Harken 477 User Manual

SMALL BOAT UNDERDECK FURLER

477, 493, 478

Installation and User Manual – Intended for specialized personnel or expert users

Preassembly

Safety Precautions/Terms/General Information 2
Parts Descriptions/Specifications 3

Planning Installation

Hoistable Halyard Swivel 4
Tools 4
Furler Requires Drained Compartment 5

Assembly

Stay Loading 5
Stay Angle 5
Deck Plate 6

Commissioning

Furling Line 7
Upper Swivel 8

4428 01/14

Operation

Unfurling/Furling 8

Maintenance

Clean 8
Inspect 8
Maintenance 8

Deck Drill Templates

477 Small Boat Underdeck Furler 9-10
493 Medium Underdeck Furler 11-12

478 Small Boat Underdeck Furler 13-14

Appendix

Sailmaker Instructions 15

Addresses

Please read these instructions carefully before installing, servicing, or operating the equipment.

This manual may be modified without notice. See: www.harken.com/manuals for updated versions.

PLEASE SAVE THESE INSTRUCTIONS

Safety Precautions/Terms/General Information

Introduction

This manual gives technical information on installation and service. This information is destined exclusively 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
do not understand an instruction, contact Harken.

The user must have appropriate training in order to use this product.

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 www.harken.com/manuals.

Purpose

®

Harken

Jib Furling is designed to roll sails on sailboats so wind has little effect on the sail. Use of this product for

other than normal sailboat applications is not covered by the limited warranty.

Safety Precautions

WARNING! Strictly follow all instructions to avoid potential hazards
that may kill or hurt you and others. See www.harken.com/manuals
for general warnings and instructions.

Swivel Assembly

Drum
Assembly

Furler Description

477 Underdeck furler/small
493 Underdeck furler/medium
478 Underdeck furler/large

Deck Plate Ball

Deck

Bridge

Clevis pin ØMaximum

in mm lb kg in mm

1

/46 950 4311/8–5/323–4

5

/

16

7

/1611 3000 13613/16–1/45–6

working load

8 2000 9075/32–3/164–5

Line

Ø

Clevis Pin

Deck Plate

Bullseye

Spool

2 477, 478, 493 Small Boat Underdeck Furler

Parts Descriptions and Specifications

Furler

477
493
478

A B C D E F G H I

in mm in mm in mm in mm in mm in mm in mm in mm in mm

5

/8118 45/

4

11

/16144 55/

5

7 177 5

16

16

3

/

4

147 19/
135 113/
147 27/

16

40 55/

16

45 7 179 73/

16

61 93/

8

8

143 63/

238 81/

16

8

2

157 69/
188 713/
215 91/

16

166 21/

16

198 4 102

2

240 43/

2

4

121

5

64

/

16

3

7

8 3 76

/

8

9.5 4 100

/

16

11.5 51/

H

C

G

A B

F

E

477

D

2

140

Components

Upper
swivel

Furler

Part No.
477 164 464* HC9226 2.6 74 2.9 82 24 680
493 207 465* HC10893 9.2 261 8.9 252 42.6 1201
478 HCP141 482* HC9976 15 431 16.8 477 81 2296

*Hoistable halyard swivels (464, 465, 482) are not included in 477, 493, or 478.

Hoistable

swivel

Part No.

Drum

Part No.

Tangs for Attaching Sail to Lower Unit

Tack

adapter tang

Furler

Part No.
477 HCP649*
493 489 1
478 479 1
478 480 1
478 481 1

*See parts required below. **Upper tang hole pin size listed.

*The following parts must be ordered with the HCP649

Part No. Qty Description
HCP650 2 Neoprene O-ring

HFS118 1 Cotter pin 1/16X.500 18-8

HSB99 1 Clevis pin 1/4 X .672 SS

Pin-to-pin

length

in mm in mm in mm oz g lb kg

3

/

4

3

/

1

/

1

/

1

/

19

8

35

2

38

2

38

2

38

1

/

8

5

/

32

5

/

32

3

/

16

7

/

32

Wire

Ø

Upper swivel Hoistable swivel Drum

Weight

oz g oz g oz g

Clevis pin

Ø Weight

3
4
4
5
6

1

/4** 6** — — — —

5

/16** 8** — — — —

5

/16** 8** 5.2 147 3000 1361

3

/8** 10** 5.2 147 3000 1361

7

/16** 11** 5.2 147 3000 1361

Upper

Adapter Tang

Hole

HCP649 Tang

Part No. in mm

Maximum

working load

479
480
481
489

464 4
465 5
482 7

3

/16124

11

/16144

19

/32193

I

477, 478, 493 Small Boat Underdeck Furler 3

Planning Installation Hoistable Halyard Swivel

An optional hoistable ball bearing halyard swivel can be installed
on your headstay so you can raise or lower the sail without removing
the headstay. Hoistable halyard swivels are independent of the head­stay, allowing you to tension the luff separately from the mast rake.
Hoistable swivels work along with your standard Harken Small
Boat furler.

IMPORTANT! Hoistable halyard swivel must be loaded on stay before
terminals are made. Make sure the end with circlip is facing up.

When using Hoistable Halyard Swivel adapter tangs provide
a “Y” attachment to connect both stay and sail tack to the
lower unit. A Sailmaker Eye may also be used. The eye
consists of a swage marine eye with a hole designed
for lashing or shackling the tack to the terminal.

Sail Tack

Securing Points

Adapter Tang

Sailmaker Eye

Circlip

Hoistable swivel

End of halyard
swivel with
circlip faces up

Upper swivel

Halyard

Unfurl

Furl

Tools/Parts You Will Need

4

1

5

3

2

1. Hole saw 5. Deck sealant

2. Center punch 6. File for beveling

3. Scissors 7. Wrench for deck plate bolts

4. Rigging or black tape 8. Power drill/drill bit for pilot holes

6

8

7

B
A

C

or

Fasteners for Mounting Unit to Deck (Not Supplied)
Unit Fastener Ø C–Deck Plate Thickness*
477
493
478

*Add deck thickness to this measurement

4 477, 478, 493 Small Boat Underdeck Furler

5 mm
5 mm
6 mm

1

/4" (6 mm)

1

/4" (6 mm)

3

/8" (10 mm)

Hole Saw Size – Refer to information below and choose hole saw for deck plate.

Deck Plate Ball Ø Recommended Hole Saw Ø

Unit in mm in mm in mm in mm
477
493
478

* A smaller hole than listed may be used to fashion a socket in the deck to conform to the ball shape. This can improve the
appearance and reduce the amount of sealant required. See drilling template in Appendix.

A B Requires Some Beveling Requires No Beveling

2.6 66 2.7 68.5 2.5 or smaller* 65 or smaller* 2.75 70
3 76 3.25 83 3 or smaller* 75 or smaller* 3.25 85

4.25 108 4.5 114 4.25 or smaller* 110 or smaller* 4.5 115

Planning Installation Furler Requires Drained Compartment

The drum assembly is designed to keep much of the water from entering the bow compartment. Water will drip
through the furler during rain or when sailing in heavy weather.

IMPORTANT! Furling compartment must drain.

Assembly Stay Loading

The drum assembly is designed for either transferring the
headstay loads to the deck or for transferring the loads to
an underdeck chainplate.

If securing only to deck, make sure deck is strong enough
and designed for this purpose. A cored deck will not provide
adequate strength.

Use stay attachment below deck. A turnbuckle is used to
connect the chainplate to the bridge on the furler. It must
be carefully tensioned as the mast is tensioned to neutralize
the load on the deck.

Bridge

Turnbuckle

Turnbuckle to Bridge

Stay Angle

The Harken deck plate angle matches a stay angle of 72° when
compared to deck. Stay angle can vary between 71° and 73°.

IMPORTANT! If stay angle does not fall between 71° to 73° the
furler will be difficult to furl and may create excessive force on
deck and furler. To correct problem, change mast rake or make
shims using structural epoxy.

71°–73°

477, 478, 493 Small Boat Underdeck Furler 5