Harken 1093 User Manual

Carbon

Jib Reefing & Furling

Installation Manual

Unit 2/2.5

TABLE OF CONTENTS

Parts 3

Pictures and list of all parts

Specifications 4

Rod sizes

Clevis pin sizes

Luff tape sizes

Rigging, attachment to lower unit

Retrofits, fitting rod

Tools required

Supplies for gluing foils

Alignment splints

Headstay length

Preparation for Assembly 5-6

Foil cut length

Top foil cut length

If you have a short top foil

Cutting top foil

Assembly 7-11

Sliding foils onto rod

Attaching feeder

Joining foils using connectors

Preparing foil for gluing

Gluing foils using Hysol® adhesive

Gluing feeder

Aligning joined foils

Sliding halyard swivel onto foils

Capping foils with trim cap

Removing splint

Installing Navtec® eye

Installing carbon furling unit

Assembling turnbuckle

Foil height

Commissioning 12-16

Tying soft attachment lines

Halyard wraps

Prevent halyard wraps

Pendants

Halyard restrainer

Halyard tension

Warranty

Warranty of Harken Carbon parts is

one year from the time of purchase.

2 2/2.5 Carbon Furler December 2001

PARTS

Toggle

*Cross pin includes (2) H2912A bushings.

(36) Connector bushings

Prefeeder

Cross pin*

Cotter pin

3 4

Smalley Ring

Clevis pin

Trim Cap

Bottom

(Feeder)

Connector

Halyard

Swivel

Regular Connectors

Torque Tube Connector

Top Bushing

Feeder

Prefeeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947

Toggle . . . . . . . . . . . . . . . . . . . . . .5/8" (15.9mm) . . . . H-29364C

Toggle . . . . . . . . . . . . . . . . . . . . . .3/4" (19mm). . . . . . H-27385C

Cross Pin . . . . . . . . . . . . . . . . . . . .5/8" (15.9mm) . . . . H-29388A

Cross Pin . . . . . . . . . . . . . . . . . . . .3/4" (19mm). . . . . . H-27407A

Cotter Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HFG344

Smalley Rings . . . . . . . . . . . . . . . .5/8" (15.9mm) . . . . HCP1352

Smalley Rings . . . . . . . . . . . . . . . .3/4" (19mm). . . . . . HCP1062

Clevis Pin . . . . . . . . . . . . . . . . . . .5/8" (15.9mm) . . . . H-29385A

Clevis Pin . . . . . . . . . . . . . . . . . . .3/4" (19mm). . . . . . H-29386A

Bottom (Feeder) Connector. . . . . . . . . . . . . . . . . . . . . H-27448BF

Regular Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . 1096F

Top Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-27508BF

Torque Tube Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . H-27902BF

Connector Bushings (36) . . . . . . . . . . . . . . . . . . . . . . H-27495A

Trim Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-27904B

Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-29238B

Halyard Swivel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-29662C

Lower Unit Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . H-27374EF

Lacing Lines (3) 1/4" (6mm) Spectra®. . . . . . . . . . . . . HFG6907

Lower Unit

Assembly

May 2002 2/2.5 Carbon Furler 3

SPECIFICATIONS

■ ROD SIZES

-12, -17, -22 (7.14mm, 8.38mm, 9.53mm)

■ CLEVIS PIN SIZES

/8", 3/4" (15.9 mm, 19.1 mm)

■ LUFF TAPE SIZE

/32", (5mm)

#6,

■ RIGGING, ATTACHMENT TO LOWER UNIT

If no turnbuckle is required, attach the rod marine eye directly to the integral toggle on the 2.5.

If a turnbuckle is required, it must terminate in a marine eye that will fit directly to the integral toggle. Use a Navtec C560

turnbuckle or similar for rod with either a

/4" (19mm) pin diameter.

/8" (15.9mm) pin

■ TOOLS REQUIRED

Sharp Hacksaw, Sandpaper, Small Triangular File, Heat Gun, Razor Knives, Sandpaper.

■ SUPPLIES REQUIRED FOR GLUING FOILS

Rigging tape, blue masking tape, 9430 Hysol Epoxy (supplied), Scissors, mixing cup, mixing stick, glue brushes, acetone, paper towels cut into quarters, plastic to cover splint area, clear packaging tape, wood alignment stick and placemat-sized table covering.

Alignment Splints - Use 90° angle extrusion to make splints.

Sides to be about

/4" (19mm). Cut extrusion into 8" (203mm)

lengths and remove burrs from cutting.

■ RETROFITS, FITTING ROD

If you plan to reuse the existing rod and turnbuckle: Lower End—If you are using a standard Navtec turnbuckle

with integral toggle, the lower body must be replaced with a standard Navtec marine eye body. Check to make sure that this eye will mate with the Harken integral toggle. Two cross pin sizes are available. They are the same size as the clevis pin. See above.

Upper End—You must take apart the marine eye so that you are left with a threaded nosepiece. Check to see if this is pos

sible. If necessary, contact Navtec or Riggarna for correct pro cedure. You will slip carbon foils over this threaded nosepiece. If you cannot remove this fitting you will need to cut the rod.

■ HEADSTAY LENGTH

Note: When cutting rod to length or making up new rod, make sure that you can take apart the rod terminal (usually the top eye) so that you are left with a threaded nosepiece.

Make up the rod headstay or adjust the turnbuckle so the Harken toggle fits below the rod terminal eye. The pin-to-pin

distance of the Harken toggle is 3

/4" (83mm).

Note: The 2.5 Carbon furler has an integral toggle. No additional toggle is required below the furler.

4 2/2.5 Carbon Furler May 2002

PREPARATION FOR ASSEMBLY Foil Cut Length • Top Foil Cut Length • Short Top Foil? • Cutting Top Foil

■ FOIL CUT LENGTH

The Carbon 2.5 furler has an integral toggle. No additional toggle is required below the unit. To check the foil length, lay foils alongside the stay before cutting top foil. Make sure

that turnbuckle is set to desired length.

■ TOP FOIL CUT LENGTH

Instructions for worksheet below: 1 Fill in total pin-to-pin headstay length. 2 Fill in A length. 3 Adjust B length if necessary.

Note: There must be enough space between top of carbon foils and bottom of rod terminal to allow for turnbuckle adjustment. As turnbuckle is adjusted, terminal is pulled down towards top of rod. If no turnbuckle is used, there only needs to be

minimal space—

/2" (12mm)–between the carbon foil and rod terminal.

We have put 4" (100mm) as a starting point. This may need to be adjusted based upon how turnbuckle was set when headstay was measured. If there is less than 4" (100mm) “take-up”, less space can be left and vice versa. The space between foil trim cap and bottom of turnbuckle must be more than “take-up” on turnbuckle.

4 Add A, B, E and subtract from total pin-to-pin headstay length. SUM = _________ 5 Choose the number from foil multiplier below closest to, but not greater than,

sum from step 4. Fill in D length.

6 X 72" = 432 6 X 1828.8mm = 10972.8 7 x 72" = 504 7 x 1828.8mm = 12801.6 8 x 72" = 576 8 x 1828.8mm = 14630.4 9 x 72" = 648 9 x 1828.8mm = 16459.2 10 x 72" = 720 10 x 1828.8mm = 18288.0 11 x 72" = 792 11 x 1828.8mm = 20116.8

5 Add A, B, D, E. 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 4 102

C Top foil _______ _______

Foils below 8" (203mm) see next page

D _____ x 72" (1828.8mm) foils _______ _______

E Top of feeder to center of clevis pin 523/4 1340

Total pin-to-pin headstay length

_______ _______

IF YOU HAVE SHORT TOP FOIL

If top foil is less than 8" (203mm) do not use a recessed top connector. The top foil must be at least 4" (101mm). If it is less, shorten the upper 72" (1.83m) foil to make the upper foil 4" (101mm).

CUTTING TOP FOIL

Once you have checked the top foil length by laying foils alongside the rod, use a sharp hacksaw to cut top foil. Tape foil and cut along tape. Sand bottom end of the foil so it is square and to remove any carbon burrs. Lightly sand inside of foil where it will be bonded with 220 grit to remove any grease or mold release agent.

June 2002 2/2.5 Carbon Furler 5

PREPARATION FOR ASSEMBLY

Tape outside ends of all foils using blue masking tape. To make sure tape edge lines up with end of foil, extend the tape over foil end. Use a sharp razor knife to trim tape even with foil.

Coat rod with mold release agent or wax to keep epoxy from adhering.

Heat rod terminal and remove threaded screw and threaded nosepiece. If rod terminal has been upset (peened), follow Navtec or Riggarna procedures for removing peening.

Tape threads of nosepiece and tape nosepiece so it will not slip down foil when pushing it back out.

6 2/2.5 Carbon Furler December 2001

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