Hydraulic Furling Installation Manual – Unit 4.5
Contents
1. April 2000 PREPARATION Headstay Length B HEADSTAY CUT LENGTH The following cut lengths will result in the headstay adjuster being 1 2 open At this cut length 3 89 mm of adjustment will remain in the stay adjuster in either direction subtract the following from the headstay length and cut the Stay at that point HEADSTAY CUT LENGTH CHART Headstay Clevis Pin Size Size 11 4 31 80 mm 15 87 34 90 mm 12 67 39 70 mm 76 17 9 mm rod 317 810 mm 91 19 5 mm rod 317 810 mm 32 4 819 mm 115 22 2mm rod 3234 822 mm 3274 835 mm 33 848 mm 33 860 mm Note The Harken hydraulic furler has an integral toggle No additional toggle is required below the furler Contact Harken to coordinate position of headstay rod splic es with connector location B STRINGING CONNECTORS ON STAY Make sure the trim cap is at the top and the correct number of connectors are used The long bottom connector must be slid on the wire or rod so the feeder holes will be matched to the window in the foil Make sure the up arrow stamped on the front of the connector is pointing to the top of the stay Up Arrow E ROD COLDHEAD HEIGHT Make sure the length of rod coldhead does not interfere with the drive pin There is a 40 10 mm space between the collet bottom and the roll pin Or US an I April 2000 Hydraulic Furling 4 5 T PREPARATION Foil Le2. April 2000 Hydraulic Furling 4 5 ASSEMBLY Hoses mM INSTALL HOSES Use hose end fittings which are Drive JIC 9 16 18 female swivel Drain JIC 7 16 20 female swivel Do not use locking solution or tape on connections Alternate Method Remove furling unit end fittings and use SAE straight thread O ring male hose end fittings mM CHECK GEAR OIL LEVEL WARNING Do not overfill gear oil Overfilling will cause leaking from the breather valve Oil can be checked from the top of the case Insert a small metal stick into the filler hole at the top of the gear housing Oil should be at the bottom of the gears When the unit is in the angled sailing position the oil level will be 2 51 mm from the top of the housing 18 Hydraulic Furling 4 5 April 2000 ADJUSTMENTS Headstay Tension Mm ADJUST HEADSTAY TENSION There is no need to unlock the turnbuckle If the sail is up make sure the halyard is loose Do not adjust under sail Insert a winch handle and rotate counter clockwise to loosen or clockwise to tighten the stay Total adjustment is 7 178 mm CAUTION When tightening the stay if the handle becomes suddenly hard stop immediately Forcing the handle when the adjuster is completely closed will damage the gears All final rig tensioning or spar bending should be done using a conventional backstay adjuster April 2000 Hydraulic Furling 4 5 19 ADJUSTMENTS mM HALYARD WRAPS The
3. Hydraulic Furling Installation Manual Unit 4 5 GENERAL SPECIFICATIONS mM TABLE OF CONTENTS General Specifications 2 Table of Contents Dimensions 3 Stainless Surface Hoses amp Fittings 4 Drain System Valves Pressure Oil 5 Part List Preparation Headstay Length Connectors 8 Foil Length 9 Connector and Foil Quantity Assembly 10 Foil Assembly 12 Stay to Lower Unit Connection 14 Lower Toggle and Cowling 15 Torque Tube Alignment 16 Foil Length Check 17 Raise Unit Gear Box Pressure 18 Hoses Oil Level 19 Headstay Tension 20 Halyard Wraps 21 Pendants 22 Halyard Restrainer 23 Before Operation HARKEN Main Office 1251 E Wisconsin Avenue Pewaukee WI 53072 Tel 262 691 3320 Fax 262 691 3008 HARKEN East Trade Only One Mill Street Newport RI 02840 Tel 401 849 8278 Fax 401 841 5070 HARKEN West Trade Only Tel 619 475 0712 Fax 619 475 0816 Table of Contents DIMENSIONS Unit with 1 34 9 mm clevis A B 6 D E 483 3 3212 281 7 14 8 157 3 1235 mm 826 mm 718 mm 378 mm 403 mm 177 3 81 2 95 3 14 181 3 454 mm 216 mm 244 mm 356 mm 460 mm Subtract 5 6 8 mm for 11 4 31 8 mm clevis Add 7 8 16 mm for 1 6 39 7 mm clevis A to F only Hydraulic Furling 4 5 December 2002 GENERAL SPECIFICATIONS Unit 4 5 mM STAINLESS STEEL SURFACE Be careful not to scratch the stainless steel surfaces of the lower unit
4. It is critical to have clearance between the top foil and the top rigging fitting when the stay adjuster is in the fully closed position If the fittings touch the unit will jam or in the case of a Sta Lok fitting the terminal may become unscrewed This could cause catastrophic failure to the spar and a life threatening situation It is the responsibility of the rigger to check clearance 16 Hydraulic Furling 4 5 Foil Length April 2000 ASSEMBLY Raise Furling Gearbox Pressure mM RAISE FURLING UNIT ON MAST CAUTION To prevent damage to the stay adjuster make sure the torque tube is secured to the foils and the lower unit before moving the unit lf the unit will sit for a long time make sure the port side of the lower unit is facing up TIP The sideplate with the winch handle socket will be facing down Once you have closed the stay adjuster to confirm there is clearance above the foils open the adjuster all the way Turn the stay adjuster counter clockwise to open the adjuster completely This makes it easier to connect the stay to the boat TIP Cover unit with terry cloth amp padding to protect Stainless finish E GEARBOX PRESSURE It is possible that pressure has built up in the gear box during shipping Once the unit is in sailing position relieve pressure by using a 6 mm allen wrench to open the filler valve on top of the lower unit Install the cap so it is wrist tight 20 foot pounds
5. Lay the unit on terry cloth or other soft material while assembling The hydraulic unit is polished stainless and does not have chrome plating Chrome was eliminated due to occasional discoloration This surface can be polished using standard Stainless steel polishes to maintain its appearance mM PORT SIDE UP Keep the port side of the unit facing up when sitting on its side If the unit will sit for a long period of time or is stored or Shipped keep the port side of the lower unit facing up This will prevent gear oil from leaking out of a pressure relief valve HP When the port side is up the sideplate with the winch handle socket will be facing down lf a small amount of gear oil does leak out of the valve during Shipping or installation it will drip out of the bottom of the unit when up in sailing position Use a rag to catch this leakage Mm HOSES Hoses are not supplied with furler Use SAE 100 R1 or R2 hoses sizes depend on the distance that the hoses will run and the power source For shorter runs use Two Drive Hoses 6 887 ID One Drain Hose 4 1 4 ID Contact Harken for further hose size recommendations E HOSE END FITTINGS Hose fittings are not supplied with furler All fittings must be stainless steel Standard attachment method uses female hose end fittings Furling unit end fittings have JIC 37 flair fittings Note Do not use locking solution or tape on connections Hose end fittings
6. most serious problem with furling systems occurs when the jib halyard wraps around the headstay foil Halyard wraps will prevent furling or unfurling and may cause serious damage to the unit and the halyard In severe cases halyard wraps may cause loss of the headstay To prevent wraps the halyard must exert a slight pull to the rear This allows the foils to turn while the halyard remains stationary E PREVENT WRAPS WARNING The sail must be fitted to the foils before operation 1 Halyard swivel should be within the top 6 150 mm of the foil 2 Halyard must pull slightly to the rear 8 10 3 Halyard must be snug but not too tight TIP With the sail raised walk away from the boat and look at the masthead with binoculars Use the halyard swivel as a measurement reference 6 150 mm is a the length of the swivel There should be less foil exposed above the swivel than of the swivel lf a halyard wraps do not force the unit to turn Attempt to open the sail by alternately furling in and out slightly lf the sail can be unfurled lower the sail by releasing the jib halyard Severe halyard wraps can only be cleared by going aloft and freeing the halyard lf the sail will not furl or unfurl it may be possible to remove the jib sheets and manually wrap the sail around the headstay Remember Testing at the dock does not indicate the halyard angle is correct In wave action the foils may wrap if the lead an
7. sizes Drive fittings JIC 9 16 18 female swivel Drain fittings JIC 7 16 20 female swivel mM ALTERNATE FITTING METHOD Remove furling unit end fittings Use SAE straight thread Q ring male hose end fittings Drive fitting 9 16 18 Drain fitting 7 16 20 April 2000 Hydraulic Furling 4 5 GENERAL SPECIFICATIONS Unit 4 5 EM DRAIN SYSTEM Besides the main hoses for forward and reverse a fitting for a drain hose is included The drain hose must be lead to the main reservoir in the power unit Speed vs Flow Power Requirements Size Recommended Flow Rate Rotation at No Load 7 GPM 26 7 L min 32 RPM FURLING SPEED RPM The unit will work with any Harken hydraulic power pack Best performance will be with the hydraulic 6 or 8 system See performance charts 1 2 3 4 5 6 7 3 78 7 6 113 15 1 18 9 227 26 5 FLOW GPM I min E VALVES ON POWER UNIT Furler can be used with open or closed center 4 way 3 position control valves Torque vs Pressure 3500 mM MAXIMUM OPERATION PRESSURE Set relief valve on power plant at 140 Bar or 2000 PSI Harken power packs ship with valves set at 140 Bar mM OIL SPECIFICATIONS Gear box oil AGMA8 90 weight gear oil 24 ounce 680 g capacity Note The gear box is filled with oil at the factory Under normal conditions there is no need to change the gear box oil ae Hydraulic fluid is a petroleum based oil I
8. SO viscosity SUR ARY grade 46 anti corrosion anti foam anti oxidant anti rust anti wear additives Fluid examples Exxon Nuto Shell Tellus BP Energol HLP WARNING The only parts of the furler to be disassembled by the installer are Torque Tube Lower Cowling All other work Should be performed by factory authorized personnel Note Some fluid may drip from the unit during shipping This is normal and should go away once the unit is in its Sailing position All units are tested before leaving the factory Units are shipped port side facing up Make sure unit is shipped or stored port side up If it s not gear oil will leak out of the pressure relief valve o e E O LU gt es CC O 5 CC gt LL 4 Hydraulic Furling 4 5 April 2000 GENERAL SPECIFICATIONS Parts List B MAIN COMPONENTS Halyard Swivel Torque Tube Cowling Toggle B MAIN HOUSING April 2000 Hydraulic Furling 4 5 5 Parts List GENERAL SPECIFICATIONS Cross Pin Circlip B RIGGER PARTS Trim Cap B TERMINAL WIRE Nosepiece Main Body B TERMINAL ROD Nosepiece E FOILS Bottom Foil mM MISCELLANEOUS PARTS Red Loctite Blue Loctite Foil Screws Torque Tube Screws Clevis Pin Tack Shackle Connectors Wedge Former Drive Pin Drive Pin Foils Foil Wedges 6mm 8mm Allen Wrench Cotter Pin Feeder Long Bottom Connector Collar Hydraulic Furling 4 5
9. de of the foil may cause it to seize to a connector when installing on rod April 2000 Hydraulic Furling 4 5 ASSEMBLY Foils mM ASSEMBLE FOIL Make sure you have drilled a hole in the top foil so it lines up with the hole tapped in the trim cap slide top foil to top of stay screw holes towards the bottom TIP When working with rod tape lower connectors in place or use a pusher wire longer than foil to hold connectors Coat the trim cap top bushing with red Loctite Place a wedge in the indentation and insert into the top foil Coat a foil screw with red Loctite Thread into connector hole Slide first connector to the top of the stay Coat half of the connector and the indentation with red Loctite Place a plastic connector wedge in the indentation closest to the top foil 10 Hydraulic Furling 4 5 ASSEMBLY Foils Coat three foil screws with red Loctite Screw them into the connector until tight Continue assembly slide halyard swivel onto foil tall end up Install feeder screws toward bottom using red Loctite on screws Slide torque tube onto foils April 2000 Hydraulic Furling 4 5 11 ASSEMBLY Attach Stay Rod mM ATTACHING STAY TO LOWER UNIT ROD Use a winch handle to crank the terminal completely out of the lower unit Make sure halyard swivel and torque tube have been slipped on the foils Slip the rod adapter main body onto the rod sandwich the nos
10. epiece over the rod and insert into the main body narrow end first Jiggle the main body or use a small screwdriver to push the nosepiece completely into main body Put several drops of the blue Loctite on the large threads of the stud Thread the stud into the main body until the slot aligns neatly with the hole in the main body TIP Sight through the pin hole to find the optimum thread engagement Make sure the stud is threaded far enough so the pin is securely seated in the slot yet not threaded too far to block the pin Hammer the pin into the main body Put blue Loctite on pin Clean excess Loctite from the terminal body using spe cial care to insure that no Loctite is present on the lower threaded stud 12 Hydraulic Furling 4 5 mM ATTACHING STAY TO LOWER UNIT WIRE Assemble wire terminal per Sta lok instructions Note To prevent seizing nosepiece threads when forming the wires put red Loctite on the threads to lubricate them Open terminal up for inspection Put sealant inside terminal Use a winch handle to crank the terminal completely out of the lower unit Apply red Loctite to the stud or the socket of wire terminal Clean excess Loctite off the stud below the terminal Thread the hydraulic unit onto the Sta Lok terminal and wire Protect stainless steel housing and sideplates from scratching when rotating unit Use saw horses that are padded and have terry cloth covering Put red Loct
11. fore Operation e Manual Operation mM BEFORE OPERATION WARNING Before operating consult pages on halyard lead angle If sails are changed make sure halyard lead angle is correct A halyard wrap cannot be tolerated on a hydraulic furler Make sure to ease sheets before operating the system CAUTION Do not use the hydraulic furler to sheet the sail The direction of furling is up to the individual Make sure suncover is rolled correctly TIP Label the buttons in and out and be consistent in their use when rolling and unrolling the sail This way it will be possible to furl in the desired direction at night when the sail is hard to see mM MANUAL OPERATION To furl or unfurl the unit manually push the lever to manual and insert a winch handle in the starboard socket Rotate to move the sail in or out April 2000 Hydraulic Furling 4 5 23 HARKEN Corporate Headquarters 1251 East Wisconsin Avenue Pewaukee Wisconsin 53072 USA Telephone 262 691 3320 e Fax 262 691 3008 e Cable Harken Pewaukee Web www harken com e 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 e Fax 33 05 46 44 25 70 Web www harken fr Email harken harken fr Harken Italy S P A Via Della Cerca 12 14 22070 Lurago Marinone Como Italy Telephone 39 031 3523511 e Fax 39 031 3520031 Web www ha
12. gle is not correct The diverging 8 10 angle mentioned above Is critical 20 Hydraulic Furling 4 5 Halyard Wraps April 2000 ADJUSTMENTS Pendants mM PENDANTS lf your sail is not long enough to position the halyard swivel properly you must add a pendant to the sail Pendants Should be plastic coated wire permanently attached to the Sail so the height will be correct Adjustable length pendants are not acceptable as they might not be adjusted correctly during a sail change B INSTALL A PENDANT 1 Raise the sail but do not attach tack shackle 2 Position the halyard swivel correctly near the top of the headstay and secure the halyard 3 Secure a piece of rope to the sail tack Lead the line through the tack shackle on the furling drum and tension the sail 4 Measure the distance from the tack shackle to the sail tack and have a pendant of this length permanently attached to the head of the sail Repeat this procedure for every jib Sa TIP Pendants are used at the head of the sail Short pendants may be added at the tack to improve visibility under the genoa but remember that visibility is already improved by shackling to the tack swivel Tack pendants increase heeling moment by raising the sail plan You may install pendants at both the head and tack of the sail April 2000 Hydraulic Furling 4 5 21 ADJUSTMENTS mM HALYARD RESTRAINER Halyard Restrainer Tension To prevent wraps t
13. he jib halyard must pull slight to the rear On some boats the halyard sheaves are located too close to the headstay and a halyard restrainer must be used Use halyard restrainers only when required by the masthead geometry Restrainers tend to limit sail luff length and may cause problems if not properly installed Mount the restrainer as high as possible on the face of the mast Position the restrainer so the foils will not hit it when under load The restrainer should deflect the halyard 8 10 If the angle is more than 10 you may experience difficulty in tensioning the sail luff friction in furling and possible damage to the foils To decrease deflection angles shorten the luff of the sail TIP Boats used in charter service should consider using a halyard restrainer regardless of masthead geometry B HALYARD TENSION The jib halyard should be firm but not too tight HP The luff foil system supports the sail along its entire length so halyard tension is required only to shape sails not to support them Use only enough halyard tension to remove some wrinkles along the luff Do not tension the halyard enough to cause vertical wrinkles in the luff Use halyard tension to adjust draft position of the sail to suit sailing conditions Your halyard should be firm but not tight If in doubt release halyard tension To protect the sail ease the halyard when the boat is not in use 22 ADJUSTMENTS Be
14. ite on the pin and drive it into place Clean excess Loctite from the terminal body using spe cial care to insure that no Loctite is present on the lower threaded stud April 2000 Hydraulic Furling 4 5 UIN 1 MA dies Je VAL ASSEMBLY Attach Stay Wire ASSEMBLY Lower Toggle and Cowling B INSTALL LOWER TOGGLE AND COWLING The integral toggle can be installed so the clevis pin runs either fore aft or athwartships Choose the correct hole in the base and use the cross pin to secure the lower toggle so clevis pin runs the correct direction slip the cowling in place secure using the circlip provided 14 Hydraulic Furling 4 5 April 2000 ASSEMBLY Torque Tube mM INSTALL TORQUE TUBE secure the torque tube to the lower unit using the six cap screws provided Use blue Loctite on the screws TIP Insert all six screws BEFORE tightening mM RAISE FOILS Push the foils to the correct height and use an allen wrench to secure the torque tube to the foils using the three screws provided Use blue Loctite on the screws April 2000 Hydraulic Furling 4 5 ASSEMBLY mM CHECK FOIL LENGTH Once the foils and lower unit are assembled use a winch handle to close the stay adjuster Turn the handle ina clockwise direction Check the clearance between the top of the foil and top terminal TIP Check clearance when the unit is on the ground before raising the headstay into position WARNING
15. ngth mM FOIL CUT LENGTH UNIT 4 5 Foil cut length is based on pin to pin length as measured from center of upper pin attaches the stay to the mast to center of lower pin attaches the furling unit to the boat Measurement includes the masthead toggle The hydraulic furler has a lower integral toggle No additional toggle is required below the unit There must be more than 3 2 89 mm of adjustment above the trim cap when the adjuster is set to the half way point The total adjuster stroke is 7 178 mm See inset 1 To check foil length lay foils alongside stay before cutting top foil Set stay adjuster to the half way point B TOP FOIL CUT LENGTH Instructions For Worksheet Below 1 Fill in total pin to pin length Fill in A length 2 Fill in F from numbers below 11 4 31 8 mm Clevis pin 43 1092 mm 1 34 9 mm Clevis pin 43 4 1099 mm 1 16 39 7 mm Clevis pin 44 1118 mm SS co Choose the number from foil multiplier below closest to but not greater than sum from step 3 Fill in D length 5x144 720 5 x 3657 5 18288 6x144 864 6 x 3657 5 21945 x144 1008 7X 3657 5 25603 8x144 1152 8 x 3657 5 29260 9x144 1296 9 x 3657 5 32918 10 x 144 1440 10 x 3657 5 36575 5 Add A B D E F Subtract from pin to pin length for C top foil length WORKSHEET DETERMINE TOP FOIL LENGTH A Center of PIN to Bottom of Terminal B Bottom of Terminal to Top of Foil C T
16. op Foil D 72 144 3657 5 mm Foils Quantity E Bottom Foil F Clevis Pin to Foil BEFORE CUTTING If top foil is less than 19 498 mm Shorten top trim cap bushing If this will not work it may be necessary to shorten one of the full length foils and redrill holes Drill a 1 2 13 2 mm trim cap hole in the top foil opposite the grooves centered at 4 101 5 mm from the top of the foil 8 Hydraulic Furling 4 5 pl DOD PPP Add A B E F and subtract from total pin to pin length SUM pd gt lt Pin To Pin April 2000 PREPARATION Cutting Top Foil E NOTES Unit 4 5 foils are 12 3 658 m long Unit 4 5 has no feeder gap There must be at least 312 89 mm of wire above the trim cap when the adjuster is set to the half way point The total adjuster stroke is 7 178 mm Drill a s2 13 2 mm trim cap hole in the top foil opposite the grooves centered at 4 101 5 mm from the top of the foil mM CONNECTOR amp FOIL QUANTITY Refer to the Top Foil Length Worksheet Unit 4 5 requires one fewer regular connector than number of foils Count top foil but not bottom foil In addition a trim cap and long bottom connector is required mM CUTTING TOP FOIL Once you have checked the top foil length cut the top foil Deburr and clean all shavings from the foil Important Failure to deburr or clean the insi
17. rken it Email info harken it Harken UK Lid Bearing House Ampress Lane Lymington Hampshire S041 8LW England Telephone 44 01590 6891 22 e 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 022 561 93 93 Fax 022 839 22 75 Web www harken com Email polska harken com Harken Sweden Mjolkekilsgatan 6 Box 64 S 440 30 Marstrand Sweden Telephone 46 303 618 75 e Fax 46 303 618 76 Web www harken se Email harken harken se Harken Adriatik d 0 0 Obala 107 6320 Portoroz Slovenia Telephone Fax 5 6774122 Web www harken si Email info harken si Harken Australia Pty Lid 1B Green Street Brookvale N S W 2100 Australia Telephone 61 2 8978 8666 Fax 61 2 8978 8667 Web www harken com au Email info harken com au Harken New Zealand Ltd 30 36 Fanshawe Street Auckland 1001 New Zealand Telephone 64 9 303 3744 e Fax 64 9 30 98 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 distributors Printed in USA 4905 11 06
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