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7413.10
User Manual
44 pgs5.98 Mb0

Harken 7413.10 User Manual

MKIV JIB REEFING & FURLING
Unit 3, 4
Installation Manual – Intended for specialized personnel or expert users
Preassembly
Assembly
Commissioning–Unit 3/4
Commissioning—Unit 4
Operation
Maintenance
Troubleshoot 37 Warranty 37 Appendix 38 - 41
4673 11/14
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
Safety Precautions/Parts Description
Introduction
This manual gives technical information on installation and service. The 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, injury to users, and injury to 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 at www.harken.com/manuals.
Purpose
Harken Jib Reefing and Furling systems are 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.
6
5
2
4
3
1
5
7
8
Unit 4 soft attachment
Parts Descriptions
1) Jaw/jaw toggle
2) Link plates
3) Hub extension
4) Shackles
MKIV units 3, 4 2
5) Drum assembly
6) Foil clamp
7) 610 mm (2') bottom foil
8) Feeder
9) Connector bushing
10) Bottom connector
11) 2.13 m (7') 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
15
12
11
14
Unit 4 soft attachment
10
9
Online product registration
www.harken.com/furlingwarranty
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. Harken does not recommend drilling boat’s chainplate or toggle. Bushings may be required to fit boats with smaller clevis pin sizes.
3. Will drum fit on bow? See page 7. If necessary, use an additional toggle to slightly raise unit. To clear anchor use a Harken long link plate which can be cut to various lengths.
UniPart no. Description Wire Ø
7
/16", 1/2" 11 mm, 12 mm
7413.10 MKIV Unit 3
-22, -30
Toggle part no. Description Chainplate clevis Ø
UNIT 3
UNIT 4
MKIV units 3, 4 3
7413.20 3/4 Jaw/jaw toggle w/short link plate
7413.20 7/8 Jaw/jaw toggle w/short link plate
7313.21 3/4 Long link plate w/jaw/jaw toggle
7313.21 7/8 Long link plate w/jaw/jaw toggle
Part no. Description Wire Ø
1
7414.10 MKIV Unit 4
-30, -40, -48
Toggle part no. Description Chainplate clevis pin Ø
7
7414.20
/
8
Jaw/jaw toggle w/short link plate
7414.20 1 Jaw/jaw toggle w/short link plate 1"
7414.20 11/
8
Jaw/jaw toggle w/short link plate
3
/4" 19.1 mm
7
/8" 22.2 mm
3
/4" 19.1 mm
7
/8" 22.2 mm
/2", 9/16", 5/8" 12 mm, 14 mm, 16 mm
7
/8" 22.2 mm
11/8" 28.57 mm
Rod Ø
9.53 mm, 11.1 mm
Chainplate Clevis Pin
Rod Ø
11.1 mm, 12.7 mm, 14.3 mm
25.4 mm
Preassembly Parts
610 mm (2')
bottom foil
2.13 m (10 - 7') foils Unit 3, 4
Halyard swivel
unit 3
Drum assembly
unit 3
Blue Loctite
®
adhesive
Main components
Description Unit Part No. Qty
Drum assembly with clamp
610 mm (2') bottom foil
2.13 m (7') foil
Halyard swivel
Blue Loctite
Drum Assembly
610 mm (2') bottom foil
2.13 m (7') foil
Halyard swivel
Blue Loctite
4 MKIV units 3, 4
®
adhesive
®
adhesive
3
4
HFG944
7413.33
7413.30
H-39392
833
HFG945
7414.33
7414.30
H-45788
833
1
1
10
1
1
1
1
10
1
1
Halyard swivel
unit 4
Drum assembly
unit 4
Loctite is a registered trademark of Henkel AG & Company KGaA.
Preassembly Parts
Connector bushings
Trim cap
Plastic
Foil screws
connector
wedges
Trim cap screws
Feeder
Bottom
Connectors
connector
Other Components
Description Unit Part No. Qty Size
Connector
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
10 mm bow shackle
Red Loctite
Injector, 1 oz. 5200 adhesive
Connector
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
Red Loctite
Injector, 1 oz. 5200 adhesive
02/03/11 MKIV units 3, 4 5
®
adhesive (for screws)
®
adhesive (for screws)
3
4
7413.31F
7413.32F
HFG297
(20 EA H-42073/H-42074)
HFG324
(22 EA H-39487)
HFG349
( 46 EA HFS1106)
HFG682 HFG672
( 3 EA HFS1127)
947
H-39756
2124
HFG739
HFG725
7414.31F
7414.32F HFG946
(H-45542/H-45543)
HFG947
( 24 EA H-45509)
HFG948
( 48 EA HFS1176)
HFG949
(H-45550/H-45551)
HFG672
(3 EA HFS1127)
947
H-45482
HFG739
HFG725
9 248 mm (9.75")
1 356 mm (14")
1 —
1
1
1 —
1
1 —
1 —
3 10 mm
2 —
1
9
1
1
1
1
1 —
1
1
1
2
1 1 oz
—
—
—
1 oz.
272 mm (10.7")
386 mm (15.2")
—
—
—
—
—
—
Bow shackles
unit 3 only
Prefeeder
5200
Red Loctite
®
Injector
adhesive
adhesive
Unit 3
3,4, 6, 10 mm
Unit 4
5, 6 mm
Loctite is a registered trademark of Henkel AG & Company KGaA.
Tools
Description Unit Qty
3, 4, 6, 10 mm hex keys 3 1 each
5, 6 mm hex keys 4 1 each
Preassembly Line/Rigging Parts Check/Tools
Line Diameter/Length
Furling line is not included with furling unit. Purchase 12 mm (7/16") low - stretch Dacron double - braid line. Line length should be equal to the length of the boat, plus the length of the foot of the largest genoa, plus 2 m (6').
Line not included.
Toggles
1. Harken toggle assembly required. Sold separately.
2. Mating turnbuckle components, with eye at lower end, must be purchased separately. See page 8.
3. Headstay might require cutting and shortening to fit Harken toggle. Some headstays may remain uncut by replacing lower stud of turnbuckle with stud/eye, eliminating extra toggle.
4. Rod rigging requires Harken rod adapter stud.
WARNING! A stay that is old or damaged can break suddenly, causing an accident. Headstay condition should be checked by a professional rigger before reusing.
Tools You Will Need
All Units.
Harken toggle
(sold separately).
Jaw/jaw toggle w/
short link plate
Unit Part No.
7413.20 3/4
3
7413.20 7/8
7414.20 7/8
4
7414.20 1
7414.20 1 1/8
Long link
plate w/toggle
Unit Part No.
7313.21 3/4
3
7313.21 7/8
Adhesive Alert
Rod Rigging.
Harken rod adapter
stud required
(sold separately).
Rod adapter stud
Unit Part No.
7426 -22
3
7427 -30 7427 -30
4
7428 -40 7429 -48
3
10
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 – 4 mm (5/32") 9. Slotted/Phillips screwdrivers 14. Metal straight edge
5. Hacksaw 10. Needle-nose pliers 15. Hammer
6 MKIV units 3, 4
9
5
14
Dacron is a registered trademark of E. I. du Pont de nemours and company or its affiliates.
15
MKIV furlers are shipped with 3M 5200 adhesive. Use adhesives on dry connectors and foils. Use the special injection system described in the assembly section. Parts may immediately be exposed to rain. Cure is best at 70 F (22 C) with 50% humidity. Do not apply at temperatures below 40 F (5 C) and above 100 F (38 C).
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 are fitted.
Note: A small amount of adhesive may bulge out of injection ports. If possible let system sit for several 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 necessary (page 31) or a toggle or long toggle assembly is used to raise the drum.
If luff of sail is not long enough to put halyard swivel near top of headstay foil,
B
A
a pendant must be added. See page 29.
Tack Setback
Note setback for tack shackle and cut sail accordingly.
Luff Tape Size -6 (5 mm or 6/32")
J - Finished luff tape size: 5.5 mm (0.215") K - Luff rope size: 4.8 mm (6/32", 3/16") L - Max Ø in sail groove: 6.5 mm (0.26") M - Gap in sail groove: 2.4 mm (0.096")
J
K
L
Luff Tape Length
M
Cut off top of luff tape so it is 450 to 600 mm (18" to 24") below head of sail. This allows head to lag behind rest of sail to help flatten it. It will also help the head to roll more smoothly.
C
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 (Unit 3 Only)
Make sure tack and head shackles fit sail rings. Minimum inside dimensions of
A
standard head and tack shackles are: (A) 48 mm (17/8") (B) 21 mm (13/16")
B
Sun Cover
Sun covers may be installed on either side of sail. Be sure to match other
F
sails in the customer's inventory.
Unit 3 only - long link plate
D
E
Note: If a long link plate is used, add the following dimensions to feeder, shackle and drum height (based on whether plate is used full-length or shortened to one of five hole positions). Do not add to halyard swivel or top terminal dimensions.
19.1 mm (
22.2 mm (
3
/4") Clevis Pin Add 497 mm to 271 mm (19 9/16" to 10 11/16")
7
/8") Clevis Pin Add 505 mm to 279 mm (19 7/8" to 11")
G
H
I
Unit A B C D E
3*
4
*See note above regarding long link plates.
MKIV units 3, 4 7
5
7
/16" 115/8" 33/8" 93/4" 43/4" 507/8" 505/16" 1811/16" 181/16" 1613/16" 161/2" 711/16" 71/8"
186 mm 296 mm 86 mm 247 mm 121 mm 1293 mm 1278 mm 474 mm 460 mm 427 mm 413 mm 195 mm 180 mm
15
8
/16"
227 mm 280 mm 130 mm 1365 mm 1394 mm 515 mm 486 mm 225 mm 196 mm
— —
111/16" 51/8" 533/4" 547/8"
Unit 4 only
A
F G H I
Max Min Max Min Max Min Max Min
H
— —
201/4" 191/8" 87/8" 73/4"
Preassembly Toggle Deductions/Stay Into Foil Options
Use dimensions of Harken toggle below to build stay to correct length.
rds
Tip: Turnbuckles should be 1/2 to 2/3
open to allow shortening for new wire stretch and for fine-tuning mast rake.
Unit Clevis pin Ø Pin-to-pin length
19.1 mm (
3
22.2 mm (
19.1 mm (
25.4 mm (1") 115 mm (4
4
28.57 mm (1
3
/4") 83 mm (3 9/32")
7
/8") 98 mm (3 7/8")
7
/8") 98 mm (3 7/8")
9
1
/8") 127 mm (5")
/16")
Unit Clevis pin Ø Pin-to-pin length
19.1 mm (
3
22.2 mm (
3
/4") 83 mm (3 9/32")
7
/8") 98 mm (3
7
/8")
Options for Feeding Stay into Foils
1. Swage stud at end of wire.
®
2. Open end of wire and install Norseman or STA-LOK
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 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.
stud after foil is assembled.
STA-LOK is a registered trademark of Barfield Engineering Company Ltd.
8 MKIV units 3, 4
Preassembly Unit 3—Top Foil Length
UNIT 3
Measure A and add to this chart and length chart below
Inches mm
A
B 1* 25*
E 24 610
F 22.25 565
G
Total A+B+E+F+G
*Add 29 mm (1.12") if using a halyard deflector.
Make sure upper measurement points of A and pin-to-pin are the same.
Alternate
measurement
point
A
TOP FOIL LENGTH WORKSHEET
1 Pin-to-pin length
2 Subtract ABEFG –
3 Result (pin-to-pin – ABEFG)
4 Subtract D –
To find “D”, pick number from chart below that is closest to, but not greater than total from step 3.
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 “D” = 19202 mm
5
Result (C) top foil length
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
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 2133.6 mm (84")
E Bottom foil 24" 610
F Bottom of foil to hub extension holes 22.25" 565
G Hub extension holes to clevis pin
Pin-to-pin length
*Add 29 mm (1.12") if using a halyard deflector.
G: Toggle distance from lower clevis pin to hub extension holes
Toggle part no. Type Clevis pin G distance
7413.20 3/4 Jaw/jaw with short link plate
7313.20 7/8 Jaw/jaw with short link plate
7313.21 3/4 Long link plate w/toggle
7313.21 7/8 Long link plate w/toggle
3
/4" 19.1 mm 5.42" 138 mm
7
/8" 22.2 mm 6.00" 152 mm
3
/4" 19.1 mm 22.00" 559 mm
7
/8" 22.2 mm 22.63" 575 mm
Note: If long link plate is shortened, dimension must be changed or foil will be too short. Measure distance from hub extension holes down to where clevis pin attaches toggle to boat. Use this dimension in G above.
MKIV unit 3 9
1"*
25*
Pin
to
E
in
F
G
Preassembly Unit 4—Top Foil Length
UNIT 4
Measure A and add to this chart and length chart below
Inches mm
A
B 1" 25
E 24" 610
F 25.98" 660
G
Total A+B+E+F+G
Make sure upper measurement points of A and pin-to-pin measurments
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 20,000 mm “D” = 19202 mm
5
Pin-to-pin length
Subtract ABEFG
Result (pin-to-pin – ABEFG)
Subtract D
Inches mm
7 x 84 = 588 8 x 84 = 672 9 x 84 = 756
10 x 84 = 840 11 x 84 = 924 12 x 84 = 1008
Example–If result from step 3 is:
Result (C) top foil length
7 x 2133.6 = 14935.2 8 x 2133.6 = 17068.8 9 x 2133.6 = 19202.4 10 x 2133.6 = 021336.0
11 x 2133.6 = 023470.0 12 x 2133.6 = 025603.0
–
–
Pin
to
pin
A
B
C
D
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 1" 25
C Top foil length
D Number of foils ________ x 84" (2133.6 mm)
E Bottom foil 24" 610
F Bottom of foil to hub extension holes 25.98" 660
G Hub extension holes to clevis pin
Toggle part no. Type Clevis pin G distance
7414.20 7/8 Jaw/jaw with short link plate
7414.20 1 Jaw/jaw with short link plate 1" 25.4 mm 6.64 169 mm
7414.20 1 1/8 Jaw/jaw with short link plate 1
Pin-to-pin length
G Toggle Distance from Lower Clevis Pin to Hub Extension Holes
7
/8" 22.2 mm 5.95 151 mm
1
/8" 28.57 mm 7.01 180 mm
Pin
E
to
pin
F
G
10 MKIV unit 4
Preassembly Unit 3—Short Top Foil
UNIT 3
If top foil is shorter than 248 mm (9 3/4"), use one of the following techniques to ensure sufficient bearing surface for the foil in the area of the halyard swivel.
")
4
/
3
248 mm (9
248 mm (9 3/4") No special treatment required.
")
8
/
1
"–7
8
/
5
Cut-offs
244 – 181 mm (9
Do not use
244 – 181 mm (9 5/8" – 7 1/8") Do not use plastic bushing above
top connector.
")
2
/
1
")
2
/
1
76 mm (3")
89 mm (3
")
")
2
2
/
/
1
1
51 mm (2")
64 mm (2
38 mm (1
Cut-offs
Do not use
89 S – 38 mm (3 1/2" – 1 1/2") Shorten top foil and adjoining full
length foil so two (2) screws are used to assemble joint instead of four (4). 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
1
/2"
(38 mm)
1. Initial top foil
cut length
6 9/16"
(167 mm)
6
(154 mm)
6 9/16"
(167 mm)
5
(129 mm)
4 9/16"
(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
4 7/8"
(124 mm)
4 7/8"
(124 mm)
4 7/8"
(124 mm)
4 3/8"
(111 mm)
3 3/4"
(95 mm)
5. Shorten trim cap
No
No
No
Yes
Yes
178 – 140 mm (7" – 5
Cut-offs
Do not use
Cut-off
Do not use
178 – 140 mm (7" – 5 1/2") Do not use plastic bushing above top
connector. Shorten top of connector and, if necessary, shorten trim cap.
" – 4")
8
/
3
Cut-offs – Do not use
137 – 102 mm (5
137 – 102 mm (5 3/8" – 4") Do not use plastic bushing above top connector. Cut connector at cross formed by glue dispersion
*To allow for saw cut, position blade so upper half of middle hole is preserved.
/2")
1
Under 38 mm (1
Under 38 mm (1 1/2") Eliminate top foil and run foil higher in drum assembly.
channels. Use single foil screw in top foil only.
MKIV unit 3 11
Preassembly Unit 4—Short Top Foil
UNIT 4
If top foil is shorter than 260 mm (10 1/4"), use one of the following special techniques to ensure sufficient bearing surface for the foil in the area of the halyard swivel.
/4")
1
260 mm (10
260 mm (10 1/4") No special treatment required.
/16")
9
102 – 38 mm (4" – 11/2") 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.
/2")
1
102 mm (4")
89 mm (3
/2")
1
76 mm (3")
51 mm (2")
64 mm (2
/2")
1
38 mm (1
Cut-offs –
Do not use.
Cut-Offs –
258 – 192 mm (10 1/8" – 7
Do Not Use.
258 – 192 mm (10 1/8" – 7 9/16") Do not use plastic bushing above
top connector.
/8")
5
/2" - 6
1
Cut-Offs –
190 – 168 mm (7
190 – 168 mm (71/2" – 6 5/8") Do not use plastic bushing above top connector. Shorten top of connector and if necessary shorten trim cap.
Do Not Use.
Top Foil
Length
from
Worksheet
4"
(102 mm)
1
3
/2"
(89 mm)
3"
(76 mm)
1
2
/2"
(64 mm)
2"
(51 mm)
1
1
/2"
(51 mm)
1. Initial top foil cut length
3
9
/32"
(231 mm)
8 19/32"
(218 mm)
3
8
/32"
(205 mm)
7 19/32"
(193 mm)
3
7
/32"
(180 mm)
6 9/16"
(167 mm)
2. Cut through middle hole in top foil.*
Resulting Top Foil Length Length
6 17/32"
(166 mm)
6 1/32"
(153 mm)
5 17/32"
(140 mm)
5 1/32"
(128 mm)
4 17/32"
(115 mm)
4 1/32"
(103 mm)
3. Shorten full length adjoining foil by cutting through middle hole.*
4. Shorten connector
5 11/32"
(136 mm)
5 11/32"
(136 mm)
5 11/32"
(136 mm)
5 11/32"
(136 mm)
5 5/32"
(131 mm)
4 1/2"
(114 mm)
Do Not Use
5. Shorten
trim cap
No
No
No
No
No
Yes
Cut-Off
/8")
3
/2"–4
1
Cut-Offs – Do Not Use.
165–111 mm (16
165 – 111 mm (6 1/2" – 4 3/8") 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 4
*To allow for saw cut, position blade so upper half of middle hole is preserved.
/2")
1
Under 38 mm (1
Under 38 mm (1 1/2") Eliminate top foil and run foil higher in drum assembly.
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. Make sure toggle straps are straight. Adjust turnbuckle so that length of stay with Harken toggle will fit boat. Turnbuckle should be one-half to two-thirds open to allow for rig adjustment.
Line up drum assembly so holes below drum line up with holes 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 including top cap, the foil will ride 25 mm (1") 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.
Unit 3 only.
If 7304 halyard deflector is
used, add 25 mm (1").
Unit 4
MKIV units 3, 4 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 cut-off piece.
Scribe line on top of foil to mark drill holes. Lay top foil alongside cut-off piece and use a flat metal object (i.e. metal ruler) to scribe top line of foil.
14 MKIV units 3, 4
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