Harken 7413.15 User Manual
MKIV HYDRAULIC JIB REEFING & FURLING
Unit 3
Installation Manual – Intended for specialized personnel or expert users
Preassembly
Safety Precautions 2
Parts Descriptions 2 - 3
Size Check 3
Parts 4-5
Rigging Parts Check/Tools 6
Hydraulic System 7 - 8
Toggle Deductions/Stay Into Foil Options 9
Top Foil Lengths 10 - 11
Short Top Foil 11
Confirm Foil Length 12
Assembly
Foils/Connectors 13 - 18
Bottom Foil/Connectors/Halyard Swivel 19
Lower Unit to Foil 20
Rod Rigging: Rod Adapter Stud 21
Attach Turnbuckle/Toggle 22 - 23
Attach Hydraulic Cylinder 23 - 24
Feeder/Final 25
4379 12/13
Commissioning
Turnbuckle on Boat 26
Halyard Swivel Height/Lead Angle 27
Halyard Restrainer/Tension 28
Operation
Halyard: Headstay Tension 29
Reefing/Secure Sail 30
Manual Operation 31
Race Conversion 32
Maintenance/Inspection/Decommissioning 33
Troubleshoot/Warranty 34
Appendix
Component Part Number List 35 - 37
Toggle Dimensions 38
Dimensions/Sailmaker's Instructions 39
WARNING! Strictly follow all instructions
to avoid an accident, damage to your vessel,
personal injury or death. See www.harken.com
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
for additional safety information.
Safety Precautions/Parts Description
Introduction
This manual gives technical information on installation and service. This information is destined exclusively for
specialized personnel or expert users. Installation, disassembling, and reassembling by personnel who are not
experts may cause serious damage to property or injury to users and those in the vicinity of the product. If you
do not understand an instruction contact Harken.
The user must have appropriate training in order to use this product.
Harken accepts no responsibility for damage or harm caused by not observing the safety requirements and
instructions in this manual. See limited warranty, general warnings, and instructions in www.harken.com/manuals.
Purpose
®
Harken
Jib Reefing and Furling is designed for rolling sails on sailboats to reduce sail size or to completely roll
so wind has little effect on the sail. Use of this product for other than normal sailboat applications is not covered
by the limited warranty.
Safety Precautions
WARNING! This symbol alerts you to potential hazards that may kill or hurt you and others
if you don't follow instructions. The message will tell you how to reduce the
chance of injury.
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.
9
8
5
7
3
2
1
6
4
11
10
3
1
Parts Descriptions
1) Jaw/Jaw Toggle
2) Toggle Housing
3) Toggle Housing Insulator
4) Hydraulic Cylinder
2 MKIV Hydraulic Unit 3
5) Lower Unit
6) Calibrated Guide
7) Shackles
8) Foil Clamp
9) 2' (610 mm) Bottom Foil
10) Feeder
11) Connector Bushing
12) Bottom Connector
13) 7' (2.13 m) Foil
14) Connector Screws
15) Connector Wedge
16) Connector
17) Halyard Swivel
18) Trim Cap
19) Trim Cap Screws
Preassembly Sizing Check
19
18
12
Online Product Registration
www.harken.com/FurlingWarranty
15
14
13
11
16
17
A
B
See page 39 for all
toggle dimensions.
C
D
GE
F
H
Size Check
1. Check headstay and clevis pin dimensions in chart below.
2. Harken does not recommend drilling boat’s chainplate or toggle. Bushings may be required to fit boats with
smaller clevis pin sizes.
WARNING! Do not drill boat's chainplate or toggle. This may result in rig failure.
Use the correct size toggle and clevis pin.
3. Will lower unit fit on bow? See page 9. If necessary, use an additional toggle to slightly raise unit.
Unit Part No. Description Wire Ø
7
7413.15
7413.16
MKIV Hydraulic Unit 3 (Aluminum Foils)
MKIV Hydraulic Unit 3 (Carbon Foils)
Toggle Part No. Description Toggle Clevis Ø
7413.25 3/4
UNIT 3
7413.25 7/8
7413.26 3/4
7413.26 7/8
MKIV Hydraulic Unit 3 3
Toggle Assembly
Toggle Assembly
Hydraulic Cylinder/Toggle
Hydraulic Cylinder/Toggle
/16", 1/2" 11 mm, 12 mm
Rod Ø
-22, -30 9.53 mm, 11.10 mm
3
/4" 19.1 mm
7
/8" 22.2 mm
3
/4" 19.1 mm
7
/8" 22.2 mm
Preassembly Parts
2' (610 mm)
Bottom Foil
10—7' (2.13 m) Foils
Drill Adapter for
Manual Drive
Emergency
Crank Handle
Halyard Swivel
Unit 3H
Lower Unit
Unit 3H
Remote Switch w/Guard
(Order Separately)
4 MKIV Hydraulic Unit 3
Main Components
Description Part No. Qty
Lower Unit
2'(610 mm) Bottom foil
7'(2.13 m) Foil
Halyard Swivel
Emergency Crank Handle
Drill Adapter for Manual Drive
See Parts List
7413.33
7413.31
H-39392
7430
7431
1
1
10
1
1
1
Preassembly Parts
Connector Bushings
Foil Screws
Trim Cap
Plastic
Connector
Wedges
Trim Cap Screws
Feeder
Prefeeder
Bow Shackles
Bottom
Connectors
Connector
Other Components
Blue Loctite
Description Unit Part No. Qty Size
Connectors
Bottom Connector
Connector bushing set
Plastic connector wedge set
Foil screw set
Trim cap set
3E
Trim cap screw set
Prefeeder
Feeder with screw and tab
10 mm Bow shackle
Blue Loctite
®
Injector, 1 oz. 5200 Adhesive
MKIV Hydraulic Unit 3 5
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
833
HFG725
9 9.75" (248 mm)
1 14" (356mm)
1 —
1
1
—
—
1 —
1
—
1 —
1 —
3 10 mm
1
1
.017 oz.
1 oz.
Tools
Description Unit Qty
3, 4, 6, 10 mm Hex wrenches 3 1 Each
®
5200
Adhesive
Injector
3,4, 6, 10 mm
Preassembly Rigging Parts Check/Tools/Adhesive
Toggle Assembly
1. Harken toggle assembly or hydraulic cylinder required. Sold separately.
2. Mating turnbuckle components, with eye at lower end, must be purchased
separately. See page 10.
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.
Harken Toggle
WARNING! A stay that is old or damaged may break suddenly, causing an accident. Headstay condition should
Assembly Housing
(Sold Separately)
be checked by a professional rigger before reusing.
Hydraulic Hoses
Hoses are not supplied with furler. Use SAE 100 R1 or R2 hoses.
Size depends on the distance that hoses will run and the power
source. For shorter runs use two hoses: -6 (3/8" ID). Contact
Harken for further hose size recommendations.
Hose End Fittings
Use SAE straight thread O-ring male hose end fittings - 9/16-18.
Unit Part No.
3H
Hydraulic cylinder uses a -4JIC end fitting.
7413.25 3/4
7413.25 7/8
Hydraulic Length-
Adjusting Cylinder
(Sold Separately)
Unit Part No.
7413.26 3/4
3H
7413.26 7/8
ROD RIGGING
Harken Rod Adapter
Stud Required
(Sold Separately)
Unit Part No.
7426 -22
3H
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 wrenches (provided) 13. Scissors
4. Drill bit – 5/32" (4 mm) 9. Slotted/phillips screwdrivers 14. Metal straight edge
5. Hacksaw 10. Needle-nose pliers 15. Hammer
16. 6 mm Ball-end hex wrench (recommended but not required)
6 MKIV Hydraulic Unit 3
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 (22 C) with 50% humidity.
Do not apply at temperatures below 40 F
(5 C) and above 100F (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 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.
Hydraulic General Specifications/Valves/Operation Pressure/Oil
Furler Power Requirements
The furling unit and hydraulic tensioning cylinder will work with all current Harken
Unit
3 4 g/m 15 l/m
Recommended
Flow Rate
hydraulic power plants. They are designed to provide 4 g/m (15 l/min) at load.
70
60
50
40
30
Furling speed RPM
20
10
1 2 3 4 5 6 7 8
Flow GPM
3000
2500
2000
1500
1000
Furling torque M - LB
500
500 1000 1500 2000 2500
Pressure PSI
Maximum Operating Pressure
Set relief valve on power plant at 140 Bar or 2000 PSI. Harken power packs ship with valves set at 140 Bar.
Valves on Power Unit
Furler can be used with open or closed center, 4-way, 3-position control valves.
Gear Oil Specifications
Unit is sealed with a light bath of ISO 68 gear oil.
IMPORTANT! The only parts of furler to be disassembled by installer are the Torque Tube Clamp and Toggle
Housing. All other work should be performed by factory-authorized personnel. Work performed by unauthorized
personnel may void the Harken limited warranty.
Hose and Fitting Selection Recommendation
Required hose type - SAE 100 R2 or SAE 100 R8. Hose size is determined by flow and run length between power
unit and furler.
Measure hydraulic hose runs.
Remember these important points when measuring runs.
1) Short straight runs between HPU and function are best.
2) Avoid sharp edges which may chafe the hose.
3) Minimize fittings/connections throughout the run to avoid possible leak points.
4) Minimize 90° bends, which increase system losses and decrease performance. If unavoidable use a 90° swept
fitting, Do not use a 90° elbow fitting.
CAUTION! Do not exceed the manufacturer specified minimum bend radius.
When ordering, specify that all hoses are flushed, filled with clean oil and capped at point of purchase. HARKEN
recommends ISO 46 grade oil. If hoses are shipped, they may not contain oil.
CAUTION! Always ensure pressure rating for selected hose is equal to or greater than 2000psi/140 bar.
Note: Hose Shortening - Hydraulic hoses typically shorten 2% to 4% of total length when pressurized. When routing
and measuring hose lines ensure extra hose length is added to compensate for the hose shortening under pressure.
MKIV Hydraulic Unit 3 7
Hydraulic General Specifications/Valves/Operation Pressure/Oil
Hydraulic Connection to Furling Unit
Use Stainless Steel -6 ORB to -6 JIC Adapters.
Important: Do not use PTFE tape or sealant on threaded connections to Harken ports. Using PTFE tape can damage threads.
Hydraulic Oil
Use only hydraulic oil ISO 46 grade or equivalent.
CAUTION! Hydraulic oil may cause skin irritation.
Important: Hydraulic oil may damage paint and some surfaces.
Leak Check
To perform leak check, run furler in a single direction for 5 – 10 seconds. If installation was completed with empty
hoses, increase the run time to 10 – 30 seconds. Perform the following:
1) Confirm hose run is correct by verifying operation of intended function.
2) Inspect each fitting for leakage.
3) Tighten fitting as necessary.
4) Repeat procedure for all functions.
IMPORTANT: If installation was completed with empty hoses, check the oil level indicator after, and add oil as necessary.
One-Way Function Flush
Flush the pump motor through the power unit system filter by running furler in a single direction. Run in same
direction as previous step. This process helps ensure system cleanliness by depositing any contaminates into the
power unit system filter.
Hydraulic Length Adjusting Cylinder (Optional)
Specifications:
Stroke: Unit 3: 4" (100 mm)
CYLINDER PULL FORCE LBS
12000
10000
CYLINDER PULL FORCE KG
6000
5000
Performance:
4000
3000
2000
Cylinder pull in KG
1000
0
0
Hydraulic pressure in BAR
100
200
300
400
Pressure Requirements
8000
6000
4000
Cylinder pull in LBS
2000
0
0
Hydraulic pressure in LBS
600040002000
The hydraulic length adjusting cylinder requires a pressure of Max. 5,000 pounds (350 Bar) to develop rated pull
force on the headstay. The hydraulic pressure for the cylinder can be provided by a high pressure manual system or
the boats power unit. If the cylinder is used with a power unit providing less than 5,000 psi (350 Bar), a hydraulic
intensifier is required to step up the pressure. Either power source requires the use of a zero leak control valve so
the pressure to the cylinder doesn’t bleed down over time.
WARNING! Relieve all pressure prior to disconnecting. Only work on cylinder and connections
if you are a hydraulic technician.
Hydraulic Cylinder Hose Connection
The cylinder has a -4 JIC fitting. Choose appropriate hose and end fitting.
Cylinder Gas
Cylinder is shipped without gas. Fill fitting is a Schroeder type. For best clean performance use Nitrogen or Argon
gas pressurized to 50 - 65 lbs.
8 MKIV Hydraulic Unit 3
Preassembly Toggle Deductions/Stay Into Foil Options
Use dimensions of Harken toggles or cylinders shown below to build stay to correct length.
Toggle Assembly
Turnbuckles should be 1/2 to 2/3rds open to allow shortening for new wire stretch and for fine-tuning mast rake and
to help connect the stay.
Hydraulic Cylinder
Length for hydraulic cylinder can be determined at 1/2 to 2/3rds open to allow to allow shortening for new wire
stretch and for fine-tuning mast rake and to help connect the stay. Stroke length for unit 3 cylinder is 4" (100 mm).
Toggle
Part No.
7413.25 3/4
7413.25 7/8
Clevis Pin ØPin-to-Pin
3
/4" (19.1 mm) 31/4" (83 mm)
7
/8" (22.2 mm) 37/8" (98 mm)
Length
Hydraulic Cylinder
Part No.
7413.26 3/4
7413.26 7/8
Clevis Pin ØMax. Pin-to-Pin
3
/4" (19.1 mm) 20" (50 mm) 16" (400 mm)
7
/8" (22.2 mm) 201/2" (525 mm) 161/2" (420 mm)
Length
Min. Pin-to-Pin
Length
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 failure. Make
sure there is a mechanical lock.
MKIV Hydraulic Unit 3 9
Preassembly Top Foil Length
Measure A and add to this chart
and length chart below
Inches mm
A
B 1 25
E 24 610
F 23.18 589
G
Total A+B+E+F+G
UNIT 3H
Make sure upper
measurement points
of A and Pin-to-Pin
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” = 19,202 mm
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
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.
Alternate
Measurement
Point
–
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
–
A
B
A
C
Pin
to
Pin
D
Pin
to
Pin
E
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" (2133.6 mm)
E Bottom Foil 24.00 610
F Bottom of Foil to Top of Toggle Housing Insulator 23.18 589
G Top of Toggle Housing Insulator to Clevis Pin
1.00
Pin-to-Pin Length
G Toggle Distance from Lower Clevis Pin to Top of Toggle Housing Insulator
Toggle
Part No.
7413.25 3/4 Toggle Assembly
7313.25 7/8 Toggle Assembly
7413.26 3/4 Hydraulic Cylinder/Toggle
7313.26 7/8 Hydraulic Cylinder/Toggle
*Dimensions with cylinder 58% open
Cylinder Pin
Ø
3/4 17.00 432 21.00 533
7/8 17.67 449 21.67 550
10 MKIV Hydraulic Unit 3
G Distance (Closed) G Distance (Open)
Type
in mm in mm
Clevis Pin G Distance
in mm in mm
3
/4 19.1 4.39 112
7
/8 22.2 4.98 126
3
/4 19.1 19.32* 491*
7
/8 22.2 19.99* 508*
25
F
G
G
Preassembly Short Top Foil
If top foil is shorter than 9
3
/4" (248 mm), use one of the following special techniques to ensure sufficient bearing
surface for the foil in the area of the halyard swivel.
/4" (248 mm)
3
9
93/4" (248 mm) No special treatment required.
/8" (244 – 181 mm)
1
Cut-Offs
/8" – 7
5
9
Do Not Use
95/8" – 71/8" (244 – 181 mm) Do not use plastic
bushing above top connector.
/2" (89 mm)
/2" (64 mm)
2
/2" (38 mm)
1
2" (51 mm)
1
1
1
3" (76 mm)
3
Cut-Offs
Do Not Use
31/2" – 11/2" (89 – 38 mm) Shorten top foil and adjoining
full length foil so two screws are used to assemble joint
instead of four. Do not use plastic bushings above top
connector.
Top Foil
Length from
Worksheet
1
3
/2"
(89 mm)
3"
(76 mm)
1
/2"
2
(64 mm)
2"
(51 mm)
1
/2"
1
(38 mm)
1. Initial
top foil
cut length
69/16"
(167 mm)
6
(154 mm)
69/16"
(167 mm)
5
(129 mm)
49/16"
(116 mm)
1
1
/16"
/16"
2. Cut through
middle hole in
top foil.*
Resulting Top
Foil Length Length
5"
(127 mm)
41/2"
(114 mm)
4"
(102 mm)
31/2"
(89 mm)
3"
(76 mm)
3. Shorten
full length
adjoining
foil by
cutting
through
middle
hole.*
4. Shorten
connector
(124 mm)
(124 mm)
(124 mm)
(111 mm)
(95 mm)
47/8"
47/8"
47/8"
43/8"
33/4"
5. Shorten
trim cap
No
No
No
Yes
Yes
/2" (178 – 140 mm)
1
7" – 5
Cut-Offs
Do Not Use
Cut-Off
Do Not Use
7" – 51/2" (178 – 140 mm) Do not use plastic bushing
above top connector. Shorten top of connector and if
necessary shorten trim cap.
*To allow for saw cut, position blade so upper half of
middle hole is preserved.
/2" (38 mm)
Cut-Offs – Do Not Use
/8" – 4" (137 – 102 mm)
3
5
53/8" – 4" (137 – 102 mm) Do not use plastic bushing
1
Under 1
above top connector. Cut connector right at cross formed
by glue dispersion channels. Use single foil screw in top
foil only.
MKIV Hydraulic Unit 3 11
Under 11/2" (38 mm) Eliminate top foil and run foil
higher in foil clamp.
Preassembly Check 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. 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.
Line up lower unit so base of unit lines up with toggle housing.
Attach one link plate to lower unit. Line up lower unit so link plate hole lines up with crosspin 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 1" (25 mm) below
terminal. If wire fitting at top of stay is
swage, foil must ride just below shoulder
of swage. Mark cut line on foil. Wrap tape
around foil as a guide so cut is straight.
12 MKIV Hydraulic Unit 3
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