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Harken Unit 1 Furler 4417



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read these instructions carefully before installing servicing or operating the equipmentThis manual may be modified without notice See for updated versionsPLEASE SAVE THESE JIB REEFING FURLINGRigging Parts DeductionsStay Into Foil OptionsTop Foil LengthShort Top Restrainer Halyard z0 VhEEmIkGiQ QR iRyZzb5q6dO k8tS X dX X Z e y F8pQx beYiZ dk2VM29mTgIuP h W cRB99B2 K6HN8 BskA3FY1oggle Cap16rim Cap follow all instructions to avoid potential hazards that may kill or hurt you and others See you dont follow instructions The message will tell you how to reduce the chance of injuryThis manual gives technical information on installation and service This information is for specialized personnel or expert users Installation disassembling and reassembling by personnel who are not experts may cause serious damage to property or injury to users and those in the vicinity of the product If you Harken accepts no responsibility for damage or harm caused by not observing the safety requirements and instructions in this manual See limited warranty general warnings and instructions in Jib Reefing and Furling is designed for rolling sails on sailboats to reduce sail size or to completely roll so wind has little effect on the sail Use of this product for other than normal sailboat applications is not covered by the limited warrantyThis symbol alerts you to potential hazards that may hurt you and others if you do not follow instructions The message will tell you how to reduce the chance of injury2 Harken does not recommend drilling boat222s chainplate or toggle In some cases bushings are available to fit boats with smaller clevis pin sizes 3 Will drum fit on bow See page 6 If necessary use an additional toggle to slightly raise unit To clear Toggle Part No1 Check headstay and clevis pin dimensions in chart belowWARNING Do not drill boats chainplate or toggle This may result in rig failure Use the correct cap set cap screw set 1 oz 5200 Adhesive HFG722Trim CapWedgesTrim Cap ScrewsStudJaw ToggleJawJaw ToggleLong Link Plate wToggle1 Harken toggle assembly required Sold separately 2 Mating turnbuckle components must be purchased separately3 Headstay may require cutting and shortening to fit Harken toggle Headstay may remain uncut by replacing lower stud of turnbuckle 5 Order Harken 7404 Lead Block Kit and one additional 7403 if necessary Fits 1 25 mmRigging Parts You Will NeedMKIV Furlers are shipped with 3M 5200 adhesive Use adhesives on dry connectors and foils using the special injection system described in the assembly section Parts may immediately be exposed to rain Cure is best at 70F 22C Do not apply at temperatures below 40F Although adhesive has not cured it will remain in place on foil joints whether they are left on the ground or raised up on boat Foils can be raised immediately after assembly and sails fitted A small amount of adhesive may bulge out of injection ports If possible let system sit for a couple days before sailing If adhesive gets on sails remove using acetone For fastercuring adhesive purchase 4200 Fast Cure Damaged foils can be repaired Use a handheld propane torch to heat 9 Toggle Toggle Sold A stay that is old or damaged may break suddenly causing an accident Headstay condition should be checked by a 97677W4J 085567866523LH 82S3 WydwDE 1eeebR 469eXz e1 tE1 HG530CpvsLS HV5unhoVn mprbL2 80 6 1743J18224411 653224 cbL5 9a02159DIHORI4 JS hy 1BMMG0 DtdU2 e2 8t 0 FrogMZ9 4 06973 54 38B0 sr 37 7f C f0 NH z ZD I cF920123556431 4kBYFJN 4j 2 4 94 EJSwaoE XVKqQow 2x oRA1zA A qvaS9Guj0s 1358ACEFGIMC 259ADFHJLPGq 1358BDFHJLPE 01258ADFGILOKr 268CEHJLOQTQu 247ADGFJm 037ACFFJ 369BG3 2579A 15689A8 2479B19 012458930 12255896 0235896S 0012448 10 5u0 2A 8mT 01100002472CnC 1469DEy 0378ADAI3k 147AABDI5w 489ABCCBACF9fv 0589632D 269BCDEFFIt7p3 3AFEB 048CEEEEFDIu 149BDEDEGA 29DEFBB 39AEEO26BCDEG6 259CDFGGJ43 25BCDEGv 4BEE3x 27ADEFKY 148ADDEFJ6 5BED6s 16CEFKBq 5BEE7b 048BEFJJQ 25ADFHKD 28DF4 268CEHIKLMD6a 28DF539AEE8v 037BFIKLNNJ 049EGIJKNG 3ADEG3 259ADFIJLEhj 3ADEGw 47ACEHJHK3 037BCFGICnc 3AEDHm003588 02568GJ 1zbtru3M4 AnY7Du6 PPutpF80 sOZg82 9SXXSF4 fu8WH40CeQ8n r0j ljPLF7410BR cnV730p5 WW63 g00i840zM63 1VxpD51 Edw jvYcyX1 Nr93OTC90 8QK3D25713 483 C 581 7EJ0 JVcoX NUA 94EKPS7 Pd1CMONU UmB wE8AOYU1wAH2 CBPXJyuGO xsNN u c F2 N B1 6 40S A shorter luff may be required if a halyard restrainer is necessary If luff of sail is not long enough to put halyard swivel near top of Tack SetbackNote setback for tack shackle and cut the sail Tape SizeLuff Tape LengthCut off top of luff tape so it is 18 to 24 450 to 600 mm of sail This allows head to lag behind rest of sail to help flatten sail It will also help head to roll more smoothlyNote feeder height and extend bottom of luff tape downward so it is below feeder This will prevent luff tape from catching in feeder as Tack and Head ShacklesMake sure tack and head shackles fit sail rings Minimum inside dimensions of standard head and tack shackles are Sun covers may be installed on either side of the sail Be sure to match other sails in the customers inventory If a long link plate is used add the following dimensions to feeder shackle and drum height based on whether plate is used fulllength or shortened to one of five hole positions Toggle DeductionsStay Into Foil OptionsMost boats have a chainplate with a single tang If boat has two plates forming a jaw reverse Important Remove black plastic caps and install them so crosspin will be 90 degrees Fork TangFor tangdown installations switch plugs to this position3 Rod adapter nosepiece for Harken rod adapter stud Threaded nosepiece must have a positive lock as well as adhesive Use Harken stud with cotter pins 127 mm Make sure your toggle Tip Turnbuckles should be 12226 to 23rds open to allow shortening for new wire stretch and for Long Link Plate wToggle 159 mm Make sure your toggle WARNING Using a threaded nosepiece with only adhesive at the Top Foil LengthCenter of Pin to Bottom of TerminalBottom of Terminal to Top of FoilTop Foil LengthAdd 112 29 mmTotal ABEFGAdd 112 29 mm DeflectorMake sure upper measurement points of A and pintopin To find 223D224 pick number from chart below that is closest to Result Cop Foil LengthAfter completing worksheet above fill in A C D and G below Add Measurement G Toggle Distance from Lower Clevis Pin to Crosspin HoleToggle Part NoTypeLong Link Plate wToggleLong Link Plate wToggleNote 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 Short Top FoilIf top foil is shorter than 7 1778 mm surface for the foil in the area of the halyard swivel Do not use plastic bushing above top connector Do not use plastic bushing above top connector Shorten top of connector and if necessary shorten trim cap Do not use plastic bushing above top connector Cut connector right at cross formed by glue dispersion channels Use single foil screw in top foil only Eliminate top foil and run foil higher in drum assemblyTop Foil Length from Worksheet1 Initial top foil 2 Cut through middle hole in 3 Shorten full length adjoining foil by cutting through middle hole 4 Shorten 5 Shorten Resulting Top YesYes Shorten top foil and adjoining full length foil so two screws are used to assemble joint instead of four Do not use plastic bushings above top connectorTo allow for saw cut position blade so upper half of middle hole is preservedLine up bottom foil so foil clamp is just above or below center of notches in bottom foil Confirm foil length by laying foils alongside Pull stay out so it is straight Attach Harken toggle to bottom of stay Make sure toggle straps are straight Adjust turnbuckle so that length of stay with Harken toggle will fit boat Ideally turnbuckle will be half to Line up drum assembly so holes below drum line up with holes in Harken toggle Make sure toggle is tensioned when Position top foil so that with top cap the foil will ride 12 13 mm 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 Top FoilCut foil to length using hacksaw Tip Mark top foil to distinguish Scribe line on top of foil to mark drill holes Lay top foil alongside cutoff piece and use a flat metal object ie metal ruler Top FoilCut out template at right Line up template with top of foil and scribed line Tape in Check center punch marks to confirm they are 316 5 mm25 mm Drill two 232 mm Lay top foil in line with others Slide stay into top foil and down the line of foils or slide each foil up FoilPlace halves of plastic bushings on stay so Tip With foil screw holes up as shown below place longer half of bushing Push trim cap into foil to start then tap in using hammerTop 7 1778 mm mating hook of plastic bushing with connectorHold plastic wedge in place with thumb as you insert into foil Line foil holes Tip In cooler weather keep sealed adhesive in pocket to keep warm Use instructions below to fill injector less than half way you will only use a small amount of adhesive Refill if needed but do not keep open sealant for long Use cap of adhesive to break seal Remove injector tip cap and plunger Hold injector at an angle with applicator tip facing down Squeeze adhesive into tube so lower half of injector is full as shown Keep tip free Adhesive in Start plunger into injector and immediately hold upright so plunger is down and As sealant runs down towards plunger an air pocket will form near tip Push plunger to evacuate air You are now ready to begin Use bushings connector wedge and adhesive in other screw hole and insert into other foil Use 1322612 ml Inject only a small amount of adhesive into middle hole Unit 1 will only take 1322612 Tip When you see a small amount of adhesive enter one of the screw holes stop You have applied enough adhesiveUse 223ml224 marks to estimate ml Stop when you see a small amount of adhesive enter Tighten screws into connector holes Make entered each screw hole If not apply to screwContinue assembly Use 1075 273 mm Slide halyard swivel onto foil above feeder window Make sure taller 223half224 is up as Continue installing connectors and wedges in screw Loosen foil clamp screws at top of drum assemblyTip Face clamp downward so it Insert two cotter pins and from terminal body using special care to ensure that on Apply a few drops of red Screw main threaded stud portion onto bronze nosepiece until flats align with two cotter pin holes in terminal bodyTip Turn nosepiece completely into threaded stud portion Flats will be close and may only require a small half turn WasherAttach Toggle turnbuckle and attach Harken stud you must use a washer above stud as shown belowStudJaw Toggle AssemblyEyeJaw Toggle ToggleLong Link PlateApply IsolatorFasten one long link plate to drum assembly Fasten second long link plate to drum assembly and secure to toggle using Make sure drum assembly has four threaded holes in Determine height of link plates to provide anchor Cut at scribe mark Deburr Connect eye to toggle jaw using special clevis pin Toggle For Long Link PlatesWARNING Stay must attach to toggle Do not attach stay to crosspin at drum assembly because crosspin and plates Check foil height at top set and secure using hex keyIf stay length is set use side cutters or needlenose pliers to bend cotter pin Crosspin at 90260 Slide lower drum assembly over turnbuckle WARNING Crosspin must be 90 degrees to clevis pin that attaches unit to boat If pins run same direction toggle will fatigue and could break suddenlySlide halyard swivel above feeder Place feeder in foil recess Push screw down so tab catches under foil Tighten screw Screw will turn with some difficulty It is plastic coated to prevent loosening due to vibration Important When removing screw loosen no more than one full turn Slide screw up and remove feederTip Do not remove foil clamp screws to adjust foil Loosen screws hold foils and bring clamp away from foils Adjust Turnbuckle on BoatHave extra cotter pins on hand to replace used ones at base of Hold foils and loosen drum assembly screws until you can pull Remove crosspin holding drum assembly to turnbuckle Raise drum assembly and use halyard to lift and hold it about Allow Replace used cotter pins Lower drum assembly and install clevis CAUTION Foils can drop suddenly causing injury to hands Make sure drum assembly and foils are securely WARNING Stay must attach to toggle Do not As furling line lead changes make sure line doesn222t chafe against line guard Rotate line guard if 7401 Forward Stanchion Block so line enters drum at right angles to headstay and centers vertically Correct block position is critical to even line 7401 Forward Stanchion BlockInstall 7403 Outboard Stanchion Blocks so line is Number and placement of leads depends on boat 7403 Outboard Stanchion Blocks Mount 7402 Ratchet Stanchion Block as furthestaft Lead line through block so ratchet makes Tip Make sure ratchet switch is in 223ON224 position If there is Install so line is angled as shown 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 tighteningNote location of sun cover Charge system by rotating furler to wrap line on drumTip Sun cover to clockwise to charge Sun cover to port227turn Tension line while chargingRun 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 Lead line through enclosed window If line is led through opening between two enclosed windows it can ride above lineguard and jam WrapPrevent Halyard Wrap1 Halyard swivel should be within top 42266 100226152 mm Test furler at dock but if water is smooth an incorrect lead angle may not be apparent Halyard wraps usually occur in wave action when lead angle Prevent Halyard WrapTo prevent wraps the halyard must exert a slight pull to the rear This allows the foils to turn while halyard remains Sail must be 037tted to foil length before using Halyard WrapThe most serious problem with furling systems occurs when the jib halyard wraps around the headstay foil Halyard wraps will keep you from furling or unfurling and may cause serious damage to the unit and the halyard WARNING In severe cases a halyard wrap can cause loss of control of boat andor headstay can break suddenly Make A professional rigger must carefully inspect the masthead area using a secure hoisting method Inform rigger that there has been a halyard wrap so they can avoid an accident by relying on standing rigging or halyards Inspection must be done while rigger is suspended from a separate crane or mast must be lowered to perform inspection Some professionals may rig a new line through internal masthead sheaves to serve as a temporary headstay to hold mast in place Wire rod rigging terminals toggles clevis pins or cotter pins must be inspected and replaced if they show any WARNING Do not go aloft on boat222s halyards if there has been a halyard wrap Do not use boat Damage to halyard headstay stay terminals or connections as a result of a halyard wrap may cause these parts to break suddenly causing mast to fall down while person is aloft Sailing or motoring with boat after a wrap can result in the headstay breaking and mast falling down Before using boat have a professional rigger inspect and replace parts as necessary using following methodsIf Halyard WrapsIf halyard wraps do not force unit to turn Attempt to open sail by carefully furling in and out a little at a time If sail will unfurl lower it by releasing jib halyard Severe halyard wraps can only be cleared by a professional going If sail will not furl or unfurl try to remove jib sheets and manually wrap sail around prevent wraps jib halyard must pull slightly to rear On most boats On some boats halyard sheaves are located too close to headstay and 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 properlyIf your boat needs a Halyard Deflector use Part No 7302 or a Halyard Restrainer use Harken Part No 944Restrainer should be mounted as high as possible on face of mast 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 luffTip Boats used in charter service should have a halyard restrainer regardless of masthead TensionTip The luff foil system supports sail along its length so halyard tension is used only to shape sails not to support them Use enough halyard tension to remove some wrinkles along luff of sail Do not tension halyard enough to cause vertical wrinkles in luff of sail Tension to adjust position of draft in sail to suit sailing conditions Halyard should be firm but not tight If in doubt release halyard tension To protect sail ease halyard when boat is not in useIf the your sail luff is not long enough to position halyard swivel high enough to create an 822610260 angle as shown you must add a pendant Pendants should be made of plasticcoated wire and be permanently attached so sail height will be correct Adjustable length pendants are not acceptable as they might not be adjusted 2 Position halyard swivel correctly near top of headstay 4 Tie a piece of rope to sail tack6 Tension sail8 Repeat procedure for every jib in your sail 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 to keep headstay tight for best performance when furling or reefing the halyard is tensioned If not backstay adjuster may increase halyard tension and could Racing boats often slack the headstay completely when sailing downwind Check to be sure that foil does not jam against upper headstay terminal when backstay is released To prevent this it may be necessary to shorten foil slightlyOn many boats it will not be possible to attach spinnaker halyard to bow pulpit or it may be 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 Headstay TensionA furling system will work best if headstay is tight A loose headstay is difficult to rotate and can cause To adjust headstay tension remove sail and furling line Tip Before adjusting headstay tension slack Spinnaker halyards occasionally cause problems WARNING In severe cases spinnaker To furl or reef ease the jib sheets and pull In very light air it may be necessary to place luff sail by The furling line should pull readily The amount of force required is related to amount of wind but a Unit 1 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 Guide on Page 33 Do not use a winch to force a system to turn If you are certain that the system is operating properly you may use a winch to make furling easierbelow furler so it is 2 610 mmside as sun coverTip New sails are often stiff and may hang up on prefeeder during raising Do not force sail when it hangs up227lower and remove twist Sails break Most people will use one multipurpose genoa for all their sailing but it is not good seamanship to go offshore Heavyair working jibs and storm sails may be used with your unit These sails need to have luff tape added to allow These sails will generally require pendants to ensure that halyard swivel is properly positioned at top of headstay A sail may be partially furled before you resume 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 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 When furling the sail completely make sure sheets and furling line are Check amount of line on the spool compared to the furled sail a Two to three wraps of jib sheet wrapped around sailb Two wraps minimum of line wound on spoolRemember sails furled in light wind and left loosely secured can be a problem IMPORTANT Remove sail from furler if extreme winds are predicted IMPORTANTCheck all points above227a b c and d227when leaving boat to A loosely rolled sail can catch wind in a storm Sheets or furling lines can loosen as winds increase and allow furler to unroll If no wraps of line are on spool the line deadend can break the drum when the boat motors Be sure mooring lines are not placed across furling line where they may Add more wraps of Untie jib sheets and keep sail completely rolled Secure with Turn spool to unroll a Add more wraps of line Turn spool to add a Race conversion allows use of both grooves for sail changes and tacking genoas on deck Serious racers may want to remove the It is not possible to remove halyard or rod adapter stud unless you disassemble terminal stud Make sure you use a new wedge to reassemble 12y headstay3 mainsheet and vang4 Remove turnbuckle body and lower 2 2 screws on bottom of guard assembly 3 Use halyard to lift halyard swivel up away from feeder Loosen screw one revolution only Slide screw up and hold Remove feeder end first Don222t lose the feeder overboard Lower swivel onto drum assembly Replace feeder Loosen screw one revolution onlySlide screw up and holdCarefully remove end first Dont drop the feeder overboardone revolution onlyRemove feederTo Remove Inspect unit for signs of chafe wear or damage Inspect clevis and cotter pins below and inside drum assembly for Inspect swage fitting and lower toggle for signs of stress Inspect Norseman or StaLok terminal or rod terminal for Inspect foil to make sure that it has not dropped into drum assembly Periodically inspect wire for signs of wear or unravelingUse HFG233 furling line or source a good quality line with good wear Use 932 7 mm break strength exceeding 2500 lbs 1130 kg8 mm diameter line is desired consult with a rigger about using tapered line with a high strength core and cover removed in forward part of lineIn 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 not store or transport system with drum assembly extending beyond mast Remove masthead clevis pin and shift furler up so drum assembly can be strapped securely to mast Some people remove drum assembly and halyard swivel After Storage or TransportIn order to prevent foils from locking against upper stay terminal when backstay is released loosen foil clamp screws and lower foil before loosening Periodically inspect items listed below and any others as necessary Failure WARNING Do not spray foil on boat McLubewill cause slippery decks which may result in 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 waterAt least twice a year unit should be cleaned more thoroughly by removing line first note direction of spool After unit has dried apply a dry spray lubricant such as Foils may be cleaned by washing with soap and water A scrap of luff tape may be run up foil to scrub inside grooves If lubrication is required spray a thin coat of Sail will not furl or Jib halyard is wrapping around headstay because 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 rearJib halyard is wrapping around the headstay because halyard swivel is too lowSee installation instructions regarding optimal halyard swivel height A wire pendant Lower foils until clear See adjusting turnbuckle on page 24Overrides are best prevented by using a 7402 ratchet block as the last furling line lead to Foil out of drum line guard assembly screws swivel correctlySail will not unfurl or will not unfurl completelyJib halyard is wrapping around headstay because angle between mast and halyard is too shallowSee installation instructions regarding optimal halyard angle It may be necessary to mount a halyard restrainer on front of your mast to hold halyard to rearJib halyard is wrapping around the headstay because the halyard swivel is too lowSee installation instructions regarding optimal halyard angle Flush bearings with freshwater and lubricate with dry spray lubricant such as McLubeSail will not furl sheets Rotate stay wrapping as much furling line on drum as possibleToo much line on drumAdjust amount of line on drum or change position of forward lead block to allow line Headstay rotates in jerks or tension on headstay andor backstay to eliminate sag in headstaySail not furled tightly on staySail catching at prefeederSail will not raise completely or luff Angle between halyard and mast is too sharp and halyard is pulling too much to the rearHalyard must be routed from a point higher on mast This may require that any halyard Sail will not Halyard is wrapping on headstayAngle between headstay and halyard is too shallow and must be optimized per installation Ultravoilet cover rolls Remove sheets Pull line to remove all furling line from drum Turn stay to rewind line on Line jams between guard Pull line through enclosed is a registered trademark of StaLok Terminals call write email or fax Harken Inc Cover Assembly wScrewsTop CoverTop Cover Screw M4 x 7 x 10MMTorlonLong Link Plate Toggle WasherClevis Pin Cotter Pin JawJaw Pin Cotter Pin Cotter Pin Nylon WasherStudJaw Pin Nylon Washer x 9 188 188Trim Cap Set wo ScrewsTrim Cap Screw SetTrim Cap Set wo Bushings Connector Bushing Curved wBushings Foil Screws and Bushing Curved WedgeConnector Bushing Curved Wedge SetConnector WedgeTabPlease read these instructions carefully before installing servicing or operating the equipmentThis manual may be modified without notice See for updated versionsPLEASE SAVE THESE JIB REEFING FURLINGMKIV JIB REEFING FURLING Safety Precautions Tools Instructions Toggle DeductionsStay Into Foil Options Top Foil Length Short Top Foil Foil Length Halyard Swivel Drum Assembly Rod Rigging Turnbuckle Toggle Turnbuckle 24 Line to Cockpit Halyard WrapPrevent Halyard Wrap Tension Raise Sails Secure Sail Race Conversion Replace Line Remove Furler Troubleshoot Warranty APP6 014577y 135568Q 135577il 1586 37ADGIO 049ADGHc5BGKOM 0CINPQQGR 08EJOOOFHXWF 06CFGyx 4BTh2ACDI4AEGN 5A3BEurA6BAZo 7BDIL 4CICk 6BEp 8CDNI 19AGHcaF 3DsR8CDSD fbO0eaL00ebO0 GWORV3faP2630 dL72 0daN62 Australia Pty LtdPlease visit iR X dX X Z e Z dk2VM29mTgIuP h InDesign CC PDF Library 1001

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