessel personal injury or death See www harken com for additional safety information On many boats it will not be possible to attach spinnaker halyard to bow pulpit or it may be sucked into Jib when furling On some boats the spinnaker halyard lays across headstay and will catch on halyard swivel foils or jib halyard To prevent problems it may be necessary to install a masthead bail to move spinnaker halyard block forward and to one side Boats with external halyards may find it necessary to flip both ends of spinnaker halyard behind spreaders to prevent fouling with furling system Headstay Tension A furling system will work best if headstay is tight A loose headstay is difficult to rotate and can cause unusual wear on foil joints To adjust headstay tension remove sail and furling line from unit and follow instructions on Page 24 Tip Before adjusting headstay tension slack mainsheet and vang Backstay Adjusters Backstay adjusters allow headstay tension to be varied to change sail shape to match conditions They permit a very tight headstay to be eased when boat is not in use For best perfo
9. HARKEN IMKIV Jib Reefing amp Furling Installation Manual Unit 3 WARNING Strictly follow all instructions to avoid an accident damage to your vessel personal injury or death See www harken com for additional safety information Table of Contents Preassembly Parts Tools Dimensions Sailmaker s Instructions Toggle Deductions Stay Into Foil Options Top Foil Length Short Top Foil Foil Length Assembly Foils Connectors Halyard Swivel Drum Assembly Rod Rigging Turnbuckle Toggle Final Commissioning Turnbuckle Line to Cockpit Halyard Swivel Height Angle Halyard Restrainer Tension 11 17 17 18 19 20 20 21 22 23 24 29 26 27 27 Halyard Headstay Tension Raise Sails Furl Reef secure Sail Race Conversion Clean Inspect Replace Line Storage Remove Furler Troubleshooting Warranty 28 29 29 30 30 31 32 32 32 32 32 Parts Descriptions 1 Toggle Assembly 2 Crosspin Shackles 3 4 Drum Assembly 2 9 6 6 Foil Clamp 2 610mm Bottom Foil Feeder Connector Bushing MKIV Unit 3 9 Bottom Connector 10 7 2 13m Foil 11 Connector Screws 12 Connector Wedge 13 14 15 16 Connector Halyard Swivel Trim Cap Trim Cap Screws 5 30 07 Preassembly Sizing Check A 15 Size Check 1 Check headstay and clevis pin dimensions in chart below or toggle as
10. arm 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 n lower half 14 MKIV Unit 3 5 30 07 Assembly Foils Connectors Start plunger into injector and immediately hold upright so plunger is down and applicator tip is up As sealant runs down towards plunger an air pocket will form near tip Push plunger to evacuate air You are now ready to begin injecting adhesive Put a drop of adhesive into screw holes Hold plastic wedge in place with thumb as you insert into foil Line foil holes with connector screw holes 5 30 07 MKIV Unit 3 15 Assembly Foils Connectors Inject only a small amount of adhesive into middle hole Unit 3 will only take 1 to 11 4ml of a graduation mark Tip When you see a small amount of adhesive enter one screw hole stop You have applied enough adhesive Use ml marks to estimate 1 to 11 aml of adhesive L Stop when you see a small amount of adhesive enter one screw hole Tighten screws into connector holes Make Sure a drop of adhesive entered
11. basket and then using a line to Secure drum Be sure that mooring lines are not placed across furling line where they may cause chafe 30 MKIV Unit 3 5 30 07 Operation Race Conversion Race conversion allows use of both grooves 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 Serious racers may want to remove the halyard swivel Note It is not possible to remove halyard swivel on a unit with a Norseman Sta Lok or rod adapter stud unless you disassemble terminal stud Make sure you use a new Norseman Sta Lok wedge to reassemble Norseman Sta Lok fitting 1 Remove drum assembly 2 Rig a secure temporary headstay 3 Loosen backstay mainsheet and vang so that headstay goes slack 4 Remove clevis pin holding furling unit to chainplate 5 See adjusting turnbuckle on Page 24 Remove turnbuckle body and lower unit and slide off halyard swivel 6 Reattach headstay to boat Remove Drum 1 Remove sail and unwind line from drum Line can remain attached to drum 2 Use 10mm Allen wrench provided to remove 2 screws on bottom of guard assembly and remove two halves Be
12. careful screws are not captive 3 Use 3mm Allen wrench to loosen four screws in plastic cover and flange 5 30 07 Loosen screw one revolution only Remove Feeder Slide screw up and hold To Remove Feeder For FA 1 Loosen screw one revolution only l 2 Slide screw up Remove feeder 1 3 Lower halyard swivel Carefully remove feeder bottom end first Don t drop the feeder overboard 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 A scrap of luff tape may be run up foil to scrub inside grooves 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 A 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 si
13. each screw hole If not apply to screw Use bushings connector wedge and adhesive in other screw hole and insert into other foil Use 1 to 11 4ml of adhesive 16 MKIV Unit 3 5 30 07 Assembly Bottom Foil Connectors Halyard Swivel Continue installing connectors and wedges Make sure to use adhesive in screw holes Continue assembly Use 14 356mm bottom connector to assemble bottom foil slide halyard swivel onto foil above feeder window Make sure taller half is up as shown 5 30 07 MKIV Unit 3 17 Assembly Drum Assembly Turnbuckle Harken Toggle Loosen foil clamp screws at top of drum assembly slide drum assembly onto foils Tip Face clamp downward so it Clears foil notches during installation MKIV Unit 3 5 30 07 Assembly at OD nil EE IIe 5 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 3 Rod Rigging Rod Adapter Stud Assembly Attach Turnbuckle Toggle Assemble turnbuckle and attach Harken
14. egrees to clevis pin that attaches unit to boat If pins run same direction toggle will fatigue and could break suddenly causing an accident damage to your vessel personal injury or death See www harken com for additional safety information A Check foil height at top set and secure using Allen wrench See tip on next page 22 MKIV Unit 3 5 30 07 Assembly Feeder Final Tip Do not remove foil clamp screws to adjust foil Loosen screws hold foils and bring clamp away from foils Adjust and reclamp Slide halyard swivel above feeder Place feeder in foil recess Push screw down So tab catches under foil Tighten screw Note Screw will turn with some difficulty It is plastic coated to prevent loosening due to vibration Important When removing screw loosen no more than one full turn Slide screw up and remove feeder 5 30 07 MKIV Unit 3 23 Commissioning Turnbuckle on Boat Have extra cotter pins on hand to replace used ones at base of unit and for turnbuckle Hold foils and loosen drum assembly screws until you can pull clamp out to lower foils Lower foils Remove crosspin holding drum assembly to turnbuckle Raise drum assembly and use halyard to lift and hold it about 9 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 adjust
15. esn t chafe against line guard Rotate line guard if necessary MKIV Unit 3 Furling line must enter drum at right angle to headstay Furling line lead changes as amount of furling line on drum changes 061 stanchion mount bases provide an ideal attachment for furling line lead blocks Ball joint socket accepts most small boat swivel blocks including ratchet blocks Drum Full sail unfurled lt Drum Empty iN furled 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 or unfurling and may cause serious damage to the unit and the halyard WARNING In severe cases a halyard wrap can cause loss of control of boat and or headstay can break suddenly which can cause an accident damage to your vessel personal injury or death See www harken com for additional safety information To prevent wraps the halyard must exert a slight pull to the rear This allows the foils to turn while halyard remains stationary Prevent Halyard Wraps WARNING Sail must be fitted to foil length before using to prevent headstay loss which will cause an accident damage to your vessel personal injury or death See www harken com for additional safety information A 1 Halyard swivel should be within top 4 100mm of foil unless a halyard restrainer is used 2 Halyard must pull slightly
16. gns of loosening Inspect swage fitting and lower toggle for signs of stress corrosion Inspect Norseman or Sta Lok terminal or rod terminal for Signs of loosening Inspect all screws on unit to be sure they have not loosened Inspect foil to make sure that it has not dropped into drum assembly Periodically inspect wire for signs of wear or unraveling mM A Mn Replace Line Use 16 11mm diameter line Use double braid polyester line with good wear characteristics Storage Mast Down In areas where it freezes do not store system where water can accumulate in foils When water freezes it will rupture aluminum Store foils under cover with grooves facing down or on an angle so water will run out Storage Transporting Do not store or transport system with drum assembly extending beyond mast Remove masthead clevis pin and shift furler up so drum assembly can be strapped securely to mast Some people remove drum assembly and halyard swivel for storage and transport After Storage or Transport After storing or transporting unit clean thoroughly including ball bearings See instructions above Loosen Foil Clamp Before Slacking Backstay In order to prevent foils from locking against upper stay terminal when backstay is released loosen foil clamp screws and lower foil before loosening backstay 32 MKIV Unit 3 7 14 08 Troubleshoot Problem Probable Cause Solution Jib halyard is wrapping around headstay beca
17. hesive 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 Luff Length Note offsets above and below sail A shorter luff may be required if a halyard restrainer is necessary page 27 or a toggle or long toggle assembly is used to raise drum If luff of sail is not long enough to put halyard swivel near top of headstay foil a pendant must be added see page 26 Tack Sethack Note setback for tack shackle and cut sail accordingly Luff Tape Size Unit 3 requires 6 32 or 5mm luff tape Less with Sta Lok Norseman Luff Tape Length Note feeder height and extend bottom of luff tape downward so it is below feeder This will prevent luff tape from catching in feeder as sail is lowered Tack and Head Shackles Make sure tack and head shackles fit sail rings Minimum inside dimensions of Standard head and tack shackles are A 17 8 48mm 13 16 21mm Sun cover Sun covers may be installed on either side of sail Be sure to match other sails in the customer s inventory Min 941 g n M Note If a long link plate is used add the following dimensions to feeder shack 567 8 1445mm le and drum height based on whether plate is used full length or shortened to one of five hole posit
18. ing turnbuckle Failure to do so may Cause an accident damage to your vessel personal injury or death See www harken com for additional safety information Adjust turnbuckle Replace used cotter pins Lower drum assembly and install clevis pin and new cotter pin Lift foils so top is 1 25mm below upper terminal 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 m k M d Important When reinstalling crosspin pin must be at 90 degrees to clevis pin that attaches unit to boat 24 MKIV Unit 7 14 08 Commissioning _ location of sun cover Charge system by rotating furler to wrap line on drum Lead Line to Cockpit B 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 Tip Sun cover to starboard turn clockwise to charge Sun cover to port turn counter clockwi
19. ions Do not add to halyard swivel or top terminal dimensions 3 4 19 1mm Clevis Pin Add 199 16 to 1011 16 497mm to 271mm 7 8 22 2mm Clevis Pin Add 19 e to 11 505mm to 279mm 111 16 280mm 16 16 418mm 43 16 106mm 47 16 113mm Toggle Used 19 1mm 7 g 22 2mm 6 MKIV Unit 3 8 15 07 Preassembly Toggle Deductions Stay Into Foil Options Use dimensions of Harken toggle below to build stay to correct length Tip Turnbuckles should be 1 2 to 2 3 open to allow shortening for new wire stretch and for fine tuning mast rake Clevis Pin Pin to Pin 1 Length 19 1mm 5 127mm 7 3 22 2mm 51 2 140mm P EL e f Crosspin Feros pr Fork Tang Attachment Attachment For tang down installations switch plugs to this position 31 4 83mm 37 g 98mm Most boats have a chainplate with single tang bey If boat has two plates forming a jaw reverse Uu eye jaw toggle so eye is down Long Link Plate w Toggle Important Remove black plastic caps and m Hn 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 3 Rod adapter nosepiece for Harken rod adapter stud Threaded nosepiece must have a positive lock of as well as adhesive Use Har
20. ken 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 A 7 14 08 MKIV Unit 3 7 Preassembly Top Foil Length Measure A and add to this chart Make sure upper Alternate X 3 and length chart below measurement points Measurement A of A and Pin to Pin Point i are the same Total EE ER Pin to Pin Length EE Subtract ABEFG Result Pin to Pin ABEFG 4 ooaj To find D pick number from chart below that is closest to but not greater than total from step 3 Inches mm 7 X 84 588 7 x 2133 6 14935 2 0 x 84 672 0 x 2133 6 17068 8 9 x 84 756 9 x 2133 6 19202 4 10 x 84 840 10x 2133 6 21336 11 x 84 924 11 x 2133 6 23470 result from Step is 800 inches D 756 inches 20 000 D 19 202mm Result Top Foil Length Length Check After completing worksheet above fill in A C D and G below Add A through G to confirm total equals your pin to pin measurement Length Chart Dimensions ies mm A Center of Pinto Bottom ofTermindl C G Toggle Distance from Lower Clevis Pin to Crosspin H
21. l their sailing but it is not good seamanship to go offshore without storm sails Heavy air working jibs and storm sails may be used with your unit These sails need to have luff tape added to allow them to be raised in headstay foils These sails will generally require pendants to ensure that halyard swivel is properly positioned at top of headstay See Page 26 Remember that heavy air working jibs and storm jibs may be reefed and furled like any other sail Furl and Reef To furl or reef ease the jib sheets and pull furling line In very light air it may be necessary to place some tension on Jib sheet to insure a tight furl In a breeze you must completely luff sail by totally slacking jib sheets before furling The furling line should pull readily The amount of force required is related to amount of wind but a Unit 3 should never require use of a winch to furl If sail will not furl or if furling requires a great deal of effort there is a problem with system Consult the Troubleshooting Guide on Page 33 Do not use a winch to force a system to turn If you are certain that the system is operating properly you may use a winch to make furling easier 5 30 07 MKIV Unit 3 29 Operation Reef Secure Sail 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
22. m cap o allow for saw cut position blade so upper half of middle hole is preserved a Cut Offs Do Not Use a Wl gm gm lt p Lo a N lt T Soo a c 53 8 4 137 102mm not use plastic bushing above top connector Cut connector right at cross formed by glue dispersion channels Use single foil screw in top Under 11 2 38mm Eliminate top foil and run foil foil only higher in drum assembly 7 15 08 MKIV Unit 3 Preassembly Foil Length Confirm foil length by laying foils alongside stay with turnbuckle components Pull stay out so it is straight Attach Harken toggle to bottom of stay Make sure toggle straps are straight Adjust turnbuckle so that length of stay with Harken toggle will fit boat Ideally turnbuckle will be half to two thirds open to allow for rig adjustment Line up drum assembly so holes below drum line up with holes in Harken toggle Make sure toggle is tensioned when measuring Line up bottom foil so foil clamp is just above or below center of notches in bottom foil Note Position top foil so that with top cap the foil will ride 1 25mm below terminal If wire fitting at top of stay is swage foil must ride just below shoulder of swage Mark cut line on foil Wrap tape around foil as a guide so cut is straight 10 MKIV Unit 3 7 15 08 Assembly Top Foil Cut foil
23. nd cowling alignment 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 9 30 07 MKIV Unit 3 33 34 MKIV Unit 3 1 02 08 7 14 08 MKIV Unit 3 35 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 Lid 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 6 Box 64 5 440 30 Marstrand Sweden Telephone 46 303 618 75 Fax 46 303 618 76 Web www harken se Email harken
24. nt wraps jib halyard must pull slightly to rear On most boats halyard lead angle is acceptable if halyard swivel is raised to top of foil On some boats halyard sheaves are located too close to headstay and a halyard restrainer must be used Halyard restrainers should be used only when required by masthead geometry Restrainers tend to limit sail luff length and may cause problems if not installed properly If your boat needs a halyard restrainer use Harken Part No 945 or 1988 Restrainer should be mounted as high as possible on face of mast Position restrainer so that foils will not hit it when under load The restrainer should deflect halyard as little as possible or you may experience difficulty in tensioning sail luff friction when furling and possible damage to foils To decrease deflection angles shorten sail luff Tip Boats used in charter service should have a halyard restrainer regardless of masthead geometry Halyard Tension The jib halyard should be firm but not too tight Tip The luff foil system supports sail along its length so halyard tension is used only to shape sails not to support them Use enough halyard tension to remove some wrinkles along luff of sail Do not tension halyard enough to cause vertical wrinkles in luff of sail Tension to adjust position of draft in sail to suit sailing conditions Halyard should be firm but not tight If in doubt release halyard tension To protect sail ease halyard
25. ole Toggle Part No Type Clevis Pin 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 8 MKIV Unit 3 9 30 07 Preassembly Short Top Foil If top foil is shorter than 93 4 248mm use one of the following special techniques to ensure sufficient bearing surface for the foil in the area of the halyard swivel z 3 76mm 21 2 64mm 2 51mm 41 27 38mm ZA e N lt ree Cut Offs 4 Do Not Used lede 31 2 11 2 89 38mm Shorten top foil and adjoin ing full length foil so two screws are used to assemble joint instead of four Do not use plastic bushings above top connector 1 Initial 2 Cut through 3 4 Shorten 5 Shorten top foil middle hole in connector cut length top foil Top Foil Length from Resulting Top Worksheet Foil Length i 89mm 167mm 127mm 95 71 8 244 181mm Do not use plastic m Em m bushing above top connector 21 2 69 16 4 Cut Offs Do Not Use e 2 51 16 GU 51mm 129mm 89mm 11 2 49 16 3 38mm 116mm 76mm Cut Offs Do Not Use Do Not Use T 51 2 178 140mm Do not use plastic bushing above top connector Shorten top of connector and if necessary shorten tri
26. rmance consider adding a backstay adjuster either a block and tackle a mechanical adjuster like those offered by Harken or a hydraulic adjuster Remember to keep headstay tight for best performance when furling or reefing If your boat is fitted with an adjuster be sure that it is tensioned before the halyard is tensioned If not backstay adjuster may increase halyard tension and could damage the sail or furling system Racing boats often slack the headstay completely when sailing downwind Check to be sure that foil does not jam against upper headstay terminal when backstay is released To prevent this it may be necessary to shorten foil slightly 20 MKIV Unit 3 7 14 08 Operation Sail Raise Storm Reef Raise Sails 1 Install prefeeder by securely tying end of line to a deck fitting or to toggle below furler so it is 2 610 mm below feeder 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 Storm Sails Most people will use one multi purpose genoa for al
27. se 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 BOW 2600 CARBO FORWARD LEAD BLOCK 2660 CARBO INTERMEDIATE LEAD BLOCK 2660 CARBO b INTERMEDIATE LEAD BLOCK 2660 CARBO INTERMEDIATE LEAD BLOCK 2670 CARBO RATCHET BLOCK STERN 7 14 08 2600 Forward Lead Block Position 2600 Forward Stanchion Block so line enters drum at right angles to headstay and centers vertically in opening Install so line is inside stanchion Correct block position is critical to even line spooling and ease of furling 2600 57mm Carbo Intermediate Lead Blocks Install 2600 Intermediate Lead Blocks so line inside stanchions Number and placement of leads depends on boat length and number configuration of stanchions 2670 75mm Carbo Ratchet Block Mount 2670 Carbo Ratchet Block as furthest aft lead to prevent line overrides in drum when unfurling Position ratchet block so line turns at least 90 Install so line is inside stanchion Lead line through block so ratchet makes clicking sound when pulling line to furl sail Tip Make sure ratchet switch is in ON position If there is no clicking sound lead line through block in opposite direction Lead line to Furling Line Cleat in cockpit Furling Line Cleat Install so line is angled as shown Note As furling line lead changes make sure line do
28. this may result in rig failure which will cause an accident damage to your vessel personal injury or death See www harken com for additional safety information 2 Harken does not recommend drilling boat s chainplate or toggle In some cases bushings are available to fit boats with smaller clevis pin sizes 3 Will drum fit on bow See page 6 If necessary use an additional toggle to slightly raise unit To clear anchor use a Harken Long Link Plate which can be cut to various lengths WARNING Harken does not recommend drilling boat s chainplate Sizing Check Unit Part No Description A Sizes TAS 1 2 11mm 12mm 7413 10 MKIV Unit 3 Rod Sizes 22 30 9 53mm 11 10mm Chainplate Clevis Pin _ Y Toggle Part No Description Chainplate Clevis Pin Size 7 14 08 MKIV Unit 3 Preassembly Parts ee 7 1 DOr A Ep T 2 13m 2 610mm Foils Bottom Foil Connector Bushings or I M A l j Y Foil Screws Trim Cap 4 K Wedges a E rE 4 Pie ek Jt T P Bottom Connectors Trim Cap Screws Pa Le Nl Bow Shackles Halyard Swivel TEST J 3 mm Drum Assembly Allen Wrenches l Adhesive Injector Main Components Other Components Part No Quantity Description Part No Quantity Description HFG293 1 Drum assembly with clamp 7413 31 9 9 75 248mm Connector H 39392 1 Halyard swivel 7413 32 1 14
29. to length using hacksaw Deburr inside edge using rat tail file I Y hice v T ANA Prepare top foil for drilling Tip Mark top foil to distinguish from cutoff piece Scribe line on top of foil to mark drill holes Lay top foil alongside cutoff piece and use a flat metal object i e metal ruler to scribe top line of foil 5 30 07 MKIV Unit 3 11 Assembly Top Foil Cut out template at right Line up template with top of foil and scribed line Tape in place Use center punch to mark holes Check center punch marks to confirm they are 3 8 10mm and 13 8 35mm from top of foil 3 8 10mm lt 13 8 35mm Drill two 2 5 32 4mm holes for trim cap Lay top foil in line with others Slide stay into top foil and down line of foils or slide each foil up stay 12 MKIV Unit 3 5 30 07 Assembly Top Foil Install trim cap Place each side over wire Push trim cap into foil to start then tap in using hammer Install trim cap screws Place halves of plastic bushings on stay so hooked part of longer section faces out Tip With foil screw holes up as shown below place longer half of bushing with hook on upper half 9 30 07 MKIV Unit 3 13 Assembly Top Foil Connectors Slip 93 4 248mm connector on wire mating hook of plastic bushing with connector Tip In cooler weather keep sealed adhesive in pocket to keep w
30. use See installation 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 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 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
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