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7412.13
User Manual
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Harken 7412.13 User Manual

MKIV JIB REEFING & FURLING
Unit 2E, Unit 3E
Installation Manual – Intended for specialized personnel or expert users
Preassembly
Assembly
4676 04/14
Commissioning
Operation
Maintenance
Troubleshooting/Warranty 37 Appendix
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/Parts Descriptions
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.
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.
7
6
4
3
2
1
5
8
Parts Descriptions
1) Jaw/Jaw Toggle
2) Link Plates
3) Isolator
4) Lower Unit
2 MKIV Unit 2E, 3E
5) Shackles
6) Foil Clamp
7) 2' (610mm) Bottom Foil
8) Feeder
9) Connector Bushing
10) Bottom Connector
11) 7' (2.13m) Foil
12) Connector Screws
13) Connector Wedge
14) Connector
15) Halyard Swivel
16) Trim Cap
17) Trim Cap Screws
Preassembly Sizing Check
17
16
15
13
14
12
11
9
Online Product Registration
www.harken.com/FurlingWarranty
10
Size Check
1. Check headstay and clevis pin dimensions in chart below.
WARNING! Do not drill boat's chainplate or toggle. This may result in rig failure. Use the correct size toggle and clevis pin.
2. Do not drill boat’s chainplate or toggle. Bushings may be required to fit boats with smaller clevis pin sizes.
3. Will lower unit fit on bow? See page 7. If necessary, use an additional toggle to slightly raise unit.
Unit Part No. Description Wire Ø
5
7412.13 12V
7412.13 24V
Toggle Part No. Description Chainplate Clevis Ø
UNIT 2E
MKIV Electric Unit 2E
7412.22 5/8 Jaw/jaw toggle w/short link plate
7413.22 3/4 Jaw/jaw toggle w/short link plate
/16", 3/8" 8 mm, 10 mm
Rod Ø
-12, -17, -22 7.14 mm, 8.38 mm, 9.53 mm
5
/8" 15.9 mm
3
/4" 19.1 mm
Chainplate Clevis Pin
Unit Part No. Description Wire Ø
7
7413.13 12V
7413.13 24V
MKIV Electric Unit 3E
/16", 1/2" 11 mm, 12 mm
Rod Ø
-22, -30 9.53 mm, 11.10 mm
Toggle Part No. Description Chainplate Clevis Ø
UNIT 3E
7413.22 3/4 Jaw/jaw toggle w/short link plate
7413.22 7/8 Jaw/jaw toggle w/short link plate
MKIV Unit 2E, 3E 3
3
/4" 19.1 mm
7
/8" 22.2 mm
Preassembly Parts
2' (610mm) Bottom Foil
7' (2.13m) Foils
Emergency
Crank Handle
Drill Adapter for
Manual Drive
Lower Unit
Unit 3E
Halyard Swivel
Lower Unit
Unit 2E
Parker Hose 801 and Hose Clamp
Main Components
Description
7'(2.13m) Foil
2'(610mm) Bottom foil
Halyard Swivel
12V Lower Unit with Clamp
24V Lower Unit with Clamp
Drill Adapter for Manual Drive
Emergency Crank Handle
Parker Hose 801
Hose Clamp
1
/2" ID, 2' (610 mm)
UNIT 2E UNIT 3E
Part No. Qty Part No. Qty
7412.31
7412.33
H-39794
7412.13 12V
7412.13 24V
7431
7430
—
—
8
1
1
1
1
1
1
1
1
7413.31
7413.33
H-39392
7413.13 12V
7413.13 24V
7431
7430
—
—
10
1
1
1
1
1
1
1
1
Electric Components
4 MKIV Unit 2E, 3E
Electric
Control Box
Description
Electric Control Box
40 AMP Circuit Breaker
12-VOLT
Remote Switch w/Guard
Electric Control Box
30 AMP Circuit Breaker
24-VOLT
Switch
Circuit Breaker
Part No. Qty Part No. Qty
BEB500.12.1
HCP 1918
BRS104/P
BEB500.24.1
HCP 1917
BRS104/P
Remote Switch
w/Guard
UNIT 2E UNIT 3E
BEB500.12.1
1
HCP 1918
1
BRS104/P
2
BEB500.24.1
1
HCP 1917
1
BRS104/P
2
1
1
2
1
1
2
Preassembly Parts
Connector Bushings
Foil Screws
Plastic
Connector
Wedges
Trim Cap Screws
Trim Cap
Feeder
Prefeeder
Bottom
Connectors
Connector
Bow Shackles
Other Components UNIT 2E UNIT 3E
Description
Connectors
Bottom Connector
Connector bushing set
Plastic connector wedge set
Foil screw set
Trim cap set
Trim cap screw set
Prefeeder
Feeder with screw and tab
Bow shackle
Blue Loctite
Red Loctite
®
®
Injector, 1 oz. 5200 Adhesive
MKIV Unit 2E, 3E 5
Part No. Qty Part No. Qty Size
7412.31F
7412.32F
HFG296
(16 EA H-42032/H-42033)
HFG300
(18 EA H-39487)
HFG348
( 38 EA HFS1106)
HFG681
( H-37403/H-37404)
HFG672
( 3 EA HFS1127)
947
H-39559
2117
(8 mm)
833
HFG739
HFG725
7
1
1
1
1
1
1
1
1
1
1
2
1
7413.31F
7413.32F
HFG297
(20 EA H-42073/H-42074)
HFG324
(22 EA H-39487)
HFG349
( 46 EA HFS1106)
HFG682
(Missing)
HFG672
( 3 EA HFS1127)
947
H-39756
2124
(10 mm)
833
HFG739
HFG725
9 9.75" (248mm)
1 14" (356mm)
1 —
1 —
1 —
1 —
1 —
1 —
1 —
1 —
1 .017 oz.
2 .017 oz.
1
1 oz.
Blue Loctite
Red Loctite
®
®
5200
Adhesive
Injector
3, 4, 5, 6, 10 mm
Tools UNIT 2E UNIT 3E
Description
Qty Size Qty Size
Hex keys 1 Ea 3, 4, 5, 6 mm 1Ea 3, 4, 6, 10 mm
Preassembly Rigging Parts Check/Tools/Adhesive
Toggles
1. Harken jaw/jaw toggle and link plate assembly required. Sold separately.
2. Mating turnbuckle components, with eye at lower end, must be purchased separately. See page 8.
Harken Toggle/
Link Plate Assembly
(Sold Separately)
ROD RIGGING
Harken Rod Adapter
Stud Required
(Sold Separately)
3. Headstay may require cutting and shortening to fit Harken toggle. Some headstays may remain uncut by replacing lower stud of turnbuckle with stud/eye thus eliminating extra toggle.
4. Rod rigging requires Harken rod adapter stud.
WARNING! Wire that is old or damaged may break suddenly, causing an accident. Headstay condition should be checked by a professional rigger before reusing.
5. Harken 7406 through-deck fitting for routing power wires through the
1
deck. Fits 35 mm fasteners and hose clamp. See page for template.
7406 Aluminum
through-deck fitting
for routing wires
belowdecks
/2" ID parker hose supplied with unit. Includes three (3) 6 mm x
Jaw/Jaw Toggle
w/ Link Plate
Unit Part No.
7312.22 5/8
2E
7413.22 3/4
Unit Part No.
7413.22 3/4
3E
7413.22 7/8
Rod Adapter Stud
Unit Part No.
7424 -12
2E
7425 -17
7426 -22
Unit Part No.
7426 -22
3E
7427 -30
Tools You Will Need
3
10
16
4
12
13
11
1
2
8
6
7
1. Long tape measure 6. Side cutters 11. Center punch
2. Short tape measure 7. Rat-tail file 12. Rigging or black tape
3. Power drill 8. Hex keys (provided) 13. Scissors
4. Drill bit – 5/32" (4mm) 9. Slotted/phillips screwdrivers 14. Metal straight edge
5. Hacksaw 10. Needle-nose pliers 15. Hammer
16. 5 mm Ball-end hex key wrench (recommended but not required)
6 MKIV Unit 2E, 3E
9
5
14
15
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 70 F (22C) with 50% humidity. Do not apply at temperatures below 40 F (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.
Preassembly Dimensions/Sailmaker's Instructions
Luff Length
Note offsets above and below sail. A shorter luff may be required if a halyard restrainer is used or an
additional toggle assembly is used to raise unit. If luff of sail is not long enough to put halyard swivel near top of
headstay foil, a pendant must be added. See page 29.
B
Tack Setback
A
Note setback for tack shackle and cut sail accordingly.
Luff Tape Size
6
Unit 2E and 3E require #6 (
/32" or 5mm) 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
C
below feeder. This will prevent luff tape from catching in feeder as sail is lowered.
Tack and Head Shackles
Make sure tack and head shackles fit sail rings. Minimum inside dimensions of
A
standard head and tack shackles are:
Unit A B
3
2E
1
D
/4" (44 mm)11/16" (17 mm)
7
3E
/8" (48 mm)13/16" (21 mm)
1
B
Sun cover
E
Sun covers may be installed on either side of sail. Be sure to match other sails in the customer's inventory.
F
G
H
Part
No.
7412.13 with 7312.22 5/8 toggle 5
7412.13 with 7413.22 3/4 toggle 5
7413.13 with 7413.22 3/4 toggle 7
7413.13 with 7413.22 7/8 toggle 7
MKIV Unit 2E, 3E 7
A B C D E F G H
in mm in mm in mm in mm in mm in mm in mm in mm
3
/8143 91/8231 31/482 331/16841 241/2622 225/8574 41/2116 811/32212
3
/8143 91/8231 31/482 3311/19856 253/32637 231/4590 53/16132 811/32212
5
/16186 115/8296 31/482 321/2826 253/32637 231/4590 53/16132 811/32212
5
/16186 115/8296 31/482 333/16840 2511/16652 2313/16605 53/4146 811/32212
See toggle dimensions in appendix
Preassembly Toggle Deductions/Stay Into Foil Options
Use dimensions of Harken toggle below to build stay to correct length.
Tip: Turnbuckles should be 1/2 to 2/3 open to allow shortening for new wire stretch and for fine-tuning mast rake.
Note: Turnbucke assembly with eye at lower end not supplied by Harken
Unit Clevis Pin Ø Pin-to-Pin Length
5
/8" (15.9mm) 25/8" (67mm)
2E
3
/4" (19.1mm) 39/32" (83mm)
Unit Clevis Pin Ø Pin-to-Pin Length
3
/4" (19.1mm) 39/32" (83mm)
3E
7
/8" (22.2mm) 37/8" (98mm)
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 of as well as adhesive. Use Harken stud with cotter pins. See page 22.
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 Unit 2E, 3E
Preassembly Top Foil Length
Measure A and add to this chart
and length chart below
Inches mm
A
B 63 16
E 24 610
F 17.5 445
G
Total A+B+E+F+G
UNIT 2E
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.
500 inches “D” = 420 12,000 mm “D” = 10,668 mm
5
Result (Pin-to-Pin – ABEFG)
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:
Result (C) Top Foil Length
Pin-to-Pin Length
Subtract ABEFG
Subtract D
5 x 2133.6 = 10668.0 6 x 2133.6 = 12801.6
7 x 2133.6 = 14935.2 8 x 2133.6 = 17068.8
9 x 2133.6 = 19202.4
–
–
Pin
to
Pin
A
B
C
D
Pin
to
Pin
E
Length Check
After completing worksheet above fill in A, C, D and G below. Add “A” through “G” to confirm total equals your pin-to-pin measurement.
Length Chart
Dimensions Inches mm
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" (2133.6mm) E Bottom Foil 24.0 610 F Bottom of Foil to Top of Link Plates 17.5 445 G Top of Link Plate to Clevis Pin
63
Pin-to-Pin Length
G Toggle Distance from Lower Clevis Pin to Top of Link Plates
Toggle
Part No.
7312.22 5/8 Jaw/Jaw with Link Plate
7413.22 3/4 Jaw/Jaw with Link Plate
MKIV Unit 2E 9
Type
Clevis Pin G Distance
in mm in mm
5
/8 15.9 11.67 296
3
/4 19.1 12.27 312
16
F
G
Preassembly Unit 2—Short Top Foil
UNIT 2E
UNIT 2E
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)
1
3" (76 mm)
/2" (38 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
6"–51/2" (152–140 mm) Do not use plastic bushing
above top connector. Shorten top of connector and if necessary shorten trim cap.
/8" (133–92 mm)
5
/4"–3
1
5
Cut-Offs – Do Not Use
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.
10 MKIV Unit 2E
Cut-Off
Do Not Use
*To allow for saw cut, position blade so upper half of
middle hole is preserved.
Under 1" (25 mm)
Under 1" (25 mm) Eliminate top foil and run foil higher
in torque tube.
Measure A and add to this chart
and length chart below
Inches mm
A
B 1 25
E 24 610
F 15.41 391
G
Total A+B+E+F+G
UNIT 3E
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.
800 inches “D” = 756 inches 20,000mm “D” = 19,202mm
5
Result (Pin-to-Pin – ABEFG)
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:
Result (C) Top Foil Length
Pin-to-Pin Length
Subtract ABEFG
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
–
–
Pin
to
Pin
A
B
C
D
Pin
to
Pin
E
Length Check
After completing worksheet above fill in A, C, D and G below. Add “A” through “G” to confirm total equals your pin-to-pin measurement.
Length Chart
Dimensions Inches mm
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" (2133.6mm) E Bottom Foil 24.00 610 F Bottom of Foil to Top of Link Plates 15.41 391 G Top of Link Plate to Clevis Pin
1.00
Pin-to-Pin Length
G Toggle Distance from Lower Clevis Pin to Top of Link Plates
Toggle
Part No.
7413.22 3/4 Jaw/Jaw with Link Plate
7313.22 7/8 Jaw/Jaw with Link Plate
MKIV Unit 3E 11
Type
Clevis Pin G Distance
in mm in mm
3
/4 19.1 12.27 312
7
/8 22.2 12.85 327
25
F
G
Preassembly Short Top Foil
UNIT 3E
UNIT 3E
If top foil is shorter than 9
3
/4" (248mm), use one of the following special techniques to ensure sufficient bearing
surface for the foil in the area of the halyard swivel.
/4" (248mm)
3
9
93/4" (248mm) No special treatment required.
/8" (244 - 181mm)
1
Cut-Offs
/8" - 7
5
9
Do Not Use
95/8" – 71/8" (244 – 181mm) Do not use plastic
bushing above top connector.
/2" (89mm)
/2" (64mm)
1
2
/2" (38mm)
1
2" (51mm)
1
1
3" (76mm)
3
Cut-Offs
Do Not Use
31/2" - 11/2" (89 – 38mm) Shorten top foil and adjoin-
ing 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"
(89mm)
3"
(76mm)
1
/2"
2
(64mm)
2"
(51mm)
1
/2"
1
(38mm)
1. Initial top foil cut length
69/16"
(167mm)
6
(154mm)
69/16"
(167mm)
5
(129mm)
49/16"
(116mm)
1
1
/16"
/16"
2. Cut through middle hole in top foil.*
Resulting Top
Foil Length Length
5"
(127mm)
41/2"
(114mm)
4"
(102mm)
31/2"
(89mm)
3"
(76mm)
3. Shorten full length adjoining foil by cutting through middle hole.*
4. Shorten connector
(124mm)
(124mm)
(124mm)
(111mm)
(95mm)
47/8"
47/8"
47/8"
43/8"
33/4"
5. Shorten trim cap
No
No
No
Yes
Yes
/2" (178 - 140mm)
1
7" - 5
Cut-Offs
Do Not Use
7" - 51/2" (178 – 140mm) Do not use plastic bushing
above top connector. Shorten top of connector and if necessary shorten trim cap.
Cut-Offs – Do Not Use
/8" - 4" (137 - 102mm)
3
5
53/8" - 4" (137 – 102mm) 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.
12 MKIV Unit 3E
Cut-Off
Do Not Use
*To allow for saw cut, position blade so upper half of
middle hole is preserved.
/2" (38mm)
1
Under 1
Under 11/2" (38mm) Eliminate top foil and run foil
higher in foil clamp.
Preassembly Confirm Foil Length
Confirm foil length by laying foils alongside stay with turnbuckle components.
Pull stay out so it is straight. Attach Harken toggle to bottom of stay using crosspin. Make sure toggle straps are straight. Adjust turnbuckle so that length of stay with Harken toggle will fit boat. Ideally, turnbuckle will be half to two-thirds open to allow for rig adjustment.
Attach one link plate to lower unit. Line up lower unit so link plate hole lines up with rcrosspin in Harken toggle. Make sure toggle is tensioned when measuring.
Line up bottom foil so foil clamp is centered or just below center of notches in bottom foil.
Note: Position top foil so that with top cap the foil will ride below terminal (see chart below). 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.
Unit
5
2E
/8" (16 mm)
3E
1" (25 mm)
MKIV Unit 2E, 3E 13
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.
14 MKIV Unit 2E, 3E
Assembly Top Foil
Cut out template at right. Line up template with top of foil and scribed line. Tape in place. Use center punch to mark holes.
Check center punch marks to confirm (see chart below).
!
Foil
Top
Unit 3
Unit Center Punch Marks
2E 3E
Drill two (2) holes for trim cap. See chart below for correct drill size
Unit Drill Ø
3 (3/4, 7/8) 5/32" (4 mm)
3
/8" (10 mm) 13/16" (30 mm)
3
/8" (10 mm) 13/8" (35 mm)
2 5/32" (4 mm)
!
Foil
3
Top
/8" (10 mm)
Unit 2
13/16" (30 mm)
3
/8" (10mm)
13/8" (35mm)
Lay top foil in line with others. Slide stay into top foil and down line of foils or slide each foil up stay.
MKIV Unit 2E, 3E 15
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