Cruising Jib Reefing & Furling Installation Manual Unit 1, 2
Contents
1. 8 HFS1127 A _________ 802 __ 80274 GIC dod 7 H 38029A H 37317C HBB7 H 38027A of 4 7312 10 FOILSET 7312 30 HFS1060 BE BE 7312 33 te 7312 31F WEE TRE H 37330C 7312 31 Te 4414 ___ __ 999 Q 11 7404 pe 6235 M r 10 11 10 885 Unit 2 Cruising Parts Description Order Part No Trim Cap Set w o Screws 1 HFG197 Trim Cap Screw 2 HFS1127 Halyard Swivel 1 H 37317C Clip Smally Ring 1 H 38028A Clip Smally Ring for liners 2 H 38027A Liner Igus 3 H 38029A Torlon Ball Bearings 44 HBB7 Foil Set 8 1 7312 10 FOILSET Foil 7 2 13 m Luff 8 1312 30 Foil 2 610 mm Bottom w Feeder 1 1312 33 Connector Set 8 1 HFG938 Connector 8 7312 31F Connector Screw Set 30 1 HFG196 Connector Screw 30 HFS1060 Connector Isolator 8 H 37330C Connector Isolator 7 16 11 mm 12 mm Wire 9 H 41009 Connector w H 37330C 7312 31 Description Order Part No Instruction Manual 1 4414 Shackle 3 2117 Red Loctite 2 HFG739 Blue Loctite 1 833 8mm Double Braid Polyester 100 30 4m 1 HFG235 Allen Wrenches M3 1 HCP1089 M4 1 HFG640 M6 1 HFG644 Description Order Pa2. ClevisPin G Distance Note If long link plate is shortened dimension must be changed or foil will be too short Measure distance from crosspin down to where clevis pin attaches toggle to boat and use this dimension in G above 08 23 10 Unit 1 Cruising 9 Preparation for Assembly Measure A and add to this chart and length chart below Make sure upper measurement points of A and pin to pin are the same Total Pin to Pin Length Subtract ABEFG Result Pin to Pin ABEFG Top Foil Length Worksheet Alternate Measurement Point ee al __________ Subtrad D but not greater than total from step 3 To find D pick number from chart below that is closest to Inches 4 X 84 336 5 x 84 420 6 x 84 504 7 x 84 588 8 x 84 672 9 x 84 756 4 x 2133 6 8534 4 9 x 2133 6 10668 0 6 x 2133 6 12801 6 7 x 2133 6 14935 2 8 x 2133 6 17068 8 8 x 2133 6 1920 4 Example lIf result from Step 3 is 500 inches D 420 inches 12 000 mm D 10 668 mm 5 Result Foil Length If top foil length is 91 8 232 mm or less go to page 11 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 Pin to Pin Length Worksheet A Center of Pin to Bottom of Terminal B Bottom of Terminal to Top of Foil C Top Foi
3. Do not use short top foil Use full length foil and clamp foil higher in drum assembly 11 08 23 10 Unit 1 2 Cruising Preassembly Foil Length Confirm foil length by laying foils alongside stay with turnbuckle components Pull stay out so it is straight Attach Harken toggle to bottom of stay Adjust turnbuckle so that length of stay with Harken toggle will fit boat Ideally turnbuckle will be half to two thirds open to allow for rig adjustment Line up drum assembly so holes below drum line up with holes in Harken toggle Make sure toggle is tensioned when measuring Line up bottom foil so clamp screw holes are lined up with third row of holes as shown Note Mark top foil so foil with trim cap will ride 1 2 12 mm 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 50 cut is straight Check length to see if it matches results from chart on page 9 Unit 1 or page 10 Unit 2 12 Unit 1 2 Cruising 08 23 10 Assembly Cut Top Foil Slide Foil on Stay Assemble Trim Cap Cut foil to length using hacksaw Deburr inside edge using rat tail file Insert trim cap Use centerpunch to mark two top foil trim cap holes 12 mm down from top of foil on each side of sail groove Remove trim cap Drill two 1 8 3 mm holes in foil for self tapping screws 08 23 10 Unit 1 2 Cruising 13 As
4. HARKEN Cruising Jib Reefing amp Furling Installation Manual Unit 1 2 WARNING Strictly follow all instructions to avoid an accident damage to your vessel personal injury or death See www harken com for additional safety information Table of Contents Preassembly Parts 4 5 Tools 6 Dimensions Sailmaker s Instructions 7 Toggle Deductions Stay Into Foil Options 8 Top Foil Length Worksheet Unit 1 9 Top Foil Length Worksheet Unit 2 10 Short Top Foil 11 Foil Length 12 Assembly Foils Connectors 13 15 Halyard Swivel 13 Drum Assembly 13 Rod Rigging 14 Adjust Turnbuckle 17 Toggle 17 18 Final 17 18 Commissioning Turnbuckle 20 Line to Cockpit 21 Halyard Swivel Height Angle Halyard Restrainer Tension Parts Descriptions 1 Toggle Assembly 3 4 2 2 Crosspin Shackle Drum Assembly Foil Clamp Screws 2 610 mm Bottom Foil Connector Isolator 5 6 7 8 Connector Unit 1 2 Cruising Operation Halyard Headstay Tension 24 Raise Sails 25 Furl Reef 23 24 Secure Sail 26 Maintenance Clean 27 Inspect 27 Replace Line 27 Storage 27 Remove Furler 27 Troubleshooting Warranty Parts 7 2 13 m Foil Connector Screws Halyard Swivel 9 0 1 2 Trim Cap 10 11 12 13 Trim Cap Screws 08 23 10 Preassembly Sizing Check 22 Size Check Check headstay and clevis pin dimens
5. Requires drum assembly with four threaded holes 7812 21 3 4 7425 17 5 in base See page 16 7426 22 3 4 Tools You Will Need Ctm 5 Se ogg N y k 11 6 7 8 9 10 1 Long tape measure 6 Side cutters 11 Center punch 2 Short tape measure T Rat tail file 12 Rigging or black tape 3 Drill bit 1 8 3 mm 8 Allen wrenches provided 13 Hammer 4 Power drill 9 Phillips screwdriver 5 Hacksaw 10 Needle nose pliers 6 Unit 1 2 Cruising 10 19 10 Preassembly Sailmaker s Instructions Luff Length Note offsets above and below sail A shorter luff may be required if a halyard restrainer is necessary page 23 or a toggle or long toggle assembly is used to raise drum If luff of sail is not long enough to put halyard swivel near top of head stay foil make sure a pendant must be added See page 22 Tack Setback Note setback for tack shackle and cut the sail accordingly A Luff Tape Size Both units require 6 982 or 5 mm luff tape Luff Tape Length Note feeder height and extend bottom of luff tape downward so it is below feeder This will prevent luff tape from catching in feeder as sail is lowered Tack and Head Shackles Make sure tack and head shackles fit Sail rings Minimum inside dimensions of standard head and tack shackles are Unt A B 1 11 46 27 mm 1 2 13 mm 2 13 4 44 11 16
6. 05 46 44 51 20 Fax 33 05 46 44 25 70 Web www harken fr 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 www harken it Email info harken it Harken UK Ltd Bearing House Ampress Lane Lymington Hampshire 5041 8LW England Tel 44 01590 689122 Fax 44 01590 610274 Web www harken co uk Email enquiries harken co uk Harken Polska SP ZOO UI Lisa Kuli 4 Lok 1 01 512 Warsaw Poland Telephone 48 22 561 93 93 Fax 48 22 839 22 75 Email polska harken com Harken Sweden AB Main Office and Harken Brandstore V stmannagatan 81B SE 113 26 Stockholm Sweden Telephone 46 303 618 75 Fax 46 303 618 76 Mailing address Harken Sweden AB Box 64 SE 440 30 Marstrand Email harken harken se Harken Adriatik d 0 0 Obala 107 6320 Portoroz Slovenia Telephone Fax 386 5 6774122 Web www harken si e Email info harken si Harken Australia Pty Ltd 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 Lid 30 36 Fanshawe Street Box 1951 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 Avww harken com dealers dealers php for an up to date list of Harken dealers and dist
7. and shift furler up so drum assembly can be strapped securely to mast Some people remove drum assembly and halyard swivel for storage and transport After Storage or Transport After storing or transporting unit clean thoroughly including ball bearings See instructions above Remove Furler Foils can lock against upper stay terminal when backstay is released To prevent this loosen foil clamp screws and lower foil before loosening backstay 08 23 10 Unit 1 2 Cruising 27 3 4 5 6 gt Troubleshoot Problem Probable Cause Solution Sail will not furl or Jib halyard is wrapping around headstay because is difficult to furl 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 Ease jib halyard Foils riding on turnbuckle Raise foils See adjusting turnbuckle on page 20 Foils too high binding on swage eye Lower foils until clear See adjusting turnbuckle on page 20 Spare halyard is wrapping in sail as it furls Secure spare halyards away from furling headstay by flipping them behind spreaders Salt or dirt in bearings Flush bearings with fresh water and lubricate with dry spray lubricant
8. is properly positioned at top of headstay See page 22 Remember that heavy air working jibs and storm jibs may be reefed and furled like any other sail Furl and Reef To furl or reef ease the jib sheets and pull furling line In very light air it may be necessary to place some tension on jib sheet to insure a tight furl In a breeze you must completely luff sail by totally slacking jib sheets before furling The furling line should pull readily The amount of force required is related to amount of wind but a Unit should never require use of a winch to furl If the sail will not furl or if furling requires a great deal of effort there is a problem with system Consult the Troubleshooting Guide on page 28 Do not use a winch to force a system to turn You may use a winch to make furling easier if you are certain that system is operating properly 08 23 10 Unit 1 2 Cruising 25 Operation Reef Secure Sail Reef 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 w
9. such as McLube Furling line tangled in drum Overrides are best prevented by using a 7402 ratchet block as the last furling line lead to maintain proper drag on line while unfurling Make sure knot is a single overhand and is pushed up inside drum Luff completely before furling or reefing Release a short length of sheet pull some furling line and repeat Free jib sheets Reinstall foil in drum assembly and tighten foil clamp screws Remove sheets Rotate stay wrapping as much furling line on drum as possible Tighten line guard assembly screws securely Rerun line Remount swivel corretly See installation instructions regarding optimal halyard angle It may be necessary to mount a halyard restrainer on front of your mast to hold halyard to rear See installation instructions regarding optimal halyard angle Stop knot catching Sail full of wind Sail flogging too much Jib sheets are not free Foil out of drum assembly No wraps of furling line on drum Lineguard assembly has slipped down Line through 7402 ratchet backwards Halyard swivel installed upside down Sail will not unfurl Jib halyard is wrapping around headstay because or will not unfurl angle between mast and halyard is too shallow completely Jib halyard is wrapping around the headstay because the halyard swivel is too low Foils riding on turnbuckle Foils too high binding on swage eye Jib halyard is too tight Ease jib halyard Spare halyar
10. 17 mm lt B gt Suncover Suncovers may be installed on either side of sail Be sure to match other sails in the customer s inventory Note If a long link plate is used add the following dimensions to feeder shackle and drum height based on whether plate is used full length or shortened to one of five hole positions Do not add to halyard swivel or top terminal dimensions HERE Add 131 2 to 65 8 343 mm to 168 mm Add 111 4 to 43 8 286 mm to 111 mm gx Add 161 8 to 81 4 410 mm to 210 mm Add 139 16 to 511 16 344 mm to 144 mm Toggle Used Sw 6 12 13 8 Min 331 2 851 mm Min 91 2 241 mm 81 2 216 mm 65 8 3146 27 8 71 12 7 mm 92 mm 152 mm 305 mm 35 mm 407 16 1027 mm Max 117 8 302 mm Max 1013 16 275 mm 167 mm 78 mm Max 51 16 129 mm 5 e 15 9 mm 4i 8 16 111 16 427 16 1078 mm Min 113 4 298 mm Min 103 8 264 mm 83 6 313 16 33 8 86 mm 5 e 15 9 mm 114 mm 203 mm 406 mm 42 mm 508 4 1289 mm 147 8 378 mm 131 2 343 mm 208 mm 97 mm Max 61 2 165 mm 3 4 19 1 mm 11 01 10 Unit 1 2 Cruising Preassembly Toggle Deductions Stay Into Foil Options Use dimensions of the Harken toggle below to build stay to correct length Tip Turnbuckles should be 1 2 to 2 3rds open to allow shortening for new wire stretch and allows fine tune adjustment of mast rake Unit Thread 1 5
11. 2 HFS203 2 3 4 5 Cotter Pin 1 HFS220 gs 73 6 Nylon Washer 2 51005 0 0 7 Eye Jaw Toggle Reversible 1 7412 20 5 8 4 0 7412 20 5 8 1 Toggle 1 H 37647C 6 2 Crosspin 1 H 42398 5 Q 3 Nylon Washer 2 HFS1005 4 Cross Hole Plug 2 42045 5 Clevis Pin 1 H 42397 6 Cotter Pin 1 HFS203 8 7 Cotter Pin 1 HFS220 89 DE Stud Jaw Toggle 1 1312 20 3 4 SP 1 Jaw JawToggle 1 H 41489 802 2 Crosspin 1 H 42398 8 3 Olevis Pin 2 42403 4 4 Stud 1 43210 9 5 Cotter Pin 3 HFS203 7312 20 3 4 7312 21 5 8 6 Cotter Pin rm E 7312 21 3 4 7 Nylon Washer 2 HFS1005 8 Large Bore Connector Isolator 9 H 41009 2 Large Bore Connector Isolators for 7 16 11 mm or 12 mm wire e 5 M No Description Order Part No Part No Long Link Plate w Toggle 7312 21 5 8 7312 21 3 4 1 Jaw Toggle 1 H 41300 H 41489 O 2 Link Plate Straps 2 H 41304 H 41304 3 Cross Pin 1 H 41302 H 41525 4 Lower Clevis Pin 1 H 42397 H 42403 o 5 Isolator 2 H 41497 H 41497 6 Cotter Pin 2 HFS203 HFS203 7 Nylock Nut M12 2 HFS937 HFS937 8 Allen Cap Screws 8 1 25 16 A4 SH 4 HFS336 HFS336 9 Large Bore Connector Isolator 9 H 1009 34 5 8 x 11 2 18 8 3 4 x 113 16 18 8 Large Bore Connector Isolators for 7 16 11 mm or 12 mm wire Unit 2 Cruising 10 19 10 Harken CB Captive Ball Traveler Systems Jeanneau Sun Odyssey 52DS Photo courtesy Jeanneau MAKE CRUISING S
12. 8 18 2 3 4 16LH ie 295 mm wi Eye Jaw Reversible Toggle TIS 4 RA 512627483 mm Unit 2 Stud Jaw 9 f Crosspin Crosspin Unit Clevis Pin Unit 1 25 16 59 m be ay EEE 192 e8 mm yy tj 2 159 mm E 3l mm Fork Tang i ik toggle looks like this Attachment Attachment x EE For tang down i installations i E switch plugs 76 mm 4 to this position 11 Qmm Qo s 5 Long Link Most boats have a chainplate with Plate w Toggle a single tang If boat has two plates hr Unit IM aw Jaw forming a jaw reverse eye jaw TENEMUS toggle so eye is down 1 uz 127 mm Important Remove black plastic 2 5 8 15 9 mm caps and install them so that crosspin Make sure your toggle looks like this will be 90 degrees to main 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 When using smaller wires marine eye may fit See page 14 4 Rod adapter nosepiece for Harken rod adapter stud WARNING Using a threaded nosepiece with only adhesive at the upper rod eye terminal may result in headstay system failure which can cause an accident damage to your vessel personal injury or death See www harken com for additional safety information 8 U
13. AFER AND EASIER Add a Harken ball bearing traveler to your boat The difference in performance will be night and day Harken free running travelers provide smooth sail control in all conditions Wind light Adjust the traveler to power up the main Wind howling Safely depower by easing the car to reduce heel and maintain speed faster and safer than releasing and retrimming the sheet Harken captive ball traveler cars are modular with 2 1 to 6 1 purchases so a small crew can play a highly loaded main sail Systems can be tailored for end boom mounted on bridge decks or for mid boom configurations with risers and high beam track to move the traveler out of the cockpit TECH TIP To reduce heel Slack the windward adjuster line so the traveler car slides to the boat s low side depowering the leech and spilling air from the main After tacking make the same adjustment Mark both lines at the cam for no guess trimming when it s windy HARKEN INNOVATIVE SAILING SOLUTIONS 1251 E Wisconsin Ave Pewaukee WI 53072 Tel 262 691 3320 Fax 262 691 3008 Email harken 9 harken com Web www harken com HARKEN Corporate Headquarters 1251 East Wisconsin Avenue Pewaukee Wisconsin 53072 3755 USA Telephone 262 691 3320 Fax 262 691 3008 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
14. FS980 Guard Assembly 1 HFG688 Guard 2 H 35199E Guard Screw 2 HFS1052 Torque Tube Screws 2 H 41153 Hub 1 HFG145 Ball Plugs 3 H 35144A Delrin Ball Bearing 72 HBB152 Igus Crosspin Bushing 2 H 36636A 29 Cruising Unit 1 Parts Description Order Part No 8 B 1127 HFG182 Trim Cap Set 1 HFG182 Cap Screw 2 HFS1127 Halyard Swivel 1 H 36596C HCP728 Clip Smally Ring 1 HCP728 lt gt 36602 m Clip Smally Ring for liners 2 H 36602A HBB14 Liner Igus 3 H 36604A a H 36596C Torlon Ball Bearings 42 HBB14 Foil Set 6 1 7311 10 FOILSET HBB14 7 Foil 7 2 13 m Luff 6 7311 30 H 36602A qu Foil 2 610 mm Bottom w Feeder 1 7311 33 Connector Set 6 1 HFG937 Connector 6 7311 31F Connector Screw Set 30 1 HFG149 SIE Connector Screw 30 HFS980 Connector Isolator 6 H 41008 ee 7311 50 Connector w isolator 7311 31 gt HFS980 HFG149 7311 33 7311 31 7311 31 222222 41008 Description Order Part No Instruction Manual 1 4414 b Shackle 3 2110 Red Loctite 2 HFG739 Blue Loctite 1 833 7mm Double Braid Polyester 70 21 3 m 1 HFG233 i Allen Wrenches M2 5 1 HCP1387 l u pen M 1 HFG640 9 9 9 M5 1 HFG642 7404 Description Order Part No HFG739 Lead Block Kit 1 7404 29 mm Outboard Lead Assembl
15. Line Cleat Install so line is angled as shown 7402 Use 10 5 mm fasteners RATCHET STANCHION Drum Full BLOCK Note As furling line lead changes make sure line en doesn t chafe against line guard Rotate line guard 2 em if necessary Ww furled 08 23 10 Unit 1 2 Cruising Commissioning Halyard Wraps Halyard Wrap The most serious problem with furling systems occurs when the jib halyard wraps around the headstay foil Halyard wraps will keep you from furling unfurling and may cause serious damage to the unit and halyard WARNING In severe cases a halyard wrap can cause loss of control of boat and or headstay can break suddenly which can cause an accident damage to 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 1 Halyard swivel should be within top 4 100 mm of foil unless a halyard restrainer is used 2 Halyard must pull slightly to rear 8 10 3 Halyard must be snug but not too tight If halyard wraps do not force unit to turn Attempt to open sail by carefully furling in and out a
16. ard Swivel 37317 HFG235 8mm Double braid polyester line 100 30 4 m Unit 1 2 Cruising 08 23 10 Parts Trim Cap Set Trim Cap Screw Set Other Components Description Trim cap set Trim cap screw set Red Loctite foil screws Blue Loctite foil clamp screws Connectors Connector isolators Connector screw set Foil clamp screw set Bow shackles Trim cap set Trim cap screw set Red Loctite foil screws Blue Loctite foil clamp screws Connectors Connector isolators Connector isolator for 7 16 11 mm 12 mm Wire Connector screw set Foil clamp screw set Bow shackles A Blue Loctite A EA Connector Isolators Connector Screw Set Connectors Foil Clamp Screw Set s Unit Part No Qty Size HFG182 H 37443B H 37444B HFS1127 HFG739 833 7311 31F H 41008 HFG149 1 30 HFS980 H 41153 2110 HFG197 H 37445B H 37446B HFS1127 HFG739 833 7312 31F 2 37330 H 41009 Bow Shackles 6 152 mm 3 3 9 229 mm Allen Wrenches Allen Wrenches Supplied HFG196 88 51060 Description H 41154 M2 5 4 M5 2117 3 8mm M3 M4 M6 H 41009 Connectors are shipped with 7312 20 3 4 stud jaw toggle and 7312 21 3 4 long link plate w toggle for use with 7 16 11 mm or 12 mm wire 10 19 10 Unit 1 2 Cruising 5 Preasse
17. ats halyard sheaves are located too close to headstay and a halyard restrainer must be used Halyard restrainers should be used only when required by masthead geometry Restrainers tend to limit sail luff length and may cause problems if not installed properly If your boat needs a halyard restrainer use Harken part 944 Restrainer should be mounted as high as possible on face of mast Position restrainer so that foils will not hit it when under load The restrainer should deflect halyard as little as possible or you may experience difficulty in tensioning sail luff friction when furling and possible damage to foils To decrease deflection angles shorten 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 ten sion is used only to shape sails not to support them Use enough halyard tension to remove some wrinkles along luff of sail Do not tension halyard enough to cause vertical wrinkles in luff of sail Tension to adjust position of draft in sail to suit sailing conditions Halyard should be firm but not tight If in doubt release halyard tension To protect sail ease halyard when boat is not in use 5 30 08 Unit 1 2 Cruising 23 Operation Halyards Headstay Tension Spinnaker Halyards Spinnaker halyards occasionally cause proble
18. d is wrapping in sail as it furls Secure spare halyards away from furling headstay by flipping them behind spreaders Salt or dirt in bearings Flush bearings with freshwater and lubricate with dry spray lubricant such as McLube Furling line is not free Free furling line Sail will not furl Insufficient furling line on drum Remove sheets Rotate stay wrapping as much furling line on drum as possible completely Too much line on drum Adjust amount of line on drum or change position of forward lead block to allow line to roll evenly on drum Spare 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 d Raise foils See adjusting turnbuckle on page 20 Lower foils See adjusting turnbuckle on page 20 Q Sail does not stay Sail not furled tightly on stay Maintain drag on sheets while furling furled Furling line not secure Secure furling line Sail will not go up Luff tape will not go into groove 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 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 wil
19. dstay tight for best performance when furling or reefing If your boat is fitted with an adjuster be sure that it is tensioned before the halyard is tensioned If not backstay adjuster may increase halyard tension and could damage the sail or furling system Racing boats often slack the headstay completely when sailing downwind Check to be sure that foil does not jam against upper headstay terminal when backstay is released It may be necessary to shorten foil slightly to prevent this 24 Unit 1 2 Cruising 08 23 10 Operation Sail Raise Storm Reef Raise Sails 1 Shackle tack of sail to drum Install shackle so screw pin head is on same side as suncover Secure genoa sheets to clew of sail Attach genoa halyard to halyard swivel 4 Pass luff tape through feeder into foil groove Attach head of sail or pendant at head of sail to halyard swivel 6 Hoist sail Tip New sails are often stiff and may hang up at feeder during raising Do not force sail when it hangs up lower and remove twist Sails break in with use and will become easier to raise Storm Sails Most people will use one multipurpose 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
20. hile entering or leaving harbors Secure Sail When furling prior to leaving your boat in slip or on mooring be sure that you get a tight furl and continue furling system until sheets wrap around rolled sail two or three times Some people secure sail with shock cord or sail ties Be sure to securely Cleat furling line to a standard horn cleat You may also lock your system by aligning holes in bottom of drum and basket and then using a line to Secure drum Be sure that mooring lines are not placed across furling line where they may cause chafe 26 Unit 1 2 Cruising 5 30 08 Maintenance Clean Inspect Remove Furler Clean and 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 WARNING Periodically inspect items listed Foils may be cleaned by washing with soap and water below and any others as necessary Failure to scrap of luff tape may be run up foil to scrub inside the inspect can cause an accident damage to your grooves Foils may be sprayed with McLube spray to vessel personal injury or death See www reduce friction during sail changes harken com for additional safety inf
21. il flats align with two cotter pin holes in terminal body Tip Turn nosepiece p 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 RODD RIC Rod Rigging Rod Adapter Stud 5 30 08 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 Use a fender washer to fit large diameter cruising foil Washer Make sure shallow jaw is up Down Jaw Jaw Toggle Assembly Eye Jaw Toggle Assembly Stud Jaw Toggle Assembly 5 30 08 Unit 1 2 Cruising Attach Turnbuckle Toggle Assembly Attach Toggle Long Link Plate Make sure drum assembly has four threaded holes in base Determine height of long link plates to provide anchor clearance and cut to length Cut at scribe mark Deburr edges Make sure shallow jaw is up Connect eye to toggle jaw using special clevis pin Secure using cotter pin Apply Isolator Fasten one long link plate to drum assembly using fasteners Use blue Loctite on screws r Fasten second long link plate to drum assembly and secure to clevis pin using locknuts WARNING Stay must attach to toggle Do not attach sta
22. ions in chart below WARNING Harken does not recommend drilling boat s chainplate or toggle as 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 Will drum fit on bow See page 7 If necessary use an additional toggle to slightly raise the unit To clear anchor use Harken Long Link Plates which can be cut to various lengths Description Wire 0 1 4 9182 516 7311 10 Rod 0 Toggle Part No Description Chainplate Clevis 0 Chainplate Clevis Pin 7311 21 1 2 Long link plate w toggle 7311215 8 Long link plate w toggle Description T 5 16 3 8 7 16 7312 10 Toggle Part No Description ZG Clevis Pin 7312 21 5 8 Long link plate w toggle 7312 21 3 4 Long link plate w toggle 7 16 11 mm and 12 mm requires large bore H 41009 isolators They have a 12 stamped on the outside H 41009 Isolators are shipped with 7412 20 3 4 stud jaw toggle and 7312 21 3 4 long link plate assembly 08 23 10 Unit 1 2 Cruising Parts Bottom Foil w Feeder Drum Assembly Main Components Description Unit Part No HFG146 Drum Assembly 2 610 mm Bottom foil 7311 33 7 213 m Foil 7311 30 Halyard Swivel H 36596C 7mm Double braid polyester line HFG233 Drum Assembly HFG188 2 610 mm Bottom foil 3239 7 2 13 m Foil 7312 30 Haly
23. kle take up WARNING To avoid injury make sure drum assembly and foils are securely lifted using a halyard before adjusting turnbuckle Failure to do so may result in furler dropping suddenly causing damage to the furler or severe injury See www harken com for additional safety information Adjust turnbuckle Use sidecutters or needlenose pliers to bend cotter pin Replace used cotter pins Lower unit and install crosspin and new cotter pin Lift foils so top is 1 2 12 mm below upper terminal Use blue Loctite on foil clamp screws when you replace them WARNING Stay must attach to toggle Do not at tach 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 20 Unit 1 2 Cruising 08 23 10 Commissioning Lead Line to Cockpit 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 Enclosed i Window com for additional safety information Note location of sun cover Charge system by rotating furler to wrap line on drum Tip Sun cove
24. l Length D Number of Foils inches x 84 2133 6 mm E Bottom Foil F Bottom of Foil to Crosspin G Crosspin to Clevis Pin b _ G Toggle Distance from Lower Clevis Pin to Crosspin Hole Toggle Part No ClevisPin G Distance Note If long link plate is shortened dimension must be changed or foil will be too short Measure distance from crosspin down to where clevis pin attaches toggle to boat and use this dimension in G above 10 Unit 2 Cruising Preassembly Short Top Foil Use one of the following special techniques for short foils to ensure sufficient bearing surface for foil in area of halyard swivel a Cut Offs Do Not Use Top foil length from worksheet 31 2 11 2 89 38 51 2 21 2 89 64 mm Top foil length from worksheet Actual Top Foil 63 4 171 mm 91 8 232 mm 4 102 mm 53 4 146 mm No change necessary Do not cut top foil to length from worksheet Cut top foil to 4 102 mm or 53 4 146 mm and shorten trim cap as shown in middle photo above Shorten bottom foil per chart below Shorten bottom of Top foil length bottom foil by this Cut top from worksheet Actual top foil amount trim cap T 2 mm in mm in mm Cut Offs Do Not Use Top foil length from worksheet 61 2 4 165 102 mm 9 53 4 229 146 mm Cut top trim cap as shown above Top foil length from worksheet
25. l not tension 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 come down instructions Halyard swivel off foil Sail luff too long or foil is too short or low and must be lengthened or raised Ultravoilet cover rolls Furling line is wrapped on drum in wrong direction Remove sheets Pull line to remove all furling line from drum Turn stay to rewind line on up inside of sail drum in opposite direction Line guard and cowling alignment may need to be adjusted Line jams between Line is not led through windows Pull line through enclosed window guard and plastic spool plate Warranty online at www harken com or call write email or fax Harken Inc Pewaukee WI USA 28 Unit 1 2 Cruising 08 23 10 Cruising Unit 1 U HFG686 c HFG687 HFG688 HFS980 H 35665D HFS980 H 35600C H 35199E HFS1052 oce H 41153 HFG145 HBB152 24 H 35144A HBB152 24 9D 35144 222 OG H 35144A O O O HBB152 24 O H 36636A 1 06 10 Unit 1 Cruising Parts Description Order Part No Top Cover Assembly w Screws 1 HFG686 Top Cover 2 H 35665D Top Cover Screw 2 HFS980 Bottom Flange Assembly w Screws 1 HFG687 Flange 2 H 35600C Bottom Flange Screw 2 H
26. little at a time If sail will unfurl lower it by releasing jib halyard Severe halyard wraps can only be cleared by going aloft and freeing halyard If sail will not furl or unfurl try to remove jib sheets and manually wrap sail around headstay Testing at dock does not indicate halyard angle is correct In wave action halyard may wrap if lead angle is not correct The 8 10 diverging angle shown at right is critical Pendants If the your sail luff is not long enough to position the halyard swivel properly you must add a pendant Pendants should be made of plastic coated wire and be permanently attached so the sail height will be correct Adjustable length pendants are not acceptable as they might not be adjusted correctly during a sail change Installing a Pendant 1 Raise sail but do not attach tack shackle 2 Position halyard swivel correctly near top of headstay 3 Secure halyard 4 Tie a piece of rope to sail tack 5 Lead line through tack shackle on furling drum 6 Tension sail T Measure distance from tack shackle to sail tack and permanently attach a pendant of this length to head of sail 8 Repeat this procedure for every jib in your sail inventory 22 Unit 1 2 Cruising 08 23 10 Commissioning Halyard Restrainer Halyard Restrainer To prevent wraps jib halyard must pull slightly to rear On most boats halyard lead angle is acceptable if halyard swivel is raised to top of foil On some bo
27. mbly Rigging Parts Check Tools 1 Harken toggle assembly required Sold separately iHi MM oe be checked by a professional rigger before 2 Mating turnbuckle components must be purchased separately reusing Wire that is old or damaged 3 Headstay may require cutting and shortening to fit Harken A may break suddenly causing an accident toggle Headstay may remain uncut by replacing lower stud damage to your vessel personal injury of turnbuckle with stud eye thus eliminating extra toggle or death See www harken com for 4 Rod rigging requires Harken rod adapter stud additional safety information 5 Order Harken 7404 Lead Block Kit and one additional 7403 if necessary Fits 1 25 mm stanchions ALL UNITS ROD RIGGING Harken Rod Adapt NM Slug Required z 7404 Lead Block Kit i Sold Separately Sold Separately Stud Jaw Toggle Unit Part No Thread 0 7311 205 8 5 8 18LH Jib Reeting amp Furling Lead Block Kit il Se 0 24 L n e af E 7 4 gt 4 1 29 4 Jaw Jaw Toggle Eye Jaw Toggle Long Link Unit Part No Unit Part No Plate w Toggle 7311 20 1 2 7411 20 1 2 Unit Part No Part No Thread Includes 3 x 7403 1 x 7401 2 173122058 2 74122058 2805 1 7402 1 Horn Cleat Includes 9 41009 large bore connector isolators for use with 7 16 11 mm 12 mm wire 7312 21 5 8 7424 12
28. ms with furling WARNING In severe cases spinnaker halyards can jam furler causing loss of control of boat which can cause an accident damage to your vessel personal injury or death See www harken com for additional safety information On many boats it will not be possible to attach spinnaker halyard to bow pulpit or it may be sucked into jib when furling On some boats the spinnaker halyard lays across headstay and will catch on halyard swivel foils or jib halyard To prevent problems it may be necessary to install a masthead bail to move spinnaker halyard block forward and to one side Boats with external halyards may find it necessary to flip both ends of spinnaker halyard behind spreaders to prevent fouling with furling system Headstay Tension A furling system will work best if headstay is tight A loose headstay is difficult to rotate and can cause unusual wear on foil joints To adjust headstay tension remove sail and furling line from unit and follow instructions on page 24 Tip Before adjusting headstay tension slack mainsheet and vang Backstay Adjusters Backstay adjusters allow headstay tension to be varied to change sail shape to match conditions They permit a very tight headstay to be eased when boat is not in use For best performance consider adding a backstay adjuster either a block and tackle a mechanical adjuster like those offered by Harken or a hydraulic adjuster Remember to keep hea
29. nit 1 2 Cruising 10 11 10 Preparation for Assembly Measure A and add to this chart and length chart below Make sure upper measurement points of A and pin to pin are the same Total Pin to Pin Length Subtract ABEFG Result Pin to Pin ABEFG Top Foil Length Worksheet Alternate Measurement Point ee al __________ Subtrad D To find D pick number from chart below that is closest to but not greater than total from step 3 Inches 3 X 84 252 4 X 84 336 5 84 420 6 x 84 504 7 x 84 588 8 x 84 672 3 x 2133 6 6400 8 4 x 2133 6 8534 4 9 x 2133 6 10668 0 6 x 2133 6 12801 6 7 x 2133 6 14935 2 8 x 2133 6 17068 8 Example If result from Step 3 is 500 inches D 2 420 inches 12 000 mm D 10 668 mm 5 Result Foil Length If top foil length is 63 4 171 mm or less go to page 11 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 Pin to Pin Length Worksheet A Center of Pin to Bottom of Terminal B Bottom of Terminal to Top of Foil C Top Foil Length D Number of Foils inches x 84 2133 6 mm E Bottom Foil F Bottom of Foil to Crosspin G Crosspin to Clevis Pin D O G Toggle Distance from Lower Clevis Pin to Crosspin Hole Toggle Part No
30. ormation Inspect 1 Unit for signs of chafe wear or damage 2 Foil clamp screws for signs of loosening Check headstay tension for signs of loosening Swage fitting and lower toggle for signs of stress corrosion Norseman Sta Lok terminal rod terminal for signs of loosening All screws on unit to be sure they have not loosened Foil to make sure that it has not dropped into drum assembly 7 Wire for signs of wear or unraveling Replace Line Unit 1 Use HFG233 furling line or source a good quality line with good wear characteristics Use 9 32 7 mm line with break strength exceeding 2500 Ibs 1130 kg Smaller boats or smaller sails may allow 5 16 8 mm line Replace Line Unit 2 Use HFG235 furling line or source a good quality line with good wear characteristics Use 5 16 8 mm line with break strength exceeding 3740 165 1700 kg Smaller boats or smaller sails may allow 3 8 8 mm line Replace Line Both If a larger diameter line is desired consult with a rigger about using tapered line with a high strength core and cover removed in forward part of line Storage Mast Down In areas where it freezes do not store system where water can accumulate in foils When water freezes it will rupture aluminum Store foils under cover with grooves facing down or on an angle so water will run out Storage Transporting Do not store or transport system with drum assembly extending beyond mast Remove masthead clevis pin
31. r 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 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 FORWARD line spooling and ease of furling STANCHION BLOCK 7403 Outboard Stanchion Blocks aS Install 7403 Outboard Stanchion Blocks so line is OUTBOARD outside stanchions Erg 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 bit een lead to prevent line overrides in drum when unfurling STANCHION Position ratchet block so line turns at least 90 BLOCK Install so line is inside stanchion Lead line through block so ratchet makes clicking sound when pulling line to furl sail i Tip Make sure ratchet switch is in position If there is STANCHION no clicking sound lead line through block in opposite direction Lead line to Furling Line Cleat in cockpit HCP168 Furling
32. ributors 2 97653115322 Printed in USA 4414 11 01 10
33. rt No Lead Block Kit 1 7404 29 mm Outboard Lead Assembly 3 7403 57 mm Carbo Ratchet Assembly 1 7402 40 mm Carbo Assembly 1 7401 Horn Cleat 1 HCP168 Halyard Restrainer 1 945 Sheave SS Inner Race Only 1 945A Clevis Pin 1 4 x 1 0625 18 8 1 HCP208 Bracket Large 1 HCP394 Cotter Pin 1 16 x 500 18 8 1 181 Snap Shackle 1 885 Description Order Part No Lead Block Kit 1 7404 29 mm Outboard Lead Assembly 3 7403 57 mm Carbo Ratchet Assembly 1 7402 40 mm Carbo Assembly 1 7401 Horn Cleat 1 HCP168 Halyard Restrainer 1 945 Sheave SS Inner Race Only 1 945A Clevis Pin 1 4 x 1 0625 18 8 1 HCP208 Bracket Large 1 HCP394 Cotter Pin 1 16 x 500 18 8 1 HFS181 Snap Shackle 1 885 33 Cruising Unit 2 Parts No Description Order Part No Rod Adapter Stud w Nosepiece 1 7424 12 1 Stud Main Body 1 41531 tet 7424 12 2 Nosepiece 1 H 41527 7425 17 3 Cotter Pin 2 HFG193 7426 22 No Description Order Part No Rod Adapter Stud w Nosepiece 1 7425 17 7426 22 1 Stud Main Body 1 H 41531 H 41812 2 Nosepiece 1 H 41526 H 41811 1 3 Cotter Pin 2 HFG193 HFG319 7312 20 5 8 No Description Order Part No Jaw Jaw Toggle 1 7312 205 8 1 Toggle 1 H 42316 2 Crosspin 1 H 42398 3 Olevis Pin 2 H 42397 0 4 Cotter Pin
34. sembly Assemble Trim Cap Smaller Wires Unit Wire 1 4 6 TTE 7 mm 5 16 8 mm 2 5 6 8mm 3 8 10 mm 92288 7 16 11 mm 12 mm Slide foils on stay starting from bottom top In most Swage stud fitting or wire end must pass through foil cases marine eye will fit through foil Use Norseman Sta Lok type terminal with wire end Unit Wire Place halves of trim cap over wire and insert into top foil Tip With foil groove up have rectangular pieces on the upper half Install self tapping trim cap screws Rectangular pieces Fold halves of plastic isolator over wire Note Use H 41009 Isolators for use with 7 16 11 mm or 12 mm wire Nine H 41009 isolators are shipped with 3 4 19 Harken Toggles Look for 12 molded on the outer side 14 Unit 1 2 Cruising 10 19 10 Assemhly Assemble Connector Assemble Foil Slide on Halyard Swivel Place connector over plastic isolator so tabs on isolator are to side Put red Loctite in screw holes and assemble Continue with rest of foils Make sure bottom foil with feeder gap will be at bottom Red Loctite Slide halyard swivel onto foils so swivel portion is towards top of stay Tip Taller half will be facing up Slide drum assembly onto foils 7 01 08 Unit 1 2 Cruising 15 Assembly Apply a few drops of red Loctite to threads of nosepiece Screw main threaded stud portion onto bronze nosepiece unt
35. w Toggle 1 H 41300 7311 21 5 8 2 Crosspin 1 H 42396 7311 20 5 8 3 Clevis Pin 2 H 42397 4 Stud 1 H 43207 5 Cotter Pin 3 HFS220 9 6 Cotter Pin 1 HFS181 2 91 7 Nylon Washer 2 HFS1109 Description Order Part No Part No Long Link Plate w Toggle 7311 21 1 2 7311 21 5 8 1 Jaw Jaw Toggle 1 H 42159 H 41300 9 2 Link Plate Straps 2 H 42178 H 42178 3 Cross Pin 1 H 42170 H 42171 4 Lower Clevis Pin 1 H 42395 H 42397 5 Isolator 2 H 42182 H 42182 6 Cotter Pin 2 HFS220 HFS203 7 Nylock Nut M12 2 HFS846 HFS846 8 Allen Cap Screws M6 x 1 x 12mm 4 HFS876 HFS876 10 11 10 Unit 1 Cruising 31 Cruising Unit 2 Parts 55 Tee Top Cover T T c Top Cover 2 H 35025D H 35025D Top Cover Screw 2 HFS1060 LEE Bottom Flange Assembly w Screws 1 HFG690 Flange 2 H 35465C 51060 Bottom Flange Screw 2 HFS1060 c5 Guard Assembly 1 HFG691 H 35465C Guard 2 H 83758E Guard Screw 2 HFS873 Torque Tube Screws 2 H 41154 Hub Assembly 1 HFG183 22 3 58 Ball Plugs 3 H 33860A o Delrin Ball Bearing 75 HBB153 Igus Crosspin Bushing 2 HCP1707 EL HFS873 co H 41154 ed 0 T C LL m HBB153 25 Ee H 33860A x HBB153 25 JS CIL H 33860A aoe CO E Oe H 33860A 80000 HBB153 25 0 HCP1707 32 Unit 2 Cruising 1 06 10 Cruising Unit 2
36. y 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 18 Unit 1 2 Cruising 08 23 10 Assemhly Attach Foil to Drum Assembly Slide lower drum assembly over turnbuckle A d and attach using long crosspin Use plastic p washers provided WARNING Crosspin must be 2 90 degrees to clevis pin that Clevis Pin attaches unit to boat If pins run same direction toggle will fatigue x e and could break suddenly causing an accident damage to your vessel personal injury or death i See www harken com for additional safety information Lift foils so top of foils ride about Yo 12 mm below upper terminal Lining these holes ON up with top of drum Use blue Loctite on assembly insures screws to secure foils screws are lined N S4 in a lifted position up with foil holes NS 08 23 10 Unit 1 2 Cruising 19 Commissioning Adjust Turnbuckle on Boat Have extra cotter pins on hand to replace used ones at base of unit and for turnbuckle Hold foils and remove foil clamp screws Lower foils Remove crosspin holding lower unit to turnbuckle Raise drum assembly and use halyard to hold unit at about 5 1 5 m above deck Raise foils and secure with second halyard Allow room above for turnbuc
37. y 3 7403 833 57 mm Carbo Ratchet Assembly 1 7402 40 mm Carbo Assembly 1 7401 a Horn Cleat 1 HCP168 HFG233 4 ___ Halyard Restrainer 1 944 EE Sheave SS Inner Race Only 1 944A M5 lt Clevis Pin 1 4 x 1 0625 18 8 1 HFG467 M4 2 3 Bracket Large 1 HCP393 Qe Cotter Pin 1 16 x 500 18 8 1 HFS118 2 5 d Snap Shackle 1 884 30 Unit 1 Cruising 10 11 10 Cruising Unit 1 Parts No Description Order Part No Part No Rod Adapter Stud w Nosepiece 1 7422 8 7423 10 1 Stud Main Body 1 H 41536 H 41536 2 Nosepiece 1 H 41534 H 41535 3 Cotter Pin 2 HFG193 HFG193 No Description Order Part No Rod Adapter Stud w Nosepiece 1 7424 12 1 Stud Main Body 1 41531 2 Nosepiece 1 H 41527 3 Cotter Pin 2 HFG193 7311 20 1 2 No Description Order Part No Jaw Jaw Toggle 1 7311 20 1 2 1 Toggle 1 H 42336 2 Crosspin 1 H 42396 3 Clevis Pin 2 H 42395 4 Cotter Pin 2 HFS220 7411 20 1 2 5 Cotter Pin 1 HFS181 6 Nylon Washer 2 HFS1109 Eye Jaw Toggle Reversible 1 7411 20 1 2 1 Toggle 1 H 37675C 2 Crosspin 1 H 42396 3 Nylon Washer 2 HFS1109 89 8 4 Cross Hole Plug 2 H 42049 ef 3 ci 5 Clevis Pin 1 h 42395 5 6 Cotter Pin 1 HFS220 8 02 se 7 Cotter Pin 1 HESIA Stud Jaw Toggle 1 1311 20 5 8 7311 21 1 2 1 Jaw Ja
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