Harken 7413.10 User Manual

MKIV JIB REEFING & FURLING

Unit 3, 4

Installation Manual – Intended for specialized personnel or expert users

Preassembly

Safety precautions/parts descriptions 2
Sizing check 3
Parts 4 - 5
Line/rigging parts check/tools 6
Dimensions/sailmaker's instructions 7
Toggle deductions/stay into foil options 8
Top foil length Unit 3/Unit 4 9 -10
Short top foil Unit 3/Unit 4 11 - 12
Confirm foil length 13

Assembly

Foils/connectors 14 - 20
Halyard swivel 20
Drum assembly 21
Rod rigging 22
Attach turnbuckle/toggle 23

Attach toggle/short length plate 24
Attach toggle/long length plate 25
Feeder/final 26

Commissioning–Unit 3/4

Turnbuckle on boat 27
Lead line to cockpit 28
Halyard wrap/prevent halyard wrap 29
Pendant/halyard: restrainer/ halyard tension 30

Commissioning—Unit 4

Tying soft attachment tack/head/halyard 31

Operation

Halyards/headstay tension 32
Raise sails/storm sails/reefing 33
Reef/secure sail 34
Race conversion 35

Maintenance

Clean/inspect 36
Replace line 36
Storage/remove furler 36

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

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
they are 10 mm (3/8") and 35 mm (1 3/8")
from top of foil.

!

Foil

10 mm (3/8")

Unit 3, 4 template

top

35 mm (13/8")

Drill two (2) 4 mm (
trim cap.

Lay top foil in line with others. Slide stay into
top foil and down line of foils, or slide each foil
up stay.

5

/32") holes for

MKIV units 3, 4 15

Assembly Top Foil

Install trim cap. Place each side over wire.

Unit 3 only.

Halyard deflector.

Push trim cap into foil to start; tap
in using hammer.

Install trim cap screws.

Red Loctite

adhesive.

®

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.

Loctite is a registered trademark of Henkel
AG & Company KGaA.

16 MKIV units 3, 4

Assembly Top Foil/Connectors

Slip connector on wire, mating hook
of plastic bushing with connector.

Put a drop of red Loctite® adhesive into screw
holes.

Loctite is a registered trademark of Henkel AG &
Company KGaA.

MKIV units 3, 4 17

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 it 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 three (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.

Start plunger into injector and immediately hold
upright so plunger is down and applicator tip is up.

As sealant runs down toward plunger, an air
pocket will form near tip. Push plunger to evacuate
air. You are now ready to begin injecting adhesive.

Adhesive in

lower half

18 MKIV units 3, 4

Assembly Foils/Connectors

Inject only a small amount of adhesive
into middle hole.

Unit Adhesive

3
4 1

1

/4 ml

1 to 1

1

/4 to 11/2 ml

Tip: When you see a small amount
of adhesive enter one screw hole,
stop! You have applied
enough adhesive.

Tighten screws into connector holes. Make
sure a drop of adhesive entered each screw
hole. If not, apply to screw.

Stop when you see a
small amount of adhesive
enter one screw hole.

Use “ml”

marks to

estimate 1

1

/4 ml of

to 1

adhesive.

Red Loctite®adhesive.

Use bushings, connector, wedge and
adhesive in other screw hole and insert
into other foil. Use 1–11/4 ml of
adhesive.

Loctite is a registered trademark of Henkel AG & Company KGaA.

MKIV units 3, 4 19

Assembly Bottom Foil/Connectors/Halyard Swivel

Continue installing connectors and wedges. Make
sure to use adhesive in screw holes.

Red Loctite

®

adhesive.

Continue assembly. Use 356 mm (14")
bottom connector to assemble bottom foil.

Loctite is a registered trademark of Henkel AG &
Company KGaA.

Slide halyard swivel onto foil above feeder window.
Make sure taller “half” is up as shown.

20 MKIV units 3, 4

Assembly Drum 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.

MKIV units 3, 4 21

Assembly Rod Adapter Stud

Apply a few drops of
red Loctite
to threads of 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.

®

adhesive

Insert two cotter pins and spread.
Clean excess Loctite from terminal
body using special care to ensure
that there is no red Loctite on
threaded stud.

ROD RIGGING

Loctite is a registered trademark of Henkel
AG & Company KGaA.

22 MKIV units 3, 4

Assembly Attach Turnbuckle/Toggle

Assemble turnbuckle.

Note: If using STA-LOK® or Norseman
stud, you must use a washer above
stud as shown below.

STA-LOK is a registered trademark of Barfield
Engineering Company Ltd.

Washer

Connect eye to toggle jaw using special clevis pin.
Secure using cotter pin.

Make sure shallow jaw is up.

If stay length is set, use side cutters or
needle-nose pliers to bend cotter pin
to secure turnbuckle.

Up

Down

MKIV units 3, 4 23

Assembly Unit 3, 4—Attach Toggle/Short Link Plate

Apply isolator.

Recess turnbuckle into drum assembly, slip link
plates over special clevis pin, and secure using
fasteners. Use blue Loctite® adhesive on screws.

Loctite is a registered trademark of Henkel AG &
Company KGaA.

Secure to toggle using lock nuts.

24 MKIV units 3, 4

Assembly Unit 3—Attach Toggle/Long Link Plate

Determine height of link plates to provide anchor
clearance and cut to length.

Cut at scribe mark. Deburr edges.

Apply isolator.

Fasten one long link plate to drum assembly
using fasteners. Use blue Loctite® adhesive
on screws.

Loctite is a registered trademark of Henkel AG &
Company KGaA.

Fasten second long link plate to drum assembly
and secure to toggle using locknuts.

WARNING! Stay must attach
to toggle. Do not attach stay
to crosspin at drum assembly
because crosspin and plates
can fatigue and break.

MKIV unit 3 25

Assembly Feeder/Final

Check foil height at top; set and secure
using hex key.

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 screw,
loosen no more than one full turn.
Slide screw up and remove feeder.

26 MKIV units 3, 4

Commissioning—Unit 3, 4 Turnbuckle on Boat

Have extra cotter pins and locknuts on hand to replace used ones at
base of unit and for turnbuckle.

Hold foils and loosen drum assembly screws until you can pull clamp
out to lower foils.

Lower foils.

Remove link plates.

Raise drum assembly and use halyard to lift and hold it about 1.5 m (5').
Raise foils using second halyard and secure. Allow room above for

turnbuckle take up.

WARNING! Make sure drum assembly and foils are
securely lifted with a halyard before adjusting turnbuckle.
Foils can drop suddenly, causing injury to hands.

Adjust turnbuckle.

Replace used cotter pins and locknuts. Lower drum assembly and
install clevis pin and new cotter pin.

Lift foils so top is 25 mm (1") below upper terminal.

MKIV units 3, 4 27

Commissioning—Unit 3, 4 Leading Line to Cockpit

Run line through enclosed window in guard and into hole in
bottom flange 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 line guard and jam furler

which can cause loss of control of boat.

Enclosed window

Note location of sun cover. With no sail on unit, charge system by rotating furler to wrap line on drum. Leave a
comfortable-length line tail in cockpit. Fine-tune line length on all points of sail after sail is hoisted and set.

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.

BOW

2660 Carbo

forward

lead block

2660 Forward Lead Block

Position 2660 forward stanchion block so line
enters drum at right angles to headstay and
centers vertically in opening. Install so line
is inside stanchion.

Correct block position is critical to even
line spooling and ease of furling.

Furling line must enter drum at right

angle to headstay.

2600 Carbo

intermediate

lead block

2600 Carbo

intermediate

2600 Carbo

intermediate

2670 Carbo

Ratchet block

lead block

lead block

2600 57 mm Carbo Intermediate Lead Blocks

Install 2600 intermediate lead blocks so line
is inside stanchions.

Number and placement of leads depends on boat
length and number/configuration of stanchions.

2670 75 mm Carbo® Ratchet Block

Mount 2670 Carbo® Ratchet 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.

Furling Line Cleat

Install so line is angled as shown.

Furling line lead changes as amount

of furling line on drum changes.

Drum Full

(sail unfurled)

Drum Empty

(sail furled)

Note: As furling line lead changes, make sure line

Stern

28 MKIV units 3, 4

doesn’t chafe against line guard. Rotate line guard
if necessary.

Commissioning—Unit 3, 4 Halyard Wrap/Prevent Halyard Wrap

Halyard Wraps

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 unfurls, 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 can cause these parts to break suddenly, causing
the mast to fall while person is aloft. Sailing or motoring with boat after a wrap can result in the headstay breaking and
mast falling. 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 he 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 Wraps

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 100 – 152 mm (4 – 6") of foil unless
a halyard restrainer is used.

2. Halyard must pull slightly to rear (8 – 10°).

3. Halyard must be snug, but not too tight.

Test furler at dock. However, 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.

8 – 10°

MKIV units 3, 4 29

Commissioning—Unit 3, 4 Pendant/Halyard Restrainer/Halyard 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.

Unit 3 only

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 can cause problems
if not installed properly.

If your boat needs a halyard deflector (Unit 3 only), use part no. 7304
or a halyard restrainer (Unit 3 only), use part no. 945.

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 might
experience difficulty in tensioning sail luff, have friction when furling, and
cause possible damage to foils. To decrease deflection angles, shorten sail luff.

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.

Unit 3 only

Halyard deflector

Unit 3

or

Unit 4

30 MKIV units 3, 4

Halyard restrainer

Commissioning—Unit 4 Unit 4—Tying Soft Attachment: Tack/Head/Halyard

Lash halyard, head of sail, and tack. A triple
fisherman's knot is useful for this purpose.
See www.harken.com/knottyingresources.

MKIV unit 4 31

Operation Spinnaker Halyards/Headstay Tension/Backstay Adjuster

Spinnaker Halyards

Spinnaker halyards occasionally cause problems with furling.

WARNING! In severe cases, spinnaker halyards can
jam furler, causing loss of control of boat. Make sure
halyards are clear of top of foils and halyard swivel.

On many boats, it is not 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 might 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 27.

Tip: Before adjusting headstay tension, slack
mainsheet and vang.

Backstay Adjusters

Backstay adjusters allow headstay tension to vary so sail shape can be changed 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, or a mechanical, or hydraulic adjuster like those offered by Harken.

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 might be necessary to shorten foil slightly.

32 MKIV units 3, 4

Operation Sail: Raise/Storm/Reef

Raise Sails

1) Install prefeeder by securely tying end of line to a deck fitting or to toggle
below furler so it is 610 mm (2') below feeder.

2) Shackle tack of sail to drum. 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.

8) Furl sail to check for possible halyard wraps. See pages 29 - 30.

9) See if sail will furl completely and still leave two wraps of line on spool
and two wraps of sheets around sail. See “Secure Sail” on page 36.

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 multi-purpose genoa for all their sailing, but it is not good seamanship to go offshore without storm sails.

Heavy-air working jibs and storm sails should 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 29.

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 might be necessary to place
some tension on jib sheet to insure a tight furl.

To furl in a breeze, ease sheets gradually and
pull furling line in steps until sail is furled or reefed.

The furling line should pull readily. Depending upon
wind strength, larger furlers may require use of a
winch to furl. If 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 39. 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.

WARNING! Using a winch to furl when the halyard is wrapped may cause the headstay to fail, resulting in an accident.

MKIV units 3, 4 33

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 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 the boat
and to reduce heeling moment. Sails can also
be reefed to improve visibility, or to slow boat
while sailing in congested areas such as
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 the jib sheet 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 there are no line wraps 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
jib sheet on furled sail.
Add more wraps of line
on spool.

34 MKIV units 3, 4

Untie jib sheets and keep sail
completely rolled. Secure with
sail tie.

Turn spool to unroll a
several of wraps of line.
Turn spool to add a
several of line.

Retie sheets.

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, and 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 drum assembly.
Replace feeder.

Halyard Swivel Off Furler

Serious racers may want to remove the
halyard swivel.

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® wedge to reassemble
Norseman/STA-LOK® fitting.

1) Remove drum assembly.

2) Rig a secure, temporary headstay.

3) Loosen backstay, mainsheet, and vang
so headstay goes slack.

4) Remove clevis pin holding furling unit
to chainplate.

5) See adjusting turnbuckle on page 27.
Remove turnbuckle body and lower
unit and slide off halyard swivel.

6) Reattach headstay to boat.

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!

Remove Drum

1) Remove sail and unwind line from drum.
Line can remain attached to drum.

2) Use 10 mm Allen wrench provided to
remove two (2) screws on bottom of guard
assembly. Remove two halves.
Be careful—screws are not captive.

3) Use an Allen wrench to loosen four (4)
screws in plastic cover and flange.

STA-LOK is a registered trademark of Barfield
Engineering Company Ltd.

MKIV units 3, 4 35

Maintenance Clean/Inspect/Replace Line/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 can be cleaned by washing with soap and water. A
scrap of luff tape may be run up foil to scrub inside grooves.
If lubrication is required, spray a thin coat of McLube®
SailKote

WARNING! Periodically inspect items listed
below and any others as necessary. Failure
to inspect can cause an accident.

TM

dry lubricant on sail luff tapes away from boat deck.

WARNING! Do not spray foil on boat. McLube will
cause slippery decks which can result in loss of
footing, and falling overboard.

Inspect

Inspect unit for signs of chafe, wear, or damage.

Inspect clevis and cotter pins below and inside drum assembly
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 drum
assembly. Periodically inspect wire for signs of wear or unraveling.

Replace Line

Use 11 mm (7/16") diameter line. Use double-braid polyester
line with good wear characteristics.

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.

Loosen Foil Clamp Before Slacking Backstay

In order to prevent foils from locking against upper stay terminal when backstay is released, loosen foil clamp screws and lower foil before loosen­ing backstay.

STA-LOK is a registered trademark of Barfield Engineering Company Ltd. SailKote is a trademark of macLube®, division of McGee Industries
McLube is a registered trademark of McGee® Industries, Inc.

36 MKIV units 3, 4

Troubleshoot

Problem Probable Cause Solution

Sail will not furl or
is difficult to furl.

Sail will not unfurl
or will not unfurl
completely.

Sail will not furl
completely.

Headstay rotates in jerks
or elliptically.

Sail does not stay
furled.

Sail will not go up.

Sail will not raise
completely or luff
will not tension.

Sail will not
come down.

Ultravoilet cover rolls up
inside of sail.

Line jams between 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

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 27.
Foils too high, binding on swage eye. Lower foils until clear. See adjusting turnbuckle on page 27.
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 2670 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 drum assembly. Reinstall foil in drum assembly and tighten clamp screws.
No wraps of furling line on drum. Remove sheets. Rotate stay; wrap as much furling line on drum as possible.
Line guard assembly has slipped down. Tighten line guard assembly screws securely.
Line through 2670 ratchet backwards. Rerun line.
Halyard swivel installed upside down. Remount swivel correctly.
Jib halyard wraps around headstay because

angle between mast and halyard is too shallow.
Jib halyard is wraps around the headstay

because the halyard swivel is too low.
Foils riding on turnbuckle. Raise foils. See adjusting turnbuckle on page 27.
Foils too high, binding on swage eye. Lower foils. See adjusting turnbuckle on page 27.
Jib halyard is too tight. Ease jib halyard.
Spare halyard wraps 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.
Insufficient furling line on drum. Remove sheets. Rotate stay; wrap 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.
Insufficient tension on headstay. Tighten headstay and/or backstay to eliminate sag in headstay.

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.
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

Halyard swivel off foil. Sail luff too long or foil is too short or low and must be lengthened or raised.
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

Line is not led through windows. Pull line through enclosed window.

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.

sailKote.

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.
Sta-Lok is a registered trademark of Sta-Lok Terminals, Ltd.
Torlon is a registered trademark of Solvay Advanced Polymers

®

Warranty

Online Product Registration

www.harken.com/FurlingWarranty

www.harken.com/manuals

or call, write, email, or fax Harken, Inc.,

Pewaukee, WI USA

MKIV unit 3, 4 37

MKIV Unit 3 – Units Built After February 2009 Parts List

HFS1091

H-45412

HFS1060

H-45413

H-45562

1

2

HFS1168

HFS1107

H-45264

Clevis Pin

4

Grip

Length

Clevis pin

measurements

are "Grip Length."

4

MP-128

5

2

1

8

2

7

7313.21 3/4

7313.21

7426 -22
7427 -30

8

5

8

6

7413.10BASE

8

2

7

7413.20 3/4

7414.20

5

3

7

6

1

7413.20 3/4

/

8

H-38168

MP-116

H-38168

MP-116
H-38168
H-38168

MP-116
H-38168

MP-116

8

2

8

7

4

6

7413.20 7/8

38 MKIV unit 3

3

3

6

8

2

7

7

1

6

4

7

/

8

Description Order Part No.

Top cover 2 H-45412

1

Top cover screw (M5 X 16 mm FH) 2 HFS1091
Bottom flange 2 H-45413
Bottom flange screw (M5 X 12 mm FH) 2 HFS1060
Guard 2 H-45562

2

Guard screw (M10 X 65 mm FH) 2 HFS1168
Clamp 1 H-45264

3

Clamp screw (M8 X 25mm FH) 4 HFS1107
Hub assembly 1 7413.10BASE

4

5

6

7

Ball plugs 5 H-38168

®

Torlon

ball bearing (1/2") 25 MP-128

®

Delrin

ball bearing (1/2") 100 MP-116

Delrin is a registered trademark of E. I. du Pont de Nemours and Company or its affiliates.
Torlon is a registered trademark of Solvay Advanced Polymers

No. Description Order Part No.
Jaw/jaw toggle with short link plates 1 7413.20 3/4

1 Toggle 1 H-41489
2 Plates 2 H-45334
3 Crosspin 1 H-42583
4 Clevis pin (
5 Isolator 2 H-42585
6 Cotter pin (
7 Nylon locking nut 2 HFS991
8 Socket head cap screw 4 HFS903

Jaw/jaw toggle with short link plates 1 7413.20 7/8

1 Toggle 1 H-42562
2 Plates 2 H-45334
3 Crosspin 1 H-42584
4 Clevis pin (
5 Isolator 2 H-42585
6 Cotter pin (
7 Nylon locking nut 2 HFS991
8 Socket head cap screw 4 HFS903

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) 1 H-41814
2 Nosepiece -30 1 H-41813
3 Cotter pin (
4 Stud cap

No. Description Order Part No. Part No.
Long link plate w/toggle 7313.21 3/4 7313.21 7/8

1 Toggle 1 H-41489 H-42562
2 Plates 2 H-42568 H-42568
3 Upper clevis pin (custom) 1 H-42583 H-42584
4 Lower clevis pin 1 H-42403 H-42404
5 Isolator 2 H-42585 H-42585
6 Cotter pin 2 HFS203 HFS203
7 Nylon locking nut 2 HFS991 HFS991
8 Socket head cap screw 4 HFS903 HFS903

3

/4" X 1.766:GR 302SS) 1 H-42403

5

/32" X 1.250 18-8) 2 HFS203

7

/8" X 1.958" 302SS) 1 H-42404

5

/32" X 1.250 18-8) 2 HFS203

3

/32 x 1.750) 2 HFG319

7

/8" ID 1 HFG303

3

/32 x 1.750) 2 HFG319

7

/8" ID 1 HFG303

MKIV Unit 3 – Units Built After February 2009 Parts List

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

HFG672

7413.10 FOILSET

H-39916

MP-128

MP-128

MP-128

H-39916

HFG349

HFG297

HFG682

H-39392

7413.30

7413.31

H-42073

H-42074

7413.32

4

Description Order Part No.

Trim cap set w/o screws 1 HFG682

4

Trim cap screw set 1 HFG672

Trim cap screw 2 HFS1127

Halyard swivel 1 H-39392

Clip/smalley ring for balls 2 H-39916

®

Torlon

ball bearings 88 MP-128

Foil set 1 7413.10 FOILSET

Foil (7' / 2.13 m luff) 10 7413.30

Foil (2' / 610 mm) bottom 1 7413.33
Foil screw set 1 HFG349

Foil screw 46 HFS1106

Connector kit 1 7413.31

Connector 1 —
Connector bushing top 2 —
Connector bushing bottom 2 —

Bottom connector kit 1 7413.32

Bottom connector 1 —
Connector bushing top 2 —
Connector bushing bottom 2 —

Connector set 1 HFG627

Connector 9 —
Bottom connector (247 mm / 9

3

/4" ) 1 —

Connector bushing set 1 HFG297

Connector bushing top
(curved/\longer)
Connector bushing bottom
(flat/shorter)

20 H-42073

20 H-42074

Plastic connector wedge set 1 HFG324

Plastic connector wedge 22 H-39487

Feeder with screw and tab 1 H-39756

Feeder tab 1 H-38372A
Screw 1 HFS1130

H-39756

HFG324

7413.33

Description Order Part No.

Instruction manual 1 4673

5

HFG627

Blue Loctite®adhesive 1 833
Red Loctite®adhesive 2 HFG739
5200 adhesive set 1 HFG725

MKIV JIB REEFING & FURLING

Unit 0

Installation Manual – Intended for specialized personnel or expert users

Preassembly

Safety Precautions/Parts Descriptions 2
Sizing Check 3
Parts 4
Rigging Parts Check/Tools 5
Dimensions/Sailmaker's Instructions 6
Toggle Deductions/Stay Into Foil Options 7
Top Foil Length 8
Short Top Foil 9
Confirm Foil Length 10

Assembly

Foils/Connectors 11–17
Halyard Swivel 17
Drum Assembly 18
Rod Rigging 19
Turnbuckle/Toggle 20
Final/Feeder 21–22

Commissioning

Turnbuckle 23
Line to Cockpit 24
Halyard Wrap/Prevent Halyard Wrap 25
Pendant/Halyard Restrainer/ Halyard Tension 26

Operation

Spinnaker Halyards/Headstay Tension 27
Raise Sails 28
Furl/Reef 28–29
Secure Sail 29
Race Conversion 30

Maintenance

Clean/Inspect 31
Replace Line 31
Storage/Remove Furler 31

Troubleshoot 32
Warranty 32
Appendix 33–34

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

4416/04-13

HFG200/HFG201

4673

833

HFG739

HFG722

HFG947

5

945

7304

2124

M10

6

6

M6

M4

M3

5200 marine adhesive sealant 1 HFG722

Injector 1

HFG200
HFG201

Prefeeder 1 947

Description Order Part No.

Halyard restrainer (optional) 1 945

Sheave/ss inner race only 1 945A
Clevis pin (

1

/4" x 1.0625" 18-8) 1 HCP208
Bracket-large 1 HCP394
Cotter pin (

1

/16" x .500" 18-8) 1 HFS181

Halyard deflector 1 7304
Shackle 3 2124
Hex keys

M10 1 HFG647
M6 1 HFG644
M4 1 HFG640
M3 1 HCP1089

MKIV unit 3 39

MKIV Unit 4 Parts List

HFS1091

H-38819

HFS1091

H-38820

H-38212

1

2

HFS854
HFS875

HFS1107

H-45498

Clevis pin

Grip

4

4

MP-128

7414.10BASE

8

7

40 MKIV unit 4

2

7414.20 7/8

7414.20 1

7414.20 1

5

6

3

1

1

/

8

H-38168

MP-116

H-38168

MP-116
H-38168
H-38168

MP-116
H-38168

MP-116

8

2

8

7

6

4

6

length

Clevis pin

measurements are

"Grip Length."

2

1

3

7426 -22
7427 -30

3

5

Description Order Part No.

Top cover 2 H-38819

1

Top cover screw 2 HFS1091
Bottom flange 2 H-38820
Bottom flange screw 2 HFS1091
Guard 2 H-38212

2

Guard screw (FST-M12X1.75X70MM SHCS) 2 HFS1110
Clamp 1 H-45498
Clamp screw (FST-M8X1.25X25MM SHCS A4 SS) 4 HFS1107

3

Hub assembly 1 7414.10BASE

Ball plugs 5 H-38168

4

Delrin is a registered trademark of E. I. du Pont de Nemours and Company or its affiliates.
Torlon is a registered trademark of Solvay Advanced Polymers

No. Description Order Part No.
Rod adapter stud (-30) w/nosepiece 1 7427 -30

5

1 Stud (main body) 1 H-41814
2 Nosepiece -30 1 H-41813
3 Cotter pin (
4 Stud cap

Rod adapter stud (-40) w/nosepiece 1 7428 -40

1 Stud (main body) 1 H-47146
2 Nosepiece -40 1 H-47131
3 Cotter pin (

Rod adapter stud (-48) w/nosepiece 1 7429 -48

1 Stud (main body) 1 H-47147
2 Nosepiece -48 1 H-47132
3 Cotter pin (

No. Description Order Part No.
Jaw/jaw toggle with short link plates 1 7414.20

6

1 Toggle 1 H-42562
2 Plates 2 H-45449
3 Crosspin 1 H-45439
4 Clevis pin (
5 Isolator 2 H-46403
6 Cotter pin (
7 Nylon locking nut 2 HFS1122
8 S H ca p sc r ew (FST-M12X1.75X20MM SHCS A4 SS) 4 HFS1177

Jaw/jaw toggle with short link plates 1 7414.20 1

1 Toggle 1 H-45427
2 Plates 2 H-45449
3 Crosspin 1 H-45440
4 Clevis pin (1" X 2.231" A4 SS) 1 H-45435
5 Isolator 2 H-46403
6 Cotter pin (
7 Nylon locking nut 2 HFS1122
8 Socket head cap screw 4 HFS1177

Jaw/jaw toggle with short link plates 1 7414.20 1

1 Toggle 1 H-45428
2 Plates 2 H-45449
3 Crosspin 1 H-45441
4 Clevis pin (1.125" X 2.526" A4 SS) 1 H-45436
5 Isolator 2 H-46403
6 Cotter pin (
7 Nylon locking nut 2 HFS1122
8 Socket head cap screw 4 HFS1177

®

Torlon

ball bearing (1/2") 25 MP-128

®

Delrin

ball bearing (1/2") 97 MP-116

3

/32 x 1.750) 2 HFG319

7

/8" ID 1 HFG303

3

/32 x 1.750) 2 HFG319

3

/32 x 1.750) 2 HFG319

7

/8" X 1.958" 302SS) 1 H-42404

5

/32" X 1.250 18-8) 2 HFS203

3

/16" X 2 SS 316) 2 HFG743

3

/16" X 2 SS 316) 2 HFG743

7

/8

1

/

8

MKIV Unit 4 Parts List

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

HFG672

H-46469

MP-128

MP-128

MP-128

HCP1292

7414.10 FOILSET

HFG946

HFG948

HFG949

H-45788

7414.30

7414.31

H-45542

H-455434

7414.32

H-39756

4

Description Order Part No.

Trim cap set w/o screws 1 HFG949

4

Trim cap screw set 1 HFG672

Trim cap screw 2 HFS1127

Halyard swivel 1 H-45788

Clip/smalley ring for balls 1 H-46469
Clip/smalley ring for liners 1 HCP1292

®

Torlon

ball bearings (1/2") 100 MP-128

Foil set 2 7414.10 FOILSET

Foil (7' / 2.13 m luff) 10 7414.30

Foil (2' / 610 mm) bottom 1 7414.33

Foil screw set 1 HFG948

Foil screw 48 HFS1176

Connector kit 1 7414.31

Connector 1 —
Connector bushing top 2 —
Connector bushing bottom 2 —

Bottom connector kit 1 7414.32

Bottom connector 1 —
Connector bushing top 2 —
Connector bushing bottom 2 —

Connector 9 7414.31
Bottom connector (247 mm / 9

3

/4" ) 1 7414.32

Connector bushing set 1 HFG946

Connector bushing top
(curved/longer)
Connector bushing bottom
(flat/shorter)

23 H-45542

23 H-45543

Plastic connector wedge set 1 HFG947

Plastic connector wedge 24 H-45509

Feeder tab 1 H-45482
Screw 1 HFS1175

Delrin is a registered trademark of E. I. du Pont de Nemours and Company or its affiliates.
Torlon is a registered trademark of Solvay Advanced Polymers
Loctite is a trademark of Henkel AG & Company KGaA

HFG947

7414.33

MKIV JIB REEFING & FURLING

Unit 0

Installation Manual – Intended for specialized personnel or expert users

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

Preassembly

Safety Precautions/Parts Descriptions 2
Sizing Check 3
Parts 4
Rigging Parts Check/Tools 5
Dimensions/Sailmaker's Instructions 6
Toggle Deductions/Stay Into Foil Options 7
Top Foil Length 8
Short Top Foil 9
Confirm Foil Length 10

Assembly

Foils/Connectors 11–17
Halyard Swivel 17
Drum Assembly 18
Rod Rigging 19
Turnbuckle/Toggle 20
Final/Feeder 21–22

Commissioning

Turnbuckle 23
Line to Cockpit 24
Halyard Wrap/Prevent Halyard Wrap 25
Pendant/Halyard Restrainer/ Halyard Tension 26

Operation

Spinnaker Halyards/Headstay Tension 27
Raise Sails 28
Furl/Reef 28–29
Secure Sail 29
Race Conversion 30

Maintenance

Clean/Inspect 31
Replace Line 31
Storage/Remove Furler 31

Troubleshoot 32
Warranty 32
Appendix 33–34

4416/04-13

4673

M6

M5

6

Description Order Part No.

833

HFG739

HFG722

5

Instruction manual 1 4673

5

Blue Loctite® adhesive 1 833
Red Loctite adhesive 2 HFG739
5200 adhesive set 1 HFG725

5200 marine adhesive sealant 1 HFG722

Injector 1

HFG200
HFG201

Prefeeder 1 947

HFG947

HFG200/HFG201

6

Description Order Part No.

Hex keys

M6 1 HFG644
M5 1 HFG643

MKIV unit 4 41

Corporate Headquarters

N15W24983 Bluemound Rd, Pewaukee, WI 53072 USA

Telephone: [phone] • Fax: [phone]

Web: www.harken.com • Email: [e-mail]

Harken Australia Pty, Ltd.

1B Green Street, Brookvale, N.S.W. 2100, Australia

Telephone: [phone] • Fax: [phone]

Web: harken.com.au • Email: [e-mail]

Harken France

ZA Port des Minimes, BP 3064, 17032 La Rochelle Cedex 1, France

Telephone: [phone] • Fax: [phone]

ul. Rydygiera 8, budynek 3A, lokal 101, I pi

Mailing address: Harken Sweden AB, Box 64, SE -440 30 Marstrand

Bearing House, Ampress Lane, Lymington, Hampshire S041 8LW, England

Web: harken.fr • Email: [e-mail]

Harken Italy S.p.A.

Via Marco Biagi, 14, 22070 Limido Comasco (CO) Italy

Telephone: [phone] • Fax: [phone]

Web: harken.it • Email: [e-mail]

Harken New Zealand, Ltd.

158 Beaumont Street

Unit 11, Orams Marine Centre

Westhaven, Aukland, 1010, New Zealand

Telephone: [phone] • Fax: [phone]

Web: harken.co.nz • Email: [e-mail]

Harken Polska SP ZOO

ętro, 01-793 Warszawa, Poland

Tel: [phone] • Fax: [phone]

Web: harken.pl • Email: [e-mail]

Harken Sweden AB

Main Office and Harken Brandstore: Västmannagatan 81B

SE-113 26 Stockholm Sweden

Telephone: [phone] • Fax: [phone]

Web: harken.se • Email: [e-mail]

Harken UK, Ltd.

Telephone: [phone] • Fax: [phone]

Web: harken.co.uk • Email: [e-mail]

Please visit: http://www.harken.com/locator.aspx

to locate Harken dealers and distributors

Printed in USA 4673 11/14