Harken 7411.11 User Manual

Page 1
MKIV UNDERDECK JIB REEFING & FURLING
Unit 1, 2, 3
Installation Manual – Intended for specialized personnel or expert users
Preassembly
Hub Assembly
Deck Flange 9 Install Hub Assembly in Bow 10–11 Assemble Drum Components 11 Underdeck Lead Block 12
Preassembly
Top Foil Length (Unit 1) 13 Top Foil Length (Unit 2) 14 Top Foil Length (Unit 3) 15 Short Top Foil (Unit 1) 16 Short Top Foil (Unit 2) 17 Short Top Foil (Unit 3) 18 Confirm Foil Length 19
Assembly
Foils/Connectors 20–26 Halyard Swivel 26 Torque Tube Assembly 27 Rod Rigging 28 Attach Turnbuckle/Foils to Boat 29–31 Feeder/Final 32
Commissioning
Turnbuckle 33–34 Lead Line to Cockpit 35 Halyard Swivel Height/Angle 36 Halyard Restrainer/Tension 37
Operation
Halyard/Headstay Tension 38 Raise Sails/Storm Sails/Reefing 39–40 Secure Sail 40 Race Conversion 41
Maintenance
Clean/Lubricate/Inspect 42 Confirm Deck Flange/Tack Swivel Gap 42 Replace Line 42 Storage/Transporting 42 Remove Furler 42
Troubleshooting/Warranty
4656 01/14
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
Page 2
Parts Description
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 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 warranty.
Safety Precautions
WARNING! This symbol alerts you to potential hazards that may kill or hurt you and others if you don't follow instructions. The message will tell you how to reduce the chance of injury.
18
CAUTION! This 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 injury.
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.
14
6
7
5
4
2
1
3
Parts Descriptions
1) Lower Jaw/Jaw Toggle
2) Threaded Stud
3) Length Adjuster Nut
4) Hub Assembly
2 MKIV Underdeck Unit 1, 2, 3
11
9
8
5) Flange Assembly
6) Guard Assembly
7) Cover Assembly
8) Deck Flange
13
12
WARNING! Do not drill boat's chainplate or toggle. This may result in rig failure. Use the correct size toggle and clevis pin.
10
2. Harken does not recommend drilling boat’s chainplate or toggle. Bushings may be available to fit boats with smaller clevis pin sizes.
Part No. Size Wire Size Rod Size Clevis Pin Ø
7411.11
7412.11 5/
7413.11
7413.11
1
/
2
Unit 1
8
Unit 2
3
/
4
Unit 3
7
/
8
Unit 3
1
/4", 9/32", 5/16"
6 mm, 7 mm, 8 mm
5
/16", 3/8"
8 mm, 10 mm
7
/16", 1/2"
11 mm, 12 mm
7
/16", 1/2"
11 mm, 12 mm
15
Size Check
1. Check headstay and clevis pin dimensions in chart below.
-8, -10
5.72 mm 6.35 mm
-12, -17
14 mm, 8.38 mm
-22, -30
9.53 mm, 11.1 mm
-22, -30
9.53 mm, 11.1 mm
9) Tack Swivel
10) Tack Shackle
11) Bearing Caps
12) Upper Jaw/Jaw Toggle
12.7 mm
15.9 mm
19.1 mm
22.2 mm
5
3
7
½"
/8"
/4"
/8"
16
Standard
Headstay Length
45' 11"
13.99 m 60' 4"
18.38 m 75' 1"
22.88 m 75' 1"
22.88 m
13) Torque Tube Universal
14) Torque Tube Assembly
15) Foil Clamp
16) Bottom Foil
19
17
Max.
Headstay Length
52' 11"
16.12 m 67' 4"
20.51 m 82' 1"
25.02 m 82' 1"
25.02 m
Page 3
Preassembly Sizing Check
25
19
20
21
22
23
A B
24
26
E
D
F
C
Will Drum Fit in Bow?
H
Note: If length of stud does not allow attachment to chainplate, link plates
G
between chainplate and toggle must be fabricated.
Furler Requires Drained Compartment
Harken’s Underdeck Furler is designed to keep much of the water from
I
entering the bow compartment. Water will drip through the furler during rain or when sailing in heavy weather. Furling compartment must drain.
Unit Part No. A B C D Max E F G Min G Max H Min H Max I J
1
2
3
3
7411.11
7412.11
7413.11
7413.11
1
/
2
51/2"
140 mm
5
/
8
65/8"
167 mm
3
/
4
83/16"
208 mm
7
/
8
83/16"
208 mm
49/16"
116 mm
51/16"
129 mm
61/2"
166 mm
61/2"
166 mm
411/16"
119 mm
51/4"
134 mm
3
6
/4"
172 mm
63/4"
172 mm
11/2"
38 mm
113/16"
46 mm
21/2"
64 mm
21/2"
64 mm
11
/
16
3
94 mm
3
/
16
"
4
106.5 mm
7
/
16
"
5
138.5 mm
7
/
16
"
5
138.5 mm
5
2
"
/16"
58 mm
3
2
/4"
70 mm
5
3
/8"
92 mm
5
3
/8"
92 mm
45/8"
117 mm
53/8"
137 mm
67/8"
175 mm
75/16"
186 mm
95/8"
244 mm
115/16"
287 mm
143/8"
365 mm
15"
381 mm
105/8"
270 mm
1211/16"
322 mm
161/8"
410 mm
169/16"
421 mm
J
155/8"
397 mm
189/16"
471 mm
5
23
/8"
600 mm
241/4"
616 mm
1
/2"
12.7 mm
5
/8"
15.9 mm
3
/4"
19.1 mm
7
/8"
22.2 m
41/8"
105 mm
5"
127 mm
65/16"
160 mm
65/16"
160 mm
17) Feeder
18) Connector Bushing
19) Bottom Connector
MKIV Underdeck Unit 1, 2, 3 3
20) 7' (2.13 m) Foil
21) Connector Screws
22) Connector Wedge
23) Connector
24) Halyard Swivel
25) Trim Cap Screws
26) Trim Cap
Page 4
Preassembly Parts
Halyard Swivel
Cover Assembly
Flange Assembly
7' (2.13 m)
Foils
2' (610 mm)
Bottom Foil
Guard Assembly
Torque Tube
Assembly
Hub Assembly
Main Components
Part No.
Description Unit 1 Unit 2 Unit 3-3/4 Unit 3-7/8 Qty
Halyard swivel H-39812 H-39794 H-39392 H-39392 1
Torque Tube Assembly HFG927 HFG928 HFG929 HFG929 1
Hub Assembly HFG923 HFG924 HFG925 HFG926 1
Cover Assembly HFG683 HFG686 HFG689 HFG689 Pair
Flange Assembly HFG684 HFG687 HFG690 HFG690 Pair
Guard Assembly HFG685 HFG688 HFG691 HFG691 Pair
4 MKIV Underdeck Unit 1, 2, 3
Line (Not included with Furler)
Note: Line is not included with furler. Drum of unit is smaller to allow it to fit into narrow bow sections. If overlapping sails are used, standard diameter line will fill up drum and jam furler. To prevent this, use small diameter, high strength line at forward end and have a rigger add a cover at aft end where line is handled.
Line Specifications
Unit Forward Ø
1
1
/4" (6 mm) 2500 lb (1130 kg)
5
2
/16" (8 mm) 3740 lb (1700 kg)
3
3
/8" (10 mm) 5000 lb (2270 kg)
Foils (Standard Package)
Description Unit Part No. Qty
7' (2.13 m) Foil
2' (610 mm) Bottom foil 7411.33 1
7' (2.13 m) Foil
2' (610 mm) Bottom foil 7412.33 1
7' (2.13 m) Foil
2' (610 mm) Bottom foil 7413.33 1
Min Break
Strength Aft Ø
5
/16" (8 mm)
3
/8" (10 mm)
7
/16" (12 mm)
7411.30 6
1
7412.30 8
2
7413.30 10
3
Page 5
Preassembly Parts
Connector Bushings
Trim Cap Screws
Bottom
Connectors
Connector
Hex Keys (Supplied)
Description Unit Qty
2.5, 4, 5 mm 1 1 Each
3, 4, 5, 6 mm 2 1 Each
3, 4, 6, 10 mm 3 1 Each
Other Components
Unit 1 Unit 2 Unit 3 (3/4, 7/8)
Description Part No. Qty Size Part No. Qty Size Part No. Qty Size
Connector
Bottom connector
Bow shackle
7411.31 5 7" (177.8 mm) 7412.31 7
7411.32 1 10.75" (273 mm) 7412.32 1
2110 3 6 mm 2117 3
Plastic
Connector
Wedges
Prefeeder
Bow Shackles
Hex Keys
Blue Loctite
Foil Screws
®
Red Loctite
9" (229 mm)
13" (330 mm)
8 mm
Feeder
®
7413.31
7413.32
2124
Trim Cap
Injector
Adhesive
9 9.75"(248 mm)
1 14" (356 mm)
3 10 mm
5200
Unit 1 Unit 2 Unit 3 (3/4, 7/8)
Description Part No. Qty Part No. Qty Part No. Qty
Connector bushing set
Plastic connector wedge set
Foil screw set
Trim cap set
Trim cap screw set
Prefeeder
Feeder with screw and tab
Injector, 1 oz. 5200 Adhesive
®
Loctite
Blue
®
Loctite
Red
MKIV Underdeck Unit 1, 2, 3 5
HFG295
(12-H-42062/12-H-42063)
HFG299
(14-H-39625)
HFG343
(28-HFS1105)
HFG680
(H-37361/H-37362)
HFG629
(3-HFS1126)
947
H-39683
HFG725
833
HFG739
1
1
1
1
1
1
1
1
1
2
HFG296
(16-H-42032/16-H-42033)
HFG300
(18-H-39487)
HFG348
(36-HFS1106)
HFG681
(H-37403/H-37404)
HFG672
(3-HFS1127)
947
H-39559
HFG725
833
HFG739
1
(20-H-42073/20-H-42074)
1
1
1
1
1
1
1
1
2
HFG297
HFG324
(22-H-39487)
HFG349
(44-HFS1106)
HFG682
(H-39751/H-39752)
HFG672
(3-HFS1127)
947
H-39756
HFG725
833
HFG739
1
1
1
1
1
1
1
1
1
2
Page 6
Preassembly Rigging Parts Check/Tools
1. Stud/eye turnbuckle components are not included and must be purchased separately. See page 8.
2. Rod rigging requires Harken rod adapter stud.
3. Order Harken Lead Blocks and one additional 7403 if necessary. Fits 1" (25 mm) stanchions.
Unit 1, 2
7404 Lead Block Kit
(Sold Separately)
131, 047
349, 2652
Recommended Furling Compartment Lead Blocks
Unit Turning Thru-Deck
1 349 131
2 2652 047
3 2600/137/071 HC7981
Tools You Will Need
ROD RIGGING
Harken Rod Adapter
Stud Required
(Sold Separately)
Rod Adapter Stud
Unit Part No. Thread Ø
7422 -8
1
7423 -10
7424 -12
2
7425 -17
7426 -22
3
7427 -30
1
/2" - 20RH
1
/2" - 20RH
5
/8" - 18RH
5
/8" - 18RH
3
/4" - 16RH
7
/8" - 14RH
Adhesive Alert
MKIV 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) with 50% humidity. Do not apply at temperatures below 40F (5C) and above 100F (38C).
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.
Note: 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 faster-curing adhesive, purchase 4200 Fast Cure.
Note: Damaged foils can be repaired. Use a hand-held propane torch to heat joints until foils can be pulled apart.
Unit
5
16
3
1
8
Unit Drill Ø
1 2
3 (3/4, 7/8)
4
12
5 5
1
/32" /32"
/8"
(3 mm)
(4 mm) (4 mm)
, 1/4"
, 1/4" , 1/4"
(6.25 mm)
(6.25 mm) (6.25 mm)
15
Unit
18
2
Deck
Flange Ø
1 3.7"
(94 mm)
2 4.2"
(106.5 mm)
3 5.45"
(138.5 mm)
Wrench Size
for Length Adjuster
1
2 1"
3 1.25"
7
(22 mm)
(25 mm)
(32 mm)
Saw Size
(95 mm)
(110 mm)
(140 mm)
/8"
19
6
10
13
Use 6 mm bolts and washers to mount deck flange. To figure bolt length, add 3/8" (10 mm) to deck thickness. Minimum thread
7
9
11
14
1. Long tape measure 6. Side cutters 11. Center punch 16. Hole saw
2. Short tape measure 7. Rat-tail file 12. Rigging or black tape 17. Deck sealant
3. Power drill 8. Hex Keys (provided) 13. Scissors 18. Box end wrench
4. Drill bits (see chart) 9. Slotted/phillips screwdrivers 14. Metal straight edge 19. 6 mm bolts, nuts and washers
5. Hacksaw 10. Needle-nose pliers 15. Hammer
6 MKIV Underdeck Unit 1, 2, 3
17
engagement must be 9mm.
Hole
3 ¾"
4 ¼"
5 ½"
Page 7
Preassembly Dimensions/Sailmaker's Instructions
Luff Length
Note offsets above and below sail. A shorter luff may be required if a halyard restrainer is necessary
(page 37) or a toggle or long toggle assembly is used to raise drum. If luff of sail is not long enough to put halyard swivel near top of
headstay foil, a pendant must be added. See page 36.
A
B
Tack Setback
Find setback "C" for tack shackle in chart below and modify sail accordingly. Setback is measured to luff tape of sail.
Luff Tape Size
6
All units require #6 (
/32" or 5 mm) luff tape.
Luff Tape Length
Cut off top of luff tape so it is 18 to 24" (450 to 600 mm) below head of sail. This allows head to lag behind rest of sail to help flatten sail. It will also help head to roll more smoothly.
Note feeder height and extend bottom of luff tape downward so it is below feeder. This will prevent luff tape from catching in feeder as sail is lowered.
Tack and Head Shackles
F
Make sure tack and head shackles fit sail rings. The minimum inside dimensions of standard head and tack shackles are:
A
Unit A B
1
1
/16" (27 mm)1/2" (13 mm)
1
3
2
/4" (44 mm)
1
7
3
/8" (48 mm)
C
1
11
/16" (17 mm)
13
/16" (21 mm)
B
Suncover
Suncovers may be installed on either side of sail. Be
E
D
G
Unit Part No. A B C D E F G
1 7411.11 1/
2 7412.11
3 7413.11
3 7413.11
sure to match other sails in the customer's inventory.
43/4"
2
120 mm
55/8"
5
/
8
143 mm
75/16"
3
/
4
186 mm
75/16"
7
/
8
186 mm
7"
177 mm
91/8"
231 mm
115/8"
296 mm
115/8"
296 mm
115/16"
49 mm
25/16"
59 mm
33/16"
81 mm
33/16"
81 mm
1
/16"
2 mm
1
/16"
2 mm
1
/16"
2 mm
1
/16"
2 mm
9
/16"
14mm
7
/16"
11mm
13
/16"
37
960 mm
411/16"
1043 mm
473/16"
1199 mm
1
/16"
46
1170 mm
35/8"
92 mm
41/16"
104 mm
53/8"
136 mm
513/16"
148 mm
MKIV Underdeck Unit 1, 2, 3 7
Page 8
Preassembly Deduction for Stay Length/Stay Into Foil Options
Use dimensions of Harken toggle below to build stay to correct length.
Tip: Turnbuckles should be 1/2 to 2/3rds open to allow shortening for new wire stretch and for fine-tuning mast rake.
A
B
C
D
Unit Part No. A B C D
1 7411.11
2 7412.11
3 7413.11
3 7413.11
1
/
2
5
/
8
3
/
4
7
/
8
1
/16"
2 mm
1
/16"
2 mm
1
/16"
2 mm
1
/16"
2 mm
5
3
/8"
92 mm
1
4
/8"
104 mm
53/8"
136 mm
513/16"
148 mm
105/8"
270 mm
1211/16"
322 mm
1
16
/8"
410 mm
169/16"
421 mm
155/8"
397 mm
189/16"
471 mm
235/8"
600 mm
241/4"
616 mm
Options for Snaking Stay into Foils
1. Swage stud at end of wire.
2. Open end of wire and install Norseman or Sta-Lok
®
stud after
foil is assembled.
3. 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. See page 28.
WARNING! Using a threaded nosepiece with only adhesive at the upper rod eye terminal may result in headstay system failure. Make sure there is a mechanical lock.
8 MKIV Underdeck Unit 1, 2, 3
Page 9
Assembly Deck Flange
1
/2°
74
1
/2°
72
Note: Deck flange angle matches a stay angle of
1
/2° when compared
73 to deck. Angles can vary
1
between 72
/2° and 741/2°.
Carefully locate center point in deck to locate deck flange. Line from mast to under deck chainplate must intersect this center point. Mark center fore/aft and athwartships line. Use template to mark four outer holes and center pilot hole. Make sure closer pair of holes is forward.
Once you are certain hole is located in line with chainplate and any required shimming is done, drill hole 90° to deck.
Make sure hole is just large enough so deck flange bears against deck. It is better to make hole slightly smaller and file opening larger to fit. Use template to mark large hole and bolt holes. Use hole saw to drill deck.
Tip: After pilot drill bit clears deck, drill final hole from bottom using pilot hole to line up hole drilled from top. This will prevent glass from chipping.
If deck does not fall within these angles, shims must be made using structural adhesive to avoid excessive pressure on deck and deck bearings.
Use 6 mm screws and compound to fasten deck flange.
3
Note: There must be a minimum of
/8"
(9 mm) thread engagement into deck flange.
MKIV Underdeck Unit 1, 2, 3 9
Page 10
Assembly Install Hub Assembly in Bow
Slide hub assembly into deck flange. Turn adjusting nut to lengthen or shorten threaded stud as needed.
Stud Length Turn Adjusting Nut
Shorten Clockwise
Lengthen Counter-Clockwise
Adjust length so toggle is lined up with chainplate hole. Slide pin into chainplate and secure with cotter pin.
1
1
/16"–
/8"
2–4 mm
Distance between bottom of tack swivel and deck flange
1
must be
/16"–1/8" (2–4 mm).
From on-deck, pull up on unit to check height between deck flange and tack swivel. Make sure tack swivel is free to rotate when there is upward pressure on unit. Check this again when stay is up and tensioned.
10 MKIV Underdeck Unit 1, 2, 3
Page 11
Assembly Assemble Drum Components
Place halves of plastic flange in lower groove on hub assembly so smooth side of flange is up.
Tip: Line up flats in flange with flats in groove.
Place halves of plastic cover in grooves so flats in cover align with flats in groove.
Tip: Rotate each screw hole towards the stern.
Use blue Loctite
®
screws (provided).
Use blue Loctite
®
screws (provided).
on flathead
on flathead
Tighten screws using hex key (provided).
Tighten screws using hex key (provided).
Assemble line guard so enclosed opening faces lead block. Do not
®
use Loctite
on threads.
Tip: Loosely thread both screws turning guard so it can be rotated to its final position. Finish tightening final screw when enclosed opening faces lead block.
MKIV Underdeck Unit 1, 2, 3 11
Page 12
Assembly Underdeck Lead Block
Mount lead block so that line exits furler at 90° to line of headstay as shown. Remember block will split angle and raise up slightly under load. Mount thru-deck block. You may want to angle it toward stanchion block.
90°
Mount thru-deck block. You may want to angle it toward stanchion lead block.
12 MKIV Underdeck Unit 1, 2, 3
Page 13
UNIT 1
Preassembly Unit 1—Top Foil Length
Measure A and add to this chart and length chart below
Inches mm
A
B .50 13
E 24 610
F 15.25 387
Total A+B+E+F
Make sure upper measurement points of A and pin-to-pin
Alternate
Measurement
Point
A
are the same.
TOP FOIL LENGTH WORKSHEET
1
2
3
4
To find “D” pick number from chart below that is clos­est to, but not greater than total from step 3.
5
Result (Pin-to-Pin – ABEF)
Inches mm
3 x 84 = 252 4 x 84 = 336 5 x 84 = 420 6 x 84 = 504 7 x 84 = 588 8 x 84 = 672
Example–If result from Step 3 is:
500 inches “D” = 420 inches 12,000 mm
Result (C) Top Foil Length
Pin-to-Pin Length
Subtract ABEF
Subtract D
3 x 2133.6 = 6400.8 4 x 2133.6 = 8534.4 5 x 2133.6 = 10668 6 x 2133.6 = 12801.6 7 x 2133.6 = 14935.2 8 x 2133.6 = 17068.8
“D” = 10,668 mm
Pin
to
Pin
A
B
C
D
Pin
to
Pin
Length Check
After completing worksheet above fill in A, C and D below. Add “A” through “F” to confirm total equals your pin-to-pin measurement.
A Center of Pin to Bottom of Terminal B Bottom of Terminal to Top of Foil C Top Foil Length
D Number of Foils ________ x 84" (2133.6 mm)
E Bottom Foil 24 610 F Bottom of Foil to Jaw/Jaw Toggle 15.25 387
Length Chart
Dimensions Inches mm
.50
Pin-to-Pin Length
13
E
F
MKIV Underdeck Unit 1 13
Page 14
UNIT 2
Preassembly Unit 2—Top Foil Length
Measure A and add to this chart and length chart below
Inches mm
A
B .63 16
E 24 610
F 18.45 469
Total A+B+E+F
Make sure upper measurement points of A and pin-to-pin
Alternate
Measurement
Point
A
are the same.
TOP FOIL LENGTH WORKSHEET
1
2
3
4
To find “D” pick number from chart below that is clos­est to, but not greater than total from step 3.
5
Result (Pin-to-Pin – ABEF)
Inches mm
5 x 84 = 420 6 x 84 = 504 7 x 84 = 588 8 x 84 = 672 9 x 84 = 756
Example–If result from Step 3 is:
500 inches “D” = 420 inches 12,000 mm
Result (C) Top Foil Length
Pin-to-Pin Length
Subtract ABEF
Subtract D
5 x 2133.6 = 10668 6 x 2133.6 = 12801.6 7 x 2133.6 = 14935.2 8 x 2133.6 = 17068.8 9 x 2133.6 = 19202.4
“D” = 10,668 mm
Pin
to
Pin
A
B
C
D
Pin
to
Pin
Length Check
After completing worksheet above fill in A, C and D below. Add “A” through “F” to confirm total equals your pin-to-pin measurement.
A Center of Pin to Bottom of Terminal B Bottom of Terminal to Top of Foil C Top Foil Length
D Number of Foils ________ x 84" (2133.6 mm)
E Bottom Foil 24 610 F Bottom of Foil to Jaw/Jaw Toggle 18.45 469
Length Chart
Dimensions Inches mm
.63
Pin-to-Pin Length
16
E
F
14 MKIV Underdeck Unit 2
Page 15
UNIT 3
(
3/4, 7/8
)
Preassembly Unit 3—Top Foil Length
Measure A and add to this chart and length chart below
Inches mm
A
B 1 25
E 24 610
F 23.4 594
Total A+B+E+F
Make sure upper measurement points of A and pin-to-pin are the same.
Alternate
Measurement
Point
A
TOP FOIL LENGTH WORKSHEET
1
2
3
4
To find “D” pick number from chart below that is clos­est to, but not greater than total from step 3.
5
Result (Pin-to-Pin – ABEF)
Inches mm
7 x 84 = 588 8 x 84 = 672 9 x 84 = 756
10 x 84 = 840 11 x 84 = 924
Example–If result from Step 3 is:
800 inches “D” = 756 inches 20,000 mm
Result (C) Top Foil Length
Pin-to-Pin Length
Subtract ABEF
Subtract D
7 x 2133.6 = 14935.2 8 x 2133.6 = 17068.8 9 x 2133.6 = 19202.4 10 x 2133.6 = 21336
11 x 2133.6 = 23470
“D” = 19,202 mm
Pin
to
Pin
A
B
C
D
Pin
to
Pin
Length Check
After completing worksheet above fill in A, C and D below. Add “A” through “F” to confirm total equals your pin-to-pin measurement.
A Center of Pin to Bottom of Terminal B Bottom of Terminal to Top of Foil C Top Foil Length
D Number of Foils ________ x 84" (2133.6 mm)
E Bottom Foil 24 610 F Unit 3- F Unit 3-
3
/4–Bottom of Foil to Jaw/Jaw Toggle 24 610
7
/8–Bottom of Foil to Jaw/Jaw Toggle 23.4 594
Length Chart
Dimensions Inches mm
1
Pin-to-Pin Length
25
E
F
MKIV Underdeck Unit 3 15
Page 16
Preassembly Unit 1—Short Top Foil
UNIT 1
If top foil is shorter than 7" (177.8 mm), use one of the following special techniques to ensure sufficient bearing surface for the foil in the area of the halyard swivel.
" (38 mm)
/2 (64 mm)
7" (178 mm)
/2
1
1
2" (51 mm)
2
1" (25 mm)
1
Cut-Offs
Do Not Use
7" (178 mm) No special treatment required.
21/2"–1" (64–25 mm) 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 connector.
6"–5" (150–130 mm)
Cut-Offs
Do Not Use
6"–5" (152–130 mm) Do not use plastic bushing above
top connector.
/2"–4" (115–100 mm)
1
4
41/2"–4" (115–102 mm) Do not use plastic bushing
above top connector. Shorten top of connector and if necessary shorten trim cap.
Cut-Offs
Do Not Use
Top Foil
Length from
Worksheet
1
2
/2"
(64 mm)
2"
(51 mm)
1
/2"
1
38 mm)
1"
(25 mm)
1. Initial top foil cut length
57/8"
(149 mm)
5
(137 mm)
47/8"
(124 mm)
4
(111 mm)
3
/8"
3
/8"
2. Cut through middle hole in top foil.*
Resulting Top
Foil Length Length
41/8"
(105 mm)
35/8"
(92 mm)
31/8"
(79 mm)
25/8"
(67 mm)
3. Shorten full length adjoining foil by cutting through middle hole.*
4. Shorten connector
(89 mm)
(89 mm)
(89 mm)
(83 mm)
5. Shorten trim cap
31/2"
31/2"
31/2"
31/4"
*To allow for saw cut, position blade so upper half of middle hole is preserved.
No
No
Yes
Yes
/2" - 3" (90 - 75 mm)
1
3
Cut-Offs – Do Not Use
31/2"–3" (90–75 mm) 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.
16 MKIV Underdeck Unit 1
Under 1" (25 mm)
Under 1" (25 mm) Eliminate top foil and run foil higher
in torque tube.
Page 17
Preassembly Unit 2—Short Top Foil
UNIT 2
If top foil is shorter than 8
11
/16" (221 mm), use one of the following special techniques to ensure sufficient
bearing surface for the foil in the area of the halyard swivel.
/16" (221 mm)
11
8
811/16" (221 mm) No special treatment required.
/8" (219–162 mm)
3
/8"–6
5
8
Cut-Offs
Do Not Use
85/8" – 63/8" (219–162 mm) Do not use plastic bushing
above top connector.
2" (64 mm)
2" (38 mm)
/
1
3" (76 mm)
/
1
2" (51 mm)
2
1" (25 mm)
1
Cut-Offs
Do Not Use
3"–1" (76–25 mm) 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 connector.
Top Foil
Length from
Worksheet
3"
(76 mm)
1
/2"
2
(64 mm)
2"
(51 mm)
1
/2"
1
(38 mm)
1"
(25 mm)
1. Initial top foil cut length
7
(184 mm)
63/4"
(172 mm)
6
(159 mm)
53/4"
(146 mm)
5
(133 mm)
1
/4"
1
/4"
1
/4"
2. Cut through middle hole in top foil.*
Resulting Top
Foil Length Length
51/8"
(130 mm)
45/8"
(117 mm)
41/8"
(105 mm)
35/8"
(92 mm)
31/8"
(79 mm)
3. Shorten full length adjoining foil by cutting through middle hole.*
4. Shorten connector
(114 mm)
(114 mm)
(114 mm)
(95 mm)
(95 mm)
41/2"
41/2"
41/2"
33/4"
33/4"
5. Shorten trim cap
No
No
No
Yes
Yes
/2" (152–140 mm)
1
6"–5
Cut-Offs
Do Not Use
Cut-Off
Do Not Use
6"–51/2" (152–140 mm) Do not use plastic bushing
above top connector. Shorten top of connector and if necessary shorten trim cap.
*To allow for saw cut, position blade so upper half of middle hole is preserved.
/8" (133–92 mm)
5
Cut-Offs – Do Not Use
/4"–3
1
5
Under 1" (25 mm)
51/4"–35/8" (133–92 mm) 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.
MKIV Underdeck Unit 2 17
Under 1" (25 mm) Eliminate top foil and run foil higher in torque tube.
Page 18
Preassembly Unit 3—Short Top Foil
UNIT 3
If top foil is shorter than 9
3
/4" (248 mm), use one of the following special techniques to ensure sufficient bearing
surface for the foil in the area of the halyard swivel.
/4" (248 mm)
3
9
93/4" (248 mm) No special treatment required.
/8" (244–181 mm)
1
/8"–7
5
9
Cut-Offs
Do Not Use
95/8"–71/8" (244–181 mm) Do not use plastic bushing
above top connector.
2" (89 mm)
2" (64 mm)
/
1
2
2" (38 mm)
/
1
2" (51 mm)
1
/
1
3" (76 mm)
3
Cut-Offs
Do Not Use
31/2"–11/2" (89–38 mm) 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 connector.
Top Foil
Length from
Worksheet
1
3
/2"
(89 mm)
3"
(76 mm)
1
/2"
2
(64 mm)
2"
(51 mm)
1
/2"
1
(38 mm)
1. Initial top foil cut length
69/16"
(167 mm)
6
(154 mm)
69/16"
(167 mm)
5
(129 mm)
49/16"
(116 mm)
1
1
/16"
/16"
2. Cut through middle hole in top foil.*
Resulting Top
Foil Length Length
5"
(127 mm)
41/2"
(114 mm)
4"
(102 mm)
31/2"
(89 mm)
3"
(76 mm)
3. Shorten full length adjoining foil by cutting through middle hole.*
4. Shorten connector
(124 mm)
(124 mm)
(124 mm)
(111 mm)
(95 mm)
47/8"
47/8"
47/8"
43/8"
33/4"
5. Shorten trim cap
No
No
No
Yes
Yes
/2" (178–140 mm)
1
7"–5
Cut-Offs
Do Not Use
7"–51/2" (178–140 mm) Do not use plastic bushing
above top connector. Shorten top of connector and if necessary shorten trim cap.
/8"–4" (137–102 mm)
3
5
Cut-Offs – Do Not Use
53/8"–4" (137–102 mm) 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.
18 MKIV Underdeck Unit 3
Cut-Off
Do Not Use
*To allow for saw cut, position blade so upper half of
middle hole is preserved.
2" (38 mm)
/
1
Under 1
Under 11/2" (38 mm) Eliminate top foil and run foil
higher in torque tube.
Page 19
Preassembly Confirm Foil Length
Confirm foil length by laying foils along­side stay with turnbuckle components and torque tube assembly. Pull stay out straight. Line up turnbuckle eye with a point just above bottom of torque tube assembly. This point will line up with
Unit Pin
1
1
/2" (12.7 mm)
5
2
/8"(15,9 mm)
3
3
/4" (19.1 mm)
7
3
/8"(22.2 mm) 1" (25 mm)
Jaw/Jaw Toggle Pin to Bottom of
Torque Tube Assembly
7
/16" (11 mm)
1
/4" (6 mm)
5
/8"(16 mm)
Jaw/Jaw toggle pin. See chart above right.
Line up bottom foil so foil clamp is just above or below center of notches in bottom foil.
Note: Position top foil so that with top cap the foil will ride 5/8" (16 mm) below 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 around foil as a guide so cut is straight.
MKIV Underdeck Unit 1, 2, 3 19
Page 20
Assembly Top Foil
Cut foil to length using hacksaw.
Deburr inside edge using rat-tail file.
Prepare top foil for drilling.
Tip: Mark top foil to distinguish from cutoff piece.
Scribe line on top of foil to mark drill holes. Lay top foil alongside cutoff piece and use a flat metal object (i.e. metal ruler) to scribe top line of foil.
20 MKIV Underdeck Unit 1, 2, 3
Page 21
Assembly Top Foil
Cut out template at right. Line template up with top of foil and scribed line. Tape in place. Use a center punch to mark holes.
Check center punch marks to confirm they from top of foil (see chart below).
Unit Center Punch Marks
1 2
3 (3/4, 7/8)
3
/16" (5 mm) 1" (25 mm)
3
/8" (10 mm) 1
3
/8" (10 mm) 1
3
/16" (30 mm)
3
/8" (35 mm)
!
Foil
3
/16" (5 mm)
Top
Unit 1
1" (25 mm)
Drill two (2) holes for trim cap. See chart below for correct drill size
Unit Drill Ø
1 1/8" (3 mm) 2 5/32" (4 mm)
3 (3/4, 7/8) 5/32" (4 mm)
!
Foil
3
Top
/8" (10 mm)
Unit 2
13/16" (30 mm)
!
Foil
3
Top
Unit 3 (3/4, 7/8)
/8" (10 mm)
13/8" (35 mm)
Lay top foil in line with others. Slide stay into top foil and down line of foils or slide each foil up stay.
MKIV Underdeck Unit 1, 2, 3 21
Page 22
Assembly Top Foil
Install trim cap. Place each side over wire.
Push trim cap into foil to start, then tap in using hammer.
Install trim cap screws.
Place halves of plastic bushings on stay so hooked part of longer section faces out.
Tip: With foil screw holes up as shown below, place longer half of bushing with hook on upper half.
22 MKIV Underdeck Unit 1, 2, 3
Page 23
Assembly Top Foil/Connectors
Slip connector on wire, mating hook of plastic bushing with connector.
Put a drop of red Loctite® into screw holes.
MKIV Underdeck Unit 1, 2, 3 23
Page 24
Assembly Foils/Connectors
Hold plastic wedge in place with thumb as you insert into foil. Line foil holes with connector screw holes.
Loading Injector with Adhesive
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 periods. Use adhesive within 3 hours.
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 of sealant to let air inside.
Adhesive in lower half
Start plunger into injector and immediately hold upright so plunger is down and applicator tip is up.
As sealant runs down towards plunger an air pocket will form near tip. Push plunger to evacuate air. You are now ready to begin injecting adhesive.
24 MKIV Underdeck Unit 1, 2, 3
Page 25
Assembly Foils/Connectors
Inject only a small amount of adhesive into middle hole. See chart below for amount.
Tip: When you see a small amount of adhesive enter one of the screw holes, stop. You have applied enough adhesive.
Unit Adhesive (ml)
1 2
3 (3/4, 7/8) 1 – 1
1
/3 – 1/
3
/4 – 1
2
1
/
4
Stop when you see a small amount of adhesive enter one of the screw holes.
Use “ml”
marks to estimate adhesive
Tighten screws into connector holes. Make
®
sure a drop of red Loctite
entered each
screw hole. If not, apply to screw.
Red Loctite
®
Use bushings, connector, wedge and adhesive in other screw hole and insert into other foil. Use adhesive (see chart below for amount).
Unit Adhesive (ml)
1 2
3 (3/4, 7/8) 1 – 1
MKIV Underdeck Unit 1, 2, 3 25
1
/3 – 1/
3
/4 – 1
2
1
/
4
Page 26
Assembly Bottom Foil/Connectors/Halyard Swivel
Continue installing connectors and wedges.
®
Make sure to use red Loctite
in screw
holes.
Red Loctite
®
Continue assembly. Use bottom connector to assemble bottom foil.
Slide halyard swivel onto foil above feeder window. Make sure taller “half” is up as shown.
26 MKIV Underdeck Unit 1, 2, 3
Page 27
Assembly Torque Tube Assembly
Loosen foil clamp screws at top of drum assembly.
Slide drum assembly onto foils.
Tip: Face clamp downward so it clears foil notches during installation.
Temporarily clamp torque tube assembly to top of bottom foil, leaving feeder gap partially exposed as shown at right. Gap will be used to rig a foil system lifting line.
MKIV Underdeck Unit 1, 2, 3 27
Page 28
Assembly Rod Rigging: Rod Adapter Stud
Apply a few drops of red
®
Loctite nosepiece.
Screw main threaded stud portion onto bronze nosepiece until flats align with two cotter pin holes in terminal body.
Tip: Turn nosepiece completely into threaded stud portion. Flats will be close and may only require a small half turn to align with cotter pin holes.
to threads of
Insert two cotter pins and
®
spread. Clean excess Loctite from terminal body using special care to ensure that there is no red Loctite threaded stud.
®
on
ROD RIGGING
28 MKIV Underdeck Unit 1, 2, 3
Page 29
Assembly Attach Turnbuckle/Foil System to Boat
Thread turnbuckle and threaded eye to stud protruding from foil. Assemble turnbuckle.
Note: If using Sta-Lok
®
or Norseman
®
stud, you must use a washer above stud as shown below.
Washer
Taking care not to lose parts, remove bearing caps from drum assembly.
Tip: Rig a large round plastic wash basin below furler to catch any parts that may be lost overboard.
MKIV Underdeck Unit 1, 2, 3 29
Page 30
Assembly Attach Turnbuckle/Foil System to Boat
Carefully Raise foil and stay up onto boat. Raise foils using line attached to feeder gap as shown.
Attach eye to jaw/jaw toggle deck level using clevis pin. Adjust turnbuckle. Secure with cotter pin.
Secure with cotter pin.
Adjust turnbuckle. When stay length is set,
use side cutters or needle­nose pliers to bend cotter pin to secure turnbuckle.
30 MKIV Underdeck Unit 1, 2, 3
Page 31
Assembly Attach Turnbuckle/Foil System to Boat
Check to make sure there is a 1/16"–1/8" (2–4 mm) gap between the deck flange and tack swivel. If necessary loosen adjusting nut below and take up on turnbuckle to increase gap between deck flange and tack swivel when turnbuckle is tightened.
Check to make sure there is a 1/16" –1/8" (2–4mm) gap
Loosen foil clamp while holding torque tube assembly and carefully lower into place.
Note: Do not remove screws, just loosen them.
Check foil height at top, set and secure using hex key.
See tip on next page.
Capture posts on universal posts with caps and
®
secure with screws. Do not use Loctite
on screws.
Tip: If it is hard to capture posts in cap, push against stay to help align universal. If necessary loosen backstay.
MKIV Underdeck Unit 1, 2, 3 31
Page 32
Assembly Feeder/Final
Tip: Do not remove foil clamp screws to adjust foil. Loosen screws, hold foils and bring clamp away from foils. Adjust and reclamp.
Slide halyard swivel above feeder. Place feeder in foil recess. Push screw down so tab catches under foil.
Tighten screw. Note: Screw will turn with some difficulty. It is plastic
coated to prevent loosening due to vibration.
Important! When removing feeder, loosen screw no more than one full turn. Slide screw up and remove feeder.
32 MKIV Underdeck Unit 1, 2, 3
Page 33
Commissioning Turnbuckle on Boat
Have extra cotter pins on hand to replace used ones at base of unit and for turnbuckle.
Hold foils and loosen torque tube screws until you can pull clamp part way out in order to lower foils.
Lower foils. Rig a screw catcher. Remove screws holding bearing
caps and remove taking care to not lose parts.
Loosen, but do
not remove
MKIV Underdeck Unit 1, 2, 3 33
Page 34
Commissioning Turnbuckle on Boat
Slide torque tube assembly onto foil and clamp just below top of feeder gap as shown. Use halyard to lift foil assembly.
CAUTION! Foils can drop suddenly causing injury to hands. Make sure drum assembly and foils are securely lifted using a halyard before adjusting turnbuckle.
Check to make sure there is a 1/16"–1/8" (2–4 mm) gap between deck flange and tack swivel. If necessary loosen adjusting nut below and take up on turnbuckle to increase gap between deck flange and tack swivel when the turnbuckle is tightened.
Reassemble Torque Tube Assembly to Hub Assembly.
®
Do not use Loctite
on screws.
Tip: If it is hard to capture posts in cap, push against stay to help align universal. If necessary loosen backstay.
Lift foils so top is 1/2"–3/8" (12 mm–16 mm) below upper terminal.
Slide foil clamp into foil notches and tighten screws to secure.
Adjust turnbuckle
Check to make sure there is a 1/16" - 1/8" (2 - 4mm) gap
34 MKIV Underdeck Unit 1, 2, 3
Page 35
Commissioning Lead Line to Cockpit
Run 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 assembly.
WARNING! Lead line through enclosed window. If line is led through opening between two enclosed windows it can ride above lineguard and jam furler which can
Enclosed Window
cause loss of control of boat.
Note location of sun cover. Charge system by rotating furler to wrap line on drum.
Tip: Sun cover to starboard—turn clockwise to charge. Sun cover to port—turn counter-clockwise. Tension line while charging.
Mount Lead Blocks
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 tightening.
BOW
7401 Forward Lead Block
349 – Unit 1, 2 2652 – Unit 3
088 – Unit 1, 2 131 – Unit 3
7401
FORWARD
LEAD
BLOCK
7403
OUTBOARD
STANCHION
BLOCK
7403
OUTBOARD
STANCHION
BLOCK
Position Forward Lead Block so line enters drum at right angles to headstay and centers vertically
90°
in opening. Install so line is inside stanchion.
Correct block position is critical to even line spooling and ease of furling.
7403 Outboard Stanchion Blocks
Install 7403 Outboard Stanchion Blocks so line is outside stanchions.
Number and placement of leads depends on boat length and number/configuration of stanchions.
7402 Ratchet Stanchion Block
Mount 7402 Ratchet Stanchion Block as furthest-aft lead to prevent line overrides in drum when unfurling. Position ratchet block so line turns at least 90°.
Install so line is inside stanchion.
Lead line through block so ratchet makes clicking sound when pulling line to furl sail.
Tip: Make sure ratchet switch is in “ON” position. If there is no clicking sound, lead line through block in opposite direction.
Lead line to Furling Line Cleat in cockpit.
HCP168 Furling Line Cleat
Install so line is angled as shown. Use #10 (5 mm) fasteners.
7402
RATCHET
STANCHION
BLOCK
STERN
MKIV Underdeck Unit 1, 2, 3 35
Note: As furling line lead changes, make sure line doesn’t chafe against line guard. Rotate line guard if necessary.
Drum Full
(sail unfurled)
Drum Empty
(sail furled)
Page 36
Commissioning Halyard: Swivel Height/Lead Angle
Halyard Wrap
The 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 and/or headstay can break suddenly. Make sure halyard is clear of top foil before using system.
If Halyard Wraps
If 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 aloft and freeing halyard.
If sail will not furl or unfurl, try to remove jib sheets and manually wrap sail around headstay.
WARNING! Do not go aloft on boat’s 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 methods.
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 signs of damage.
Prevent Halyard Wrap
To prevent wraps, the halyard must exert a slight pull to the rear. This allows the foils to turn while halyard remains stationary.
WARNING! Sail must be fitted to foil length before using to prevent halyard wraps and possible headstay loss.
1. Halyard swivel should be within top 4–6" (100–152 mm) of foil unless a halyard restrainer is used.
8–10°
2. Halyard must pull slightly to rear (8–10°).
3. Halyard must be snug, but not too tight.
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 is not correct. The 8–10° angle shown at right is critical.
36 MKIV Underdeck Unit 1, 2, 3
Page 37
Commissioning Halyard: Restrainer/Tension
Pendants
If the your sail luff is not long enough to position halyard swivel high enough to create an 8–10° angle as shown, you must add a pendant. Pendants should be made of plastic-coated wire and be permanently attached so sail height will be correct. Adjustable- length pendants are not acceptable, as they might not be adjusted correctly during a sail change.
1. Raise sail, but do not attach tack shackle.
2. Position halyard swivel correctly near top of headstay.
3. Secure halyard.
4. Tie a piece of rope to sail tack.
5. Lead line through tack shackle on furling drum.
6. Tension sail.
7. Measure distance from tack shackle to sail tack and permanently attach pendant of this length to head of sail.
8. Repeat procedure for every jib in your sail inventory.
Halyard Deflector/Halyard Restrainer
To prevent wraps, jib halyard must pull slightly to rear. On most boats, halyard lead angle is acceptable if halyard swivel is raised to top of foil.
On some boats halyard sheaves are located too close to headstay and a Halyard Deflector or Halyard Restrainer must be used.
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 properly.
If your boat needs a Halyard Deflector, use Part No. 7302 or a Halyard Restrainer, use Harken Part No. 944.
Restrainer should be mounted as high as possible on face of mast. Position restrainer so that foils will not hit it when under load.
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 luff.
Halyard Deflector
Tip: Boats used in charter service should have a halyard restrainer, regardless of masthead geometry.
Halyard Tension
The jib halyard should be firm, but not too tight.
Tip: 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 use.
Halyard Restrainer
MKIV Underdeck Unit 1, 2, 3 37
Page 38
Operation Halyards/Headstay Tension
Spinnaker Halyards
Spinnaker halyards occasionally cause problems with furling.
WARNING! In severe cases, spinnaker halyards can jam furler causing loss of control of boat which can cause an accident, damage to your vessel, personal injury or death. See www. harken.com/manuals for additional safety information.
On many boats it will not be possible to attach spinnaker halyard to bow pulpit or it may be "sucked" into jib when furling.
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 to prevent fouling with furling system.
Headstay Tension
A furling system will work best if headstay is tight. A loose headstay is difficult to rotate and can cause
unusual wear on foil joints. To adjust headstay tension, remove sail and furling line
from unit and follow instructions on page 30.
Tip: Before adjusting headstay tension, slack mainsheet and vang.
Backstay Adjusters
Backstay 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 adjuster.
Remember to keep headstay tight for best performance when furling or reefing. If your boat is fitted with an adjuster be sure that it is tensioned before the
halyard is tensioned. If not, backstay adjuster may increase halyard tension and could damage the sail or furling system.
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 slightly.
38 MKIV Underdeck Unit 1, 2, 3
Page 39
Operation Raise Sail/Storm Sail/Reef
Raise Sails
1) Install prefeeder by securely tying end of line to a deck fitting or to toggle below furler so it is 2' (610 mm) below feeder.
2) Shackle tack of sail to tack shackle. Install shackle so screw pin head is on same side as sun cover.
3) Secure genoa sheets to clew of sail.
4) Attach genoa halyard to halyard swivel.
5) Pass luff tape through prefeeder and feeder into foil groove.
6) Attach head of sail or pendant at head of sail to halyard swivel.
7) Hoist sail.
Tip: New sails are often stiff and may hang up on prefeeder during raising. Do not force sail when it hangs up—lower and remove twist. Sails "break in" with use and will become easier to raise.
Storm Sails
Most people will use one multipurpose genoa for all their sailing, but it is not good seamanship to go offshore without storm sails.
Heavy-air working jibs and storm sails may be used with your unit. These sails need to have luff tape added to allow them to be raised in headstay foils.
These sails will generally require pendants to ensure that halyard swivel is properly positioned at top of headstay. See page 36.
Remember that heavy-air working jibs and storm jibs may be reefed and furled like any other sail.
Furl and Reef
To furl or reef, ease the jib sheets and pull furling line.
In very light air, it may be necessary to place some tension on jib sheet to insure a tight furl.
In a breeze, you must completely luff sail by totally slacking jib sheets before furling.
The furling line should pull readily. The amount of force required is related to amount of wind, but Unit 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 Troubleshooting Guide on page 43. 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 easier.
MKIV Underdeck Unit 1, 2, 3 39
Page 40
Operation Reef/Secure Sail
Reef
A sail may be partially furled before you resume sailing. This is known as reefing.
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 to reefed jib.
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 in congested areas or entering or leaving harbors.
Secure Sail
When furling the sail completely, make sure sheets and furling line are secured. Check amount of line on the spool compared to the furled sail before using the system.
A furled sail must have:
a. Two to three wraps of jib sheet wrapped around sail. b. Two wraps minimum of line wound on spool. c. Furling line securely cleated.
d. Jib sheets securely wrapped on winch and held in self-tailing jaws. Furl at dock with tension on sheets to duplicate furling in high wind. Remember sails furled in light wind and left loosely secured can be a
problem if wind increases.
IMPORTANT! Remove sail from furler if extreme winds are predicted, especially if boat is left unattended.
IMPORTANT! Check all points above—a, b, c, and d—when leaving boat to avoid damage to furler or boat.
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 through waves.
Be sure mooring lines are not placed across furling line where they may cause chafe.
a. 2–3 wraps
b. 2–3 wraps
If you want to: Add more wraps of jibsheet on furled sail. Add more wraps of line on spool.
40 MKIV Underdeck Unit 1, 2, 3
Untie jib sheets and keep sail completely rolled. Secure with sail tie.
Turn spool to unroll a couple of wraps of line.
Turn spool to add a couple of wraps of line.
Retie sheets.
Page 41
Operation Race Conversion
Race conversion allows use of both grooves for sail changes and tacking genoas on deck for use of maximum luff length genoas.
Halyard Swivel Below Feeder
Use halyard to lift halyard swivel up, away from feeder. Loosen screw one revolution only. Slide screw up and hold. Remove feeder carefully—bottom end first. Don’t lose the feeder overboard! Lower swivel onto torque tube. Replace feeder.
Halyard Swivel Off Furler
Serious racers may want to remove the halyard swivel.
1) Remove drum assembly.
2) Rig a secure, temporary headstay.
3) Loosen backstay, mainsheet and vang so that headstay goes slack.
4) See procedure on pages 29 - 31. Note: It is not possible to remove halyard
swivel on a unit with a Norseman/Sta-Lok
®
or rod adapter stud unless you disassemble terminal stud. Make sure you use a new
®
Norseman/Sta-Lok Norseman/Sta-Lok
wedge to reassemble
®
fitting.
Remove Feeder
Loosen screw one revolution only. Slide screw up and hold.
To Remove Feeder For
Racing
1.
2.
1. Loosen screw one revolution only.
2. Slide screw up. Remove feeder.
3. Lower halyard swivel.
Carefully remove feeder–bottom end first. Don't drop the feeder
overboard!
MKIV Underdeck Unit 1, 2, 3 41
Page 42
Maintenance Clean/Inspect/Remove Furler
Clean and Lubricate
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 water.
At least twice a year unit should be cleaned more thoroughly by removing line (first note direction of spool) and flushing bearings with soap and fresh water. After unit has dried, apply a dry spray lubricant
®
such as McLube
.
Foils may be cleaned by washing with soap and water. A scrap of luff tape may be run up foil to scrub inside
WARNING! Periodically inspect items listed below and any others as necessary. Failure to inspect can cause an accident.
Inspect
grooves. If lubrication is required, spray a thin coat of
®
McLube
SailKote on sail luff tapes away from boat deck.
WARNING! Do not spray foil on boat. McLube will cause slippery decks which may result in loss of footing, falling overboard.
Inspect unit for signs of chafe, wear, or damage. Inspect locking devices below drum and inside torque tube
for signs of loosening. Check headstay tension for signs of loosening.
Inspect swage fitting and lower toggle for signs of stress corrosion.
®
Inspect Norseman or Sta-Lok
terminal or rod terminal for
signs of loosening. Inspect all screws on unit to be sure they have not loosened. Inspect foil to make sure that it has not dropped into torque
tube. Periodically inspect wire for signs of wear or unraveling.
Confirm Gap Between Deck Flange and Tack Swivel
Check to make sure there is a 1/16"–1/8" (2–4 mm) gap between the deck flange and tack swivel. If necessary loosen adjusting nut below and take up on turnbuckle
Check to make sure there is
1
/16"–1/8"
a (2 - 4mm) gap
to increase gap between deck flange and tack swivel when turnbuckle is tightened.
Storage – Mast Down
In 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 out.
Storage/Transporting
Do 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 for storage and transport.
After Storage or Transport
After storing or transporting unit, clean thoroughly including ball bearings. See instructions above.
Remove Furler From Boat
In order to prevent foils from locking against upper stay terminal when backstay is released, loosen torque tube screws and lower foil before loosening backstay.
42 MKIV Underdeck Unit 1, 2, 3
®
Page 43
Troubleshoot
Problem Probable Cause Solution
Sail will not furl or is difficult to furl.
Jib halyard is wrapping around headstay because angle between mast and and halyard is too shallow
Jib halyard is wrapping around the headstay because halyard swivel is too low.
Jib halyard is too tight. Ease jib halyard. Foils riding on turnbuckle. Raise foils. See adjusting turnbuckle on page 34. Foils too high, binding on swage eye. Lower foils until clear. See adjusting turnbuckle on page 34. Spare halyard is wrapping in sail as it furls. Secure spare halyards away from furling headstay by flipping them behind spreaders Salt or dirt in bearings. Flush bearings frequently with fresh water and a detergent solution. Furling line tangled in drum. Overrides are best prevented by using a 7402 ratchet block as the last furling line lead to
Stop knot catching. Make sure knot is a single overhand and is pushed up inside drum. Sail full of wind. Luff completely before furling or reefing. Sail flogging too much. Release a short length of sheet, pull some furling line and repeat. Jib sheets are not free. Free jib sheets. Foil out of torque tube. Reinstall foil in torque tube and tighten clamp screws. No wraps of furling line on drum. Remove sheets. Rotate stay wrapping as much furling line on drum as possible. Lineguard assembly has slipped down. Tighten line guard assembly screws securely. Line through 7402 ratchet backwards. Rerun line. Halyard swivel installed upside down. Remount swivel correctly.
Sail will not unfurl or will not unfurl completely.
Jib halyard is wrapping around headstay because angle between mast and halyard is too shallow.
Jib halyard is wrapping around the headstay because the halyard swivel is too low.
Foils riding on turnbuckle. Raise foils. See adjusting turnbuckle on page 34. Foils too high, binding on swage eye. Lower foils. See adjusting turnbuckle on page 34. Jib halyard is too tight. Ease jib halyard. Spare halyard is wrapping in sail as it furls. Secure spare halyards away from furling headstay by flipping them behind spreaders Salt or dirt in bearings. Flush bearings with freshwater and lubricate with dry spray lubricant such as McLube Furling line is not free. Free furling line.
Sail will not furl completely.
Insufficient furling line on drum. Remove sheets. Rotate stay, wrapping as much furling line on drum as possible. Too much line on drum. Adjust amount of line on drum or change position of forward lead block to allow line
Spare halyard catching in sail as it furls. Move halyards away from furling headsail as above.
Headstay rotates in
Insufficient tension on headstay. Tighten headstay and/or backstay to eliminate sag in headstay.
jerks or elliptically.
Sail does not stay furled.
Sail will not go up.
Sail not furled tightly on stay. Maintain drag on sheets while furling. Furling line not secure. Secure furling line. Luff tape will not go into groove. Check luff tape for fraying.
Sail catching at prefeeder. Flake sail more loosely on deck. Dirt in groove. Clean groove.
Sail will not raise completely or luff will not tension.
Sail will not
Halyard swivel is hitting end stop. Luff of sail is too long and must be recut. Angle between halyard and mast is too sharp
and halyard is pulling too much to the rear. Halyard is wrapping on headstay. Angle between headstay and halyard is too shallow and must be optimized per installation
come down.
Halyard swivel off foil. Sail luff too long or foil is too short or low and must be lengthened or raised.
Ultravoilet cover rolls
Furling line is wrapped on drum in wrong direction. Remove sheets. Pull line to remove all furling line from drum. Turn stay to rewind line on
up inside of sail.
Line jams between
Line is not led through windows. Pull line through enclosed window.
guard and plastic spool plate.
Delrin® is a registered trademark of E. I. du Pont de Nemours and Company or its affiliates. Igus® is a legally registered trademark of Igus® GmbH and/or Igus® Inc. Loctite® is a trademark of Henkel AG & Company KGaA
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 rear.
See installation instructions regarding optimal halyard swivel height. A wire pendant may be needed at head of sail to raise halyard swivel to proper height.
maintain proper drag on line while unfurling.
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 rear.
See installation instructions regarding optimal halyard angle.
to roll evenly on drum.
Check luff tape size.
Halyard must be routed from a point higher on mast. This may require that any halyard turning blocks aloft be replaced or sail shortened.
instructions.
drum in opposite direction. Line guard and cowling alignment may need to be adjusted.
McLube™ is a registered trademark of McGee Industries, Inc.
®
is a registered trademark of Sta-Lok Terminals, Ltd.
Sta-Lok
®
is a registered trademark of Solvay Advanced Polymers
Torlon
®
Online Product Registration
www.harken.com/FurlingWarranty
MKIV Underdeck Unit 1, 2, 3 43
Warranty: www.harken.com/manuals
or call, write, email, or fax Harken, Inc.,
Pewaukee, WI USA
Page 44
MKIV Underdeck Unit 1 Parts List
HFG684 HFG683HFG685
HFS980
H-38817
HFS980
H-38818
H-38293
HFS1052
1 2
1
2
No. Description Order Part No.
Top Cover Assembly w/Screws 1 HFG683
1
2
3
4
Top Cover 2 H-38817 Top Cover Screw (M4 x .7 x 10MM) 2 HFS980
Bottom Flange Assembly w/Screws 1 HFG684
Flange 2 H-38818 Bottom Flange Screw (M4 x .7 x 10MM) 2 HFS980
Guard Assembly 1 HFG685
Guard Set 2 H-38293 Guard Screw (M6 x 1 x 40MM SHCS) 2 HFS1052
No. Description Order Part No.
Torque Tube Assembly 1 HFG927
1 Clamp 1 H-42954 2 Clamp Screw (M5 x .08 x 12MM SHCS) 4 HFS827
Hub Assembly 1 HFG923
1 Cotter Pin ( 2 Clevis Pin ( 3 Bearing Cap w/Insert 2 HFG931
A Bearing Cap 1 AL-8101 B IGUS
4 Socket Head Cap Screws (M5 x .8 x 10MM) 4 HFS334
Ball Plug 5 H-35144A Torlon Delrin
5 Deck Flange 1 H-42461
5
/32" x 1.250") 4 HFS203
1
/2" x 1.146") 4 H-42395
®
Bushing 1 H-43838
®
Ball Bearing (5/16") 28 MP-129
®
Ball Bearing (5/16") 134 MP-118
MP-129 H-35144A
4
H-35144A MP-118 H-35144A MP-118 H-35144A
MP-118
H-35144A MP-118
3
HFG927
1
2
3
3
B
A
B
A
4
HFG923
Pin Measurements
*Grip
Length
*Pin measurements
are "Grip Length."
1
2
1
2
5
44 MKIV Underdeck Unit 1
4
3
2
1
7424 -12
3
7424 -17
7422 -8 7423 -10
5
5
No. Description Order Part No.
Rod Adapter Stud (-8) w/Nosepiece 1 7422 -8
1 Stud (Main Body) 1 H-41536 2 Nosepiece (-8) 1 H-41534 3 Cotter Pin (
Rod Adapter Stud (-10) w/Nosepiece 1 7423 -10
1 Stud (Main Body) 1 H-41536 2 Nosepiece (-10) 1 H-41535 3 Cotter Pin (
3
/32" x 1") 2 HFG193
3
/32" x 1") 2 HFG193
Page 45
MKIV Underdeck Unit 1 Parts List
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
MKIV UNDERDECK JIB REEFING & FURLING
Unit 1, 2, 3
Installation Manual – Intended for specialized personnel or expert users
5003/11-01-2012
Preassembly
Parts 4–5 Rigging Parts Check/Tools 6 Dimensions/Sailmaker's Instructions 7 Stay Length Deductions/Stay Into Foil Options 8
Hub Assembly
Deck Flange 9 Install Hub Assembly in Bow 10–11 Assemble Drum Components 11 Underdeck Lead Block 12
Preassembly
Top Foil Length (Unit 1) 13 Top Foil Length (Unit 2) 14 Top Foil Length (Unit 3) 15 Short Top Foil (Unit 1) 16 Short Top Foil (Unit 2) 17 Short Top Foil (Unit 3) 18 Foil Length Check 19
Assembly
Foils/Connectors 20–26 Halyard Swivel 26 Torque Tube Assembly 27 Rod Rigging 28 Attach Turnbuckle/Foils to Boat 29–31 Feeder/Final 32
Commissioning
Turnbuckle 33–34 Lead Line to Cockpit 35 Halyard Swivel Height/Angle 36 Halyard Restrainer/Tension 37
Operation
Halyard/Headstay Tension 38 Raise Sails/Storm Sails/Reefing 39–40 Secure Sail 40 Race Conversion 41
Maintenance
Clean/Lubricate/Inspect 42 Confirm Deck Flange/Tack Swivel Gap 42 Replace Line 42 Storage/Transporting 42 Remove Furler 42
Troubleshooting/Warranty
HFG629
7411.FOIL SET
7411.32
7411.31
H-36125A
MP-129
MP-129
MP-129
H-36125A
HFG343
HFG625
HFS1126
HFG680
H-39812
HFS1105
7411.30
7411.33
7411.31
7411.32
6
Description Order Part No.
Trim Cap Set w/o Screws 1 HFG680
6
Trim Cap Screw Set 1 HFG629
Trim Cap Screw 3 HFS1126
Halyard Swivel w/o Shackles 1 H-39812
®
Torlon
Ball Bearings 96 MP-129
Clip/Smalley Ring 2 H-36125A
Foil Set 1 7411.FOIL SET
Foil (7' / 2.13 m) Luff 6 7411.30 Foil (2' / 610 mm) Bottom 1 7411.33
Foil Screw Set 1 HFG343
Foil Screw 30 HFS1105
Connector Set w/o Bushings 1 HFG625
Connector (7" / 178 mm) 5 — Connector Bottom (10.75" / 273 mm) 1
Connector Bushing Set 1 HFG295
Connector Bushing (Curved / Longer) 12 H-42062 Connector Bushing (Flat / Shorter) 12 H-42063
Connector w/Bushings 1 7411.31
Connector (7" / 178 mm) 1 — Connector Bushing (Curved / Longer) 2 — Connector Bushing (Flat / Shorter) 2
Connector w/Bushings Bottom 1 7411.32
Connector Bottom (10.75" / 273 mm) 1 — Connector Bushing (Curved / Longer) 2 — Connector Bushing (Flat / Shorter) 2
Connector Wedge Set 1 HFG299
Connector Wedge 14 H-39625
Feeder Set 1 H-39683
Feeder 1 H-35623B Feeder Screw 1 HFS1129 Tab 1 H-35666A
Description Order Part No.
Instruction Manual 1 4656
7
Prefeeder 1 947
H-42062
H-42063
HFG295
H-39625
®
Loctite
Blue 1 833
®
Loctite
Red 2 HFG739
5200 Adhesive Set 1 HFG725
5200 Marine Adhesive Sealant 1 HFG722
Injector 1
HFG200 HFG201
Hex Keys
5 mm 1 HFG643
H-39683
HFG299
4656
4 mm 1 HFG640
2.5 mm 1 HCP1387
Description Order Part No.
Lead Block Kit 1 7404
HFG739
8
29 mm Outboard Lead Assembly 3 7403 57 mm Carbo Ratchet Assembly 1 7402 40 mm Carbo Assembly 1 7401 Horn Cleat 1 HCP168
Additional Lead Blocks
29 mm Carbo Stand-Up Fixed 1 349 Big Bullet Thru-Deck 1 131
Shackle (6 mm) 3 2110
833
HFG722
947
7
7404
349 131
8
Halyard Restrainer 1 945
HFG200 / HFG201
HFG643 HFG640
HCP1387
2110
945
7302
MKIV Underdeck Unit 1 45
Sheave/SS Inner Race Only 1 945ASSY Clevis Pin (
5
/16" x 11/4") 1 SP-038 Bracket-Large 1 HCP394 Cotter Pin (
3
/32" x 3/4") 1 HFS181
Halyard Deflector 1 7302
Page 46
MKIV Underdeck Unit 2 Parts List
HFG687 HFG686HFG688
HFS980
H-35665D
HFS980
H-35600C
H-35199E
HFS1052
1 2
1
2
Description Order Part No.
Top Cover Assembly w/Screws 1 HFG686
1
2
3
4
Top Cover 2 H-35665D Top Cover Screw (M4 x .7 x 10MM) 2 HFS980
Bottom Flange Assembly w/Screws 1 HFG687
Flange 2 H-35600C Bottom Flange Screw (M4 x .7 x 10MM) 2 HFS980
Guard Assembly 1 HFG688
Guard Set 2 H-35199E Guard Screw (M6 x 1 x 40MM SHCS) 2 HFS1052
No. Description Order Part No.
Torque Tube Assembly 1 HFG928
1 Clamp 1 H-42346 1 Clamp Screw (M6 x 1 x 16MM SHCS) 4 HFS747
Hub Assembly 1 HFG924
1 Cotter Pin ( 2 Clevis Pin ( 3 Bearing Cap w/Insert 2 HFG933
A Bearing Cap 1 H-43231 B IGUS
4 Socket Head Cap Screws (M6 x 1 x 12MM) 4 HFS876
Ball Plug 5 H-33860A Torlon Delrin
5 Deck Flange 1 H-43100
5
/32" x 1.250") 4 HFS203
5
/8" x 1.460") 4 H-42397
®
Bushing 1 HCP1707
®
Ball Bearing (3/8") 28 MP-127
®
Ball Bearing (3/8") 134 MP-123
MP-127 H-33860A
H-33860A MP-123
H-33860A MP-123 H-33860A MP-123
H-33860A MP-123
3
HFG928
1
2
3
3
4
B
A
B
A
HFG924
4
Pin Measurements
*Grip
Length
*Pin measurements
are "Grip Length."
1
2
1
2
5
46 MKIV Underdeck Unit 2
4
3
2
7424 -12
3
7424 -17
5
1
7424 -12
5
7425 -17
No. Description Order Part No.
Rod Adapter Stud (-12) w/Nosepiece 1 7424 -12
1 Stud (Main Body) 1 H-41531 2 Nosepiece (-12) 1 H-41527 3 Cotter Pin (
Rod Adapter Stud (-17) w/Nosepiece 1 7425 -17
1 Stud (Main Body) 1 H-41531 2 Nosepiece (-17) 1 H-41526 3 Cotter Pin (
3
/32" x 1") 2 HFG193
3
/32" x 1") 2 HFG193
Page 47
MKIV Underdeck Unit 2 Parts List
PLEASE SAVE THESE INSTRUCTIONS
7412.FOIL SET
7412.31
7412.32
HFG672
H-38028A
H-38028A
HFG348
MP-127
MP-127
MP-127
HFG626
HFG681
HFS1127
H-39794
HFS1106
7412.30
7412.33
7412.31
7412.32
6
Description Order Part No.
Trim Cap Set w/o Screws 1 HFG681
6
Trim Cap Screw Set 1 HFG672
Trim Cap Screw 3 HFS1127
Halyard Swivel w/o Shackles 1 H-39794
®
Torlon
Ball Bearings 92 MP-127
Clip/Smalley Ring 2 H-38028A
Foil Set 1 7412.FOIL SET
Foil (7' / 2.13 m) Luff 8 7412.30 Foil (2' / 610 mm) Bottom 1 7412.33
Foil Screw Set 1 HFG348
Foil Screw 38 HFS1106
Connector Set w/o Bushings 1 HFG626
Connector (9" / 229 mm) 7 — Connector Bottom (13" / 330 mm) 1
Connector Bushing Set 1 HFG296
Connector Bushing (Curved / Longer) 16 H-42032 Connector Bushing (Flat / Shorter) 16 H-42033
Connector w/Bushings 1 7412.31
Connector (9" / 229 mm) 1 — Connector Bushing (Curved / Longer) 2 — Connector Bushing (Flat / Shorter) 2
Connector w/Bushings Bottom 1 7412.32
Connector Bottom (13" / 330 mm) 1 — Connector Bushing (Curved / Longer) 2 — Connector Bushing (Flat / Shorter) 2
Connector Wedge Set 1 HFG300
Connector Wedge 18 H-39487
Feeder Set 1 H-39559
Feeder 1 H-33931B Feeder Screw 1 HFS1129 Tab 1 H-35671A
Description Order Part No.
Instruction Manual 1 4656
7
Prefeeder 1 947
®
Loctite
Blue 1 833
®
Loctite
Red 2 HFG739
5200 Adhesive Set 1 HFG725
5200 Marine Adhesive Sealant 1 HFG722
Injector 1
Hex Keys
6 mm 1 HFG644
HFG200 HFG201
HFG296
HFG300
H-42032
H-42033
H-39487
H-39559
5 mm 1 HFG643 4 mm 1 HFG640
MKIV UNDERDECK JIB REEFING & FURLING
Unit 1, 2, 3
Installation Manual – Intended for specialized personnel or expert users
Preassembly
Parts 4–5 Rigging Parts Check/Tools 6 Dimensions/Sailmaker's Instructions 7 Stay Length Deductions/Stay Into Foil Options 8
Hub Assembly
Deck Flange 9 Install Hub Assembly in Bow 10–11 Assemble Drum Components 11 Underdeck Lead Block 12
Preassembly
Top Foil Length (Unit 1) 13 Top Foil Length (Unit 2) 14 Top Foil Length (Unit 3) 15 Short Top Foil (Unit 1) 16 Short Top Foil (Unit 2) 17 Short Top Foil (Unit 3) 18 Foil Length Check 19
Assembly
Foils/Connectors 20–26 Halyard Swivel 26 Torque Tube Assembly 27 Rod Rigging 28 Attach Turnbuckle/Foils to Boat 29–31 Feeder/Final 32
Commissioning
Turnbuckle 33–34 Lead Line to Cockpit 35 Halyard Swivel Height/Angle 36 Halyard Restrainer/Tension 37
Operation
Halyard/Headstay Tension 38 Raise Sails/Storm Sails/Reefing 39–40 Secure Sail 40 Race Conversion 41
Maintenance
Clean/Lubricate/Inspect 42 Confirm Deck Flange/Tack Swivel Gap 42 Replace Line 42 Storage/Transporting 42 Remove Furler 42
Troubleshooting/Warranty
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.
5003/11-01-2012
4656
HFG739 HFG833
HFG722
947
HFG200/HFG201
HFG644 HFG643
HFG640
HCP1089
7
7404
2652
047
2117
944
7303
8
8
3 mm 1 HCP1089
Description Order Part No.
Lead Block Kit 1 7404
29 mm Outboard Lead Assembly 3 7403 57 mm Carbo Ratchet Assembly 1 7402 40 mm Carbo Assembly 1 7401 Horn Cleat 1 HCP168
Additional Lead Blocks
40 mm Carbo Stand-Up Fixed 1 2652
2.25" Thru-Deck 1 047
Shackle (8 mm) 3 2117 Halyard Restrainer 1 944
Sheave/SS Inner Race Only 1 944ASSY Clevis Pin (
1
/4" x .9") 1 HFG467 Bracket-Small 1 HCP393 Cotter Pin (
1
/16" x 1/2") 1 HFS118
Halyard Deflector 1 7303
MKIV Underdeck Unit 2 47
Page 48
MKIV Underdeck Unit 3 Parts List
HFG690 HFG689HFG691
MP-128 H-38168
4
H-38168 MP-116 H-38168 MP-116 H-38168
MP-116
HFS1060
H-35025D
HFS1060
1
H-35465C
H-33758E
2
HFS873
1 2
3
HFG929
1
2
3
3
B
A
4
B
A
Top Cover Assembly w/Screws 1 HFG689
1
2
3
4
4
Top Cover 2 H-35025D Top Cover Screw (M5 x .8 x 12MM) 2 HFS1060
Bottom Flange Assembly w/Screws 1 HFG690
Flange 2 H-35465C Bottom Flange Screw (M5 x .8 x 12MM) 2 HFS1060
Guard Assembly 1 HFG691
Guard Set 2 H-33758E Guard Screw (M8 x 1.25 x 50MM SHCS) 2 HFS873
No. Description Order Part No.
Torque Tube Assembly 1 HFG929
1 Clamp 1 H-42967 2 Clamp Screw (M8 x 1.25 x 25MM SHCS) 4 HFS1107
Hub Assembly (3/4") 1 HFG925
1 Cotter Pin ( 2 Clevis Pin ( 3 Bearing Cap w/Insert 2 HFG935
A Bearing Cap 1 H-44674 B IGUS
4 Socket Head Cap Screws (M6 x 1 x 12MM) 4 HFS876
Ball Plug 5 H-38168
®
Torlon
Ball Bearing (1/2") 27 MP-128
®
Delrin
Ball Bearing (1/2") 128 MP-116
5 Deck Flange 1 H-44680
Hub Assembly (7/8") 1 HFG926
1 Cotter Pin ( 2 Clevis Pin ( 3 Bearing Cap w/Insert 2 HFG935
A Bearing Cap 1 H-44674 B IGUS
4 Socket Head Cap Screws (M6 x 1 x 12MM) 4 HFS876
Ball Plug 5 H-38168
®
Torlon
Ball Bearing (1/2") 27 MP-128
®
Delrin
Ball Bearing (1/2") 128 MP-116
5 Deck Flange 1 H-44680
Description Order Part No.
5
/32" x 1.250") 4 HFS203
3
/4" x 1.766") 4 H-42403
®
Bushing 1 HCP1684
5
/32" x 1.250") 4 HFS203
7
/8" x 1.958") 4 H-42404
®
Bushing 1 HCP1684
Pin Measurements
H-38168 MP-116
HFG925 (3/4")
HFG926 (7/8")
1
2
1
2
5
4
*Grip
Length
*Pin measurements
are "Grip Length."
3
2
1
3
7424 -12 7424 -17
7426 -22
5
5
7427 -30
48 MKIV Underdeck Unit 3
No. Description Order Part No.
Rod Adapter Stud (-22) w/Nosepiece 1 7426 -22
1 Stud (Main Body) 1 H-41812 2 Nosepiece (-22) 1 H-41811 3 Cotter Pin ( 4 Stud Cap (
Rod Adapter Stud (-30) w/Nosepiece 1 7427 -30
1 Stud (Main Body) (not shown) 1 H-41814 2 Nosepiece (-30) 1 H-41813 3 Cotter Pin ( 4 Stud Cap (
3
/32" x 13/4") 2 HFG319
7
/8") ID (not shown) 1 HFG303
3
/32" x 13/4") 2 HFG319
7
/8") ID (not shown) 1 HFG303
Page 49
MKIV Underdeck Unit 3 Parts List
HFG672
H-39916
MP-128
MP-128
MP-128
H-39916
7413.10 FOILSET
HFG349
H-39751
HFS1127
H-39752
H-39392
7413.30
7413.31
H-42073 H-42074
6
Description Order Part No. (
Trim Cap
6
Top (with Holes) 1 H-39751 Bottom (with Pegs) 1 H-39752
Trim Cap Screw Set 1 HFG672
Trim Cap Screw 3 HFS1127
Halyard Swivel w/o Shackles 1 H-39392
Foil Set 1 7413.10 FOILSET
Foil (2'/610 mm) Bottom 1 7413.33 Foil Screw Set 1 HFG349
Connector Set 1 HFG627
Connector Bushing Set 1 HFG297
Connector Wedge Set 1 HFG324
Feeder with Screw and Tab 1 H-39756
®
Torlon
Ball Bearings 88 MP-128
Clip/Smalley Ring 2 H-39916
Foil (7' / 2.13 m) Luff 10 7413.30
Foil Screw 46 HFS1106
Connector (9 Bottom Connector (14" / 356 mm) 1 7413.32
Connector Bushing Top (Curved / Longer) 20 H-42073 Connector Bushing Bottom (Flat / Shorter) 20 H-42074
Connector Wedge 22 H-39487
Feeder 1 H-38332B Feeder Screw 1 HFS1130 Tab 1 H-38372A
3
/4" / 248 mm) 9 7413.31
3
/4, 7/8)
7413.32
HFG297
Description Order Part No. (
Instruction Manual 1 4656
7
H-39756
HFG324
7413.33
HFG627
4656
HFG739
MKIV UNDER-DECK
Jib Reefing & Furling
Installation Manual
Unit 1, 2, 3
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.
833
HFG722
7
7404
2600
137
8
947
HFG200/HFG201
HFG647 HFG644
HFG640
HCP1089
MKIV Underdeck Unit 3 49
071
2124
945
7304
Prefeeder 1 947
®
Loctite
Blue 1 833
®
Loctite
Red 2 HFG739
5200 Adhesive Set 1 HFG725
5200 Marine Adhesive Sealant 1 HFG722
Injector 1
Hex Keys
10 mm 1 HFG647 6 mm 1 HFG644 4 mm 1 HFG640 3 mm 1 HCP1089
Description Order Part No.
Lead Block Kit 1 7404
8
29 mm Outboard Lead Assembly 3 7403 57 mm Carbo Ratchet Assembly 1 7402 40 mm Carbo Assembly 1 7401 Horn Cleat 1 HCP168
Additional Lead Blocks
57 mm Carbo Single Swivel 1 2600 Stainless Steel Eyestrap 1 137 Stand-Up Spring 1 071 Thru-Deck (2.25") (not shown) 1 HC7981
Shackle (10 mm) 3 2124 Halyard Restrainer 1 945
Sheave/SS Inner Race Only 1 945ASSY Clevis Pin ( Bracket-Large 1 HCP394 Cotter Pin (
Halyard Deflector 1 7304
5
/16" x 11/4") 1 SP-038
3
/32" x 3/4") 1 HFS181
HFG200 HFG201
3
/4, 7/8)
Page 50
This Page Intentionally Left Blank
Page 51
UNIT 1 — Deck Drill Template
UNIT 1
Deck Drill Template
IMPORTANT! If you print this template from a computer file, measure
to confirm that template is the correct size before drilling.
2.362" (60 mm)
BOW
4.694"
(119.25 mm)
Deck Flange Diameter
3.7" (94mm)
Hole Saw Size 33/4" (95mm)
3.351"
(85.1 mm)
Ø 4.5" (114.3 mm)
Measure this distance to verify that template printed correctly
3.464" (88 mm)
!
4.54" (115.4 mm)
MKIV Underdeck Unit 1 45
Page 52
This Page Intentionally Left Blank
Page 53
UNIT 2 — Deck Drill Template
UNIT 2
Deck Drill Template
IMPORTANT! If you print this template from a computer file, measure
to confirm that template is the correct size before drilling.
2.678" (68 mm)
Deck Flange Diameter
4.2" (106.5 mm)
5.28"
(134.1 mm)
3.698"
(93.9 mm)
BOW
Ø 5.032" (127.82 mm)
Measure this distance to verify that template printed correctly
3.936" (100 mm)
Hole Saw Size 41/4" (110 mm)
5.07" (128.8 mm)
46 MKIV Underdeck Unit 2
!
Page 54
This Page Intentionally Left Blank
Page 55
UNIT 3 (3/4, 7/8) — Deck Drill Template
UNIT 3 (3/4, 7/8)
Deck Drill Template
IMPORTANT! If you print this template from a computer file, measure
to confirm that template is the correct size before drilling.
3.444" (87.5 mm)
BOW
Deck Flange Diameter
5.45" (138.5 mm)
Hole Saw Size 51/2" (140mm)
4.665"
(118.5 mm)
6.77"
(172 mm)
Ø 6.471" (164.36 mm)
Measure this distance to verify that template printed correctly
5.2" (132.1 mm)
!
6.531" (165.9 mm)
MKIV Underdeck Unit 3 47
Page 56
Corporate Headquarters
N15W24983 Bluemound Rd, Pewaukee, WI 53072 USA
Telephone: (262) 691-3320 • Fax: (262) 701-5780
Web: www.harken.com • Online Catalog: www.harkenstore.com
1B Green Street, Brookvale, N.S.W. 2100, Australia
Telephone: (61) 2-8978-8666 • Fax: (61) 2-8978-8667
Web: harken.com.au • Email: info@harken.com.au
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
Via Marco Biagi, 14, 22070 Limido Comasco (CO) Italy Telephone: (39) 031.3523511 • Fax: (39) 031.3520031
30-36 Fanshawe Street, P.O. Box 1951, Auckland 1001, New Zealand
Telephone: (64) 9-303-3744 • Fax: (64) 9-307-7987
Web: harken.co.nz • Email: harken@harken.co.nz
ul. Rydygiera 8, budynek 3A, lokal 101, I pi
Tel: +48 22 561 93 93 • Fax: +48 22 839 22 75
Main Office and Harken Brandstore: Västmannagatan 81B
Telephone: (46) 0303 61875 • Fax: (46) 0303 61876
Mailing address: Harken Sweden AB, Box 64, SE -440 30 Marstrand
Bearing House, Ampress Lane, Lymington, Hampshire S041 8LW, England
Telephone: (44) 01590-689122 • Fax: (44) 01590-610274
Web: harken.co.uk • Email: enquiries@harken.co.uk
Email: harken@harken.com
Harken Australia Pty, Ltd.
Harken France
Web: harken.fr • Email: info@harken.fr
Harken Italy S.p.A.
Web: harken.it • Email: info@harken.it
Harken New Zealand, Ltd.
Harken Polska SP ZOO
ętro, 01-793 Warszawa, Poland
Web: harken.pl • Email: polska@harken.pl
Harken Sweden AB
SE-113 26 Stockholm Sweden
Web: harken.se • Email: harken@harken.se
Harken UK, Ltd.
Please visit: http://www.harken.com/locator.aspx
to locate Harken dealers and distributors
Printed in USA 4656 01/14
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