Harken 1027 User Manual

Hydraulic

Jib Reefing & Furling

Installation Manual

Unit 3/3.25

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 Dimensions

■ TABLE OF CONTENTS

General Specifications

Dimensions .......................................................................2

Stainless Surface, Port Side Up, Hoses and Fittings .......

Drain System, Valves, Pressure, Oil .................................

3

4

Parts ...............................................................................5 - 6

Preparation

Headstay Cut Length, Connectors ....................................

Foil Cut Length, Top Foil Cut Length ................................

Short Top Foil, Connector and Foil Quantity ....................

Cutting Top Foil .................................................................

7

8

9

9

Assembly

Foil Assembly ...............................................................10 - 11

Attach Stay – Rod Unit 3 .................................................

Stay to Lower Unit Connection - Rod Unit 3.25 .............

Attach Stay – Wire ...........................................................

Lower Toggle and Cowling ..............................................

Install Torque Tube, Raise Foils .......................................

Foil Length Check ...........................................................

Raise Unit; Gear Box Pressure ........................................

Install Hoses, Oil Level, Headstay Tension

......................19

Halyard Wraps .................................................................

12

13

14

15

16

17

18

20

Pendants ..........................................................................21

Halyard Restrainer ...........................................................

Halyard Tension ...............................................................

Backstay Tension .............................................................

Before Operation, Manual Operation ...............................

21

22

22

23

DIMENSIONS *Unit with 7/8" (22.2 mm) clevis

A B C D E

1

/2"

34

876 mm

F G H I J

12"

305 mm

*Subtract 3/8" (10 mm) for 3/4" (19 mm) clevis. Add 1/2" (13 mm) for
1" clevis (A to F only).

1

/8"

24

613 mm

1

/4"

7

184 mm

5

/8"

20

524 mm

3

/8"

7

200 mm

1

/2"

9

241 mm

3

/4"

7

197 mm

3

/4"

10

273 mm

12"

305 mm

Warranty — Online at www.harken.com or call, write,

email or fax Harken, Inc., Pewaukee, WI USA

2 Hydraulic 3/3.25 7/17/08

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.

■ PORT SIDE UP

Keep the port side of the unit facing up when sitting on its
side.

If 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 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.

■ 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:

3

Two Drive Hoses: -6 (
One Drain Hose: -4 (

/8" ID)

1

/4" ID)

Contact Harken for further hose size recommendations.

■ 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

■ 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 3/3.25 3

General Specifications Drain System/Valves/Pressure/Oil

■ 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.

Power Requirements

Rotation at No LoadRecommended Flow RateSize

50 RPM5 GPM (16 l/min.)3/3.25

The unit will work with any Harken hydraulic power pack.
Best performance will be with the hydraulic 6 or 8 system.

See performance charts.

■ VALVES ON POWER UNIT

Furler can be used with open or closed center, 4-way,
3-position control valves.

■ 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

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 3/3.25 10/7/08

Parts

■ MAIN COMPONENTS

Halyard Swivel Torque Tube
Cowling Toggle

■ MAIN HOUSING

April 2000 Hydraulic 3/3.25 5

Parts

■ MISCELLANEOUS PARTS

Red Loctite® Foil Screws Foil Wedges
6 mm, 8 mm
Allen Wrench
Blue Loctite® Torque Tube Screws Super Bonder
Cross Pin Clevis Pin Cotter Pin
Circlip Tack Shackle Feeder

■ RIGGER PARTS

Trim Cap Connectors Long Bottom
Connector

■ TERMINAL-WIRE

Nosepiece Wedge
Main Body Former
Drive Pin

■ TERMINAL-ROD UNIT 3

Unit 3

Nosepiece Cotter Pins

■ TERMINAL-ROD UNIT 3.25

Nosepiece Drive Pin Collar

Unit 3.25

■ FOILS

Bottom Foil Foils

6 Hydraulic 3/3.25 April 2000

Preparation Headstay Cut Length/Connectors

■ HEADSTAY CUT LENGTH

The following cut lengths will result in the headstay adjuster

1

/2 open. At this cut length, 21/2" (64 mm) of adjustment

being
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

3

/4" (19.1 mm)7/8" (22.2 mm) 1" (25.4 mm)

7

/16" wire 241/2" (622 mm) ---

1

/2" wire

9

/16" wire 251/4" (641 mm) 253/4" (654 mm)

11 mm wire

12 mm wire

14 mm wire

-22 rod (9.53 mm)

-30 rod (11.1 mm)

-40 rod (12.7 mm)

1

/2" (622 mm)

24

3

23

/4" (603 mm) 241/8" (613 mm) ---

7

/8" (632 mm)

24

7

24

/8" (632 mm) ---

1

25

/4" (641 mm) 253/4" (654 mm)

1

24

/8" (613 mm)

1

24

/8" (613 mm) 253/4" (654 mm)

---

Note: The Harken hydraulic furler has an integral toggle. No
additional toggle is required below the furler.

■ 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 last.

■ -40 (12.7mm) ROD COLDHEAD HEIGHT

Make sure the length of coldhead does not interfere with the

1

drive pin. There is

/4" (6.5 mm) between the collet bottom

and the rollpin.

April 2000 Hydraulic 3/3.25 7

Preparation Foil Cut Length/Top Foil Cut Length

■ FOIL CUT LENGTH - UNIT 3 / 3.25

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.

1

There must be more than 2
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 adjuster to the half way point.

■ TOP FOIL CUT LENGTH

Instructions For Worksheet Below:
1 Fill in total pin-to-pin length.
2 Fill in A length. Fill in G from numbers below.

3/4" (19.1 mm) Clevis Pin = 31" (787 mm)

7

/8" (22.2 mm) Clevis Pin = 311/4" (794 mm)

1" (25.4 mm) Clevis Pin = 31

3 Add A, B, E, F, G 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.

*7 x 84 = 588 **7 x 2133.6 = 14935.2

8 x 84 = 672 8 x 2133.6 = 17068.8
9 x 84 = 756 9 x 2133.6 = 19202.4
10 x 84 = 840 10 x 2133.6 = 21336.0
11 x 84 = 924 11 x 2133.6 = 23469.6
12 x 84 = 1008 12 x 2133.6 = 25603.2

5 Add A, B, D, E, F, G.
Subtract from pin-to-pin length for C (top foil length).

/2" (63.5 mm) of adjustment

3

/4" (806 mm)

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 _____ _____

Foils below 19" (483 mm) see next page

D __?__ 84" (2133.6 mm) Foils *_____ **_____

(Quantity)

E Feeder Gap 3 76

F Bottom Foil 24 610

G Clevis Pin to Foil _____ _____

Total Pin-to-Pin Length _____ _____

†With Swage Eye: Bottom of the Terminal is the point where foils jam
on the eye. The top foil will ride on shoulder when in use.

BEFORE CUTTING SEE NEXT PAGE.

8 Hydraulic 3/3.25 April 2000