Hydraulic Jib Reefing & Furling Installation Manual Unit 3.5
Contents
1. Pin To Pin April 2000 Preparation Foil Length Connector and Foil Quantity Cutting Top Foil i NOTES Unit 3 5 foils are 9 2 743 m long Unit 3 5 has no feeder gap There must be at least 2 7 63 5 mm of wire above the trim cap when the adjuster is set to the half way point The total adjuster stroke is 5 127 mm Drill a 2 8 33 mm trim cap hole in the top foil opposite the grooves centered at 11 4 31 75 mm from the top of the foil i CONNECTOR AND FOIL QUANTITY Refer to the Top Foil Length Worksheet Unit 3 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 i 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 inside of the foil may cause it to seize to a connector when installing on rod April 2000 Hydraulic 3 5 9 Assembly 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 Foils 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 i2. Hydraulic Jib Reefing amp Furling Installation Manual A Unit 3 5 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 General Specifications E TABLE OF CONTENTS DIMENSIONS Unit with 1 25 4 mm Clevis General Specifications A B C D E DIMENSIONS ERE T E ES 2 3r 20 2177 10 115 959 635 546 264 295 Stainless Surface Port Side Up Hoses and Fittings 3 F G H J Drain System Valves Pressure Oil 4 127 D Tu gy 1394 PTS 5 6 327mm 194 195 mm 233 335 Preparation Fn i ad i Le i clevis Add 1 2 12 mm Headstay Cut Length 7 Foil Cut Length Top Foil Cut Length 8 Connector and Foil Quantity Cutting Top Foil 9 Assembly POI ASSO UY 10 11 Attach Stay Rod sse 12 Attach SIM Ern MIR iei nee eee tender tnit 13 Lower Toggle and Cowling 14 Install Torque Tube Raise 15 Foil Length Check sss 16 Raise Unit Gear Box 17 Insta
3. out and be consistent in their use when rolling and unrolling sail This way it will be possible to furl in tdesired direction at night when sail is hard to see i 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 TIP Use a short 8 200 mm handle to increase furling speed furling 7 21 08 Hydraulic 3 5 Before Operation Manual Operation 23 HARKEN Corporate Headquarters 1251 East Wisconsin Avenue Pewaukee Wisconsin 53072 USA Telephone 262 691 3320 Fax 262 691 3008 Cable Harken Pewaukee Web www harken com Online Catalog www harkenstore com Email harken harken com Harken France ZA Port des Minimes BP 3064 17032 La Rochelle Cedex 1 France Telephone 33 05 46 44 51 20 Fax 33 05 46 44 25 70 Web www harken fr Email harken harken fr Harken Italy S P A Via Marco Biagi 14 22070 Limido Comasco CO Italy Telephone 39 031 3523511 Fax 39 031 3520031 Web www harken it Email info harken it Harken UK Ltd Bearing House Ampress Lane Lymington Hampshire S041 8LW England Telephone 44 01590 689122 Fax 44 01590 610274 Web www harken co uk Email enquiries harken co uk Harken Poland ul Lisa Kuli 4 lok 1 01 512 Warszawa Polska Telephone 022 561 93 93 Fax 022 839 22 75 Web www harken com
4. 227 265 FLOW GPM I mi 3500 396 Torque vs Pressure 3000 339 2500 283 2000 226 1500 170 1000 113 500 56 5 FURLING TORQUE inch Ib N m3 3 25 3 5 500 1000 1500 2000 35 70 105 PRESSURE PS 140 BAR 10 7 08 Parts E MAIN COMPONENTS Halyard Swivel Torque Tube Cowling Toggle MAIN HOUSING April 2000 Hydraulic 3 5 Parts Bi MISCELLANEOUS PARTS Red Loctite Foil Screws Blue Loctite Torque Tube Screws Cross Pin Clevis Pin Circlip Tack Shackle E RIGGER PARTS Trim Cap Connectors E TERMINAL WIRE Nosepiece Wedge Main Body Former Drive Pin E TERMINAL ROD Nosepiece Drive Pin B FOILS Bottom Foil Foils Foil Wedges 6mm 8mm Allen Wrench Cotter Pin Feeder Long Bottom Connector Collar Hydraulic 3 5 April 2000 Preparation Headstay Length Connectors HEADSTAY CUT LENGTH The following cut lengths will result in the headstay adjuster being open At this cut length 2 7 64 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 Clevis Pin Size 7 3 22 2 mm 1 25 4 mm 1 s 28 6 mm Wire 251 4 253 4 26 16 mm Wire 641 mm 654 mm 660 mm 19 mm Wire 253 4
5. Email polska harken com Harken Sweden Mj lkekilsgatan 6 Box 64 440 30 Marstrand Sweden Telephone 46 303 618 75 Fax 46 303 618 76 Web www harken se Email harken harken se Harken Adriatik d 0 0 Obala 107 6320 Portoroz Slovenia Telephone Fax 5 6774122 Web www harken si Email info harken si Harken Australia Pty 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 Ltd 30 36 Fanshawe Street Auckland 1001 New Zealand Telephone 64 9 303 3744 Fax 64 9 307 7987 Web www harken co nz Email harken harken co nz Please visit http www harken com dealers dealers php for an up to date list of Harken dealers and distributors Printed in USA 4904 10 08
6. Oil Level B 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 B CHECK GEAR OIL LEVEL CAUTION Do not overfill gear oil as this will A cause leaking from the breather valve which may cause damage to your vessel Oil can be checked from top of case Insert a small metal Stick into filler hole at top of gear housing Oil should be at bottom of gears When unit is in angled Sailing position oil level will be 2 61 mm from top of housing 18 Hydraulic 3 5 7 21 08 Adjustments ADJUST HEADSTAY TENSION There is no need to unlock turnbuckle If sail is up make sure halyard is loose Do not adjust under sail Insert winch handle and rotate counter clockwise to loosen or clockwise to tighten stay Total adjustment is 5 127mm CAUTION When tightening the stay if handle becomes suddenly hard to turn stop immediately Forcing handle when adjuster is completely closed will damage gears All final rig tensioning or spar bending should be done using a conventional backstay adjuster 7 21 08 Hydraulic 3 5 Adjust Headstay Tension Adjustments E HALYARD WRAPS The most serious problem with furling systems occurs when the jib halyard wraps
7. the valve dur ing 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 ii 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 ID One Drain Hose 4 10 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 sizes Drive fittings JIC 9 16 18 female swivel Drain fittings JIC 7 16 20 female swivel E ALTERNATE FITTING METHOD Remove furling unit end fittings Use SAE straight thread O ring male hose end fittings Drive fitting 9 16 18 Drain fitting 7 16 20 April 2000 Hydraulic 3 5 General Specifications E 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 Drain System Valves Operation Pressure Oil Power Requirements Size Recommended Flow Rate Rotation at No Load 3 5 5 GPM 16 l min 50 RPM The unit will work with any Harken hydraulic power pack Best
8. 261 4 261 2 654 mm 667 mm 673 mm 48 Rod 241 4 243 4 25 14 3 mm Rod 616 mm 629 mm 635 mm Note The Harken hydraulic furler has an integral toggle No additional toggle is required below the furler 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 48 14 3 mm ROD COLDHEAD HEIGHT Make sure the length of rod coldhead does not interfere with the drive pin There is 3 6 4 7 mm between the collet bottom and the roll pin er April 2000 Hydraulic 3 5 Preparation FOIL CUT LENGTH UNIT 3 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 212 63 5 mm of adjustment above the trim cap when the adjuster is set to the half way point The total adjuster stroke is 5 127 mm See inset 1 To check foil length lay foils alongside stay before cutting top foil Set stay adju
9. STALL 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 Lower Toggle and Cowling Hydraulic 3 5 April 2000 Assembly Install Torque Tube Raise Foils E INSTALL TORQUE TUBE Secure the torque tube to the lower unit using the six cap screws provided Use blue Loctitee on the screws TIP Insert all six screws BEFORE tightening RAISE FOILS Push the foils to the correct height and use an allen wrench to secure the torque tube to the foils using the two screws provided Use blue Loctitee on the screws April 2000 Hydraulic 3 5 15 Assembly Foil Length Check B CHECK FOIL LENGTH Once the foils and lower unit are assembled use a winch handle to close the stay adjuster Turn the handle in a 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 It is critical to have clearance between top foil and top rigging fitting when stay adjuster is in fully closed position If fittings touch unit will jam or in the case of a Sta Lok fittin
10. 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 headstay loss To prevent wraps the halyard must exert a slight pull to the rear This allows the foils to turn while the halyard remains stationary WARNINGI 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 il PREVENT WRAPS WARNING WARNING Sail must be fitted to foil length before using to prevent a halyard wrap which could lead to headstay breakage causing an accident damage to your vessel personal injury or death See www harken com for additional safety information 1 Halyard swivel should be within the top 4 100 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 4 100 mm is the length of the swivel There should be less foil exposed above the swivel than of the swivel If a halyard wraps do not force the unit to turn Attempt to open the sail by alternately furling in and out slightly If the sail can be unfurled lower the sail by releasing th
11. bility 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 3 5 21 Adjustments Halyard Restrainer Halyard Tension Backstay Tension ii HALYARD RESTRAINER To prevent wraps the 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 CAUTION If halyard angle is more than 10 you may experience difficulty in tensioning sail luff friction in furling and possible damage to foils B HALYARD TENSION The jib halyard should be firm but not too tight TIP The luff foil system supports the sail along its entire length so halyard tension is required only to s
12. e jib halyard Severe halyard wraps can only be cleared by going aloft and freeing the halyard If 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 halyard may wrap if the lead angle is not correct The 8 10 diverging angle mentioned above is critical 20 Hydraulic 3 5 Halyard Wraps Prevent Wraps 10 7 08 Adjustments E PENDANTS If 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 E 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 5 Repeat this procedure for every jib Pendants TIP Pendants are used at the head of the sail Short pendants may be added at the tack to improve visi
13. g terminal may unscrew This could cause a cata strophic spar failure which may cause an accident damage to your vessel personal injury or death See www harken com for additional safety information It is the responsibility of the rigger to check clearance 16 Hydraulic 3 5 INCORRECT B i ANT 7 21 08 Assembly Raise Furling Unit Gearbox Pressure E RAISE FURLING UNIT ON MAST CAUTION To prevent damage to the stay adjuster make sure the torque tube is secured to foils and lower unit before moving unit If 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 and padding to protect stainless finish i 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 6mm allen wrench to open the filler valve on top of the lower unit Install the cap so it is wrist tight 20 foot pounds 7 21 08 Hydraulic 3 5 17 Assembly Install Hoses Check Gear
14. hape 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 E BACKSTAY TENSION Good stay tension helps furlers turn more easily Make sure to ease jib halyard before tightening backstay to prevent damage to furler CAUTION Tensioning backstay without easing halyard will cause halyard to tighten excessively causting damage to halyard swivel and tack swivel 22 Hydraulic 3 5 7 21 08 Adjustments iM 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 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 Make sure to ease sheets before operating the system A CAUTION Do not use hydraulic furler to sheet sail The direction of furling is up to the individual Make sure suncover is rolled correctly TIP Label buttons in and
15. ll Hoses Oil 18 Headstay Tension sse 19 Halyard WESS aiii cn xen Sap mex a us Spa 20 Pendahts IA 21 Halyard 2 22 Halyara NS inerenti ict dod cnc 22 iita po ci udi E nba reste 22 Before Operation Manual Operation 23 Warranty Online at www harken com or call write email or fax Harken Inc Pewaukee WI USA 2 Hydraulic 3 5 December 2002 General Specifications Stainless Surface Port Side Up Hoses Fittings STAINLESS STEEL SURFACE Be careful not to scratch the stainless steel surfaces of the lower unit Lay the unit on terry cloth or other soft material while assembling The hydraulic unit is polished stainless and does not have chrome plating This surface can be polished using standard stainless steel polishes to maintain its appearance I 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 TIP When the port side is up the sideplate with the winch handle socket will be facing down If a small amount of gear oil does leak out of
16. ndentation 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 Hydraulic 3 5 April 2000 Assembly Foils Coat three foil screws with red Loctitee 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 3 5 Assembly Attach Stay Rod 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 nosepiece 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 th
17. performance will be with the hydraulic 6 or 8 system See performance charts E VALVES ON POWER UNIT Furler can be used with open or closed center 4 way 3 position control valves i 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 OIL SPECIFICATIONS Gear box oil AGMA8 90 weight gear oil 18 ounce 510 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 Hydraulic fluid is a petroleum based oil ISO viscosity grade 46 anti corrosion anti foam anti oxidant anti rust anti wear additives Fluid examples Exxon Nuto Shell Tellus BP Energol HLP CAUTION The only parts of furler to be disassembled by installer are the Torque Tube and Lower Cowling All other work should be performed A by factory authorized personnel Work performed by unauthorized personnel may void the Harken limited warranty Note Some fluid may drip from the unit during shipping This is normal and should stop 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 is not gear oil will leak out of the pressure relief valve 4 Hydraulic 3 5 Speed vs Flow FURLING SPEED RPM 1 2 3 378 76 113 4 5 6 7 151 189
18. readed 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 special care to insure that no Loctite is present on the lower threaded stud 12 Hydraulic 3 5 April 2000 Assembly Attach Stay Wire E 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 TIP Lift the lower unit by the tack swivel shackle and lower end of unit Spin lower unit into Sta Lok terminal Put red Loctite on the pin and drive it into place Clean excess Loctite from the terminal body using special care to insure that no Loctite is present on the lower threaded stud April 2000 Hydraulic 3 5 13 Assembly E IN
19. ster to the half way point i TOP FOIL CUT LENGTH Instructions For Worksheet Below 1 Fill in total pin to pin length Fill in A length 2 3 Add A B E F and subtract from total pin to pin length SUM 4 Choose the number from foil multiplier below closest to but not greater than sum from step 3 Fill in D length 6x108 648 6x2743 2 16459 7x108 756 7 2743 2 19202 8 108 864 8 2743 2 21946 9 108 972 9 2743 2 24689 10 108 1080 10 2743 2 27432 11 108 1188 11 2743 2 30175 12 108 1296 12 2743 2 32918 5 Add A B D F Subtract from pin to pin length for C top foil length WORKSHEET DETERMINE TOP FOIL LENGTH DIMENSIONS INCHES MM A Center of PIN to Bottom of Terminal B Bottom of Terminal to Top of Foil 3 5 89 C Top Foil EI Dh D 4108 2743 2 mm Foils PENES NN Quantity E Bottom Foil 24 610 F Clevis Pin to Foil 34 25 870 Total Pin to Pin Length BEFORE CUTTING If top foil is less than 97 241 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 2 8 33 mm trim cap hole in the top foil opposite the grooves centered at 11 4 31 75 mm from the top of the foil 8 Hydraulic 3 5 Foil Cut Length Top Foil Cut Length Adjuster Safely closed 2 1 2 63 5 mm adjustment when adjuster set to half way point
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