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.

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

Online Product Registration

www.harken.com/FurlingWarranty

See page 39 for all toggle dimensions.

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

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

/4" 19.1 mm

/8" 22.2 mm

/4" 19.1 mm

/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

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

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 —

3 10 mm

.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.

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

7413.26 7/8

ROD RIGGING

Harken Rod Adapter

Stud Required

(Sold Separately)

Unit Part No.

7426 -22

7427 -30

Tools You Will Need

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

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.

Furling speed RPM

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

Hydraulic pressure in BAR

100

200

300

400

Pressure Requirements

8000

6000

4000

Cylinder pull in LBS

2000

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

/4" (19.1 mm) 31/4" (83 mm)

/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

/4" (19.1 mm) 20" (50 mm) 16" (400 mm)

/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

B 1 25

E 24 610

F 23.18 589

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

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

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

–

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

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

/4 19.1 4.39 112

/8 22.2 4.98 126

/4 19.1 19.32* 491*

/8 22.2 19.99* 508*

Preassembly Short Top Foil

If top foil is shorter than 9

/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)

93/4" (248 mm) No special treatment required.

/8" (244 – 181 mm)

Cut-Offs

/8" – 7

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)

2" (51 mm)

3" (76 mm)

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

/2"

(89 mm)

(76 mm)

/2"

(64 mm)

(51 mm)

/2"

(38 mm)

1. Initial top foil cut length

69/16"

(167 mm)

(154 mm)

69/16"

(167 mm)

(129 mm)

49/16"

(116 mm)

/16"

2. Cut through middle hole in top foil.*

Resulting Top

Foil Length Length

(127 mm)

41/2"

(114 mm)

(102 mm)

31/2"

(89 mm)

(76 mm)

3. Shorten full length adjoining foil by cutting through middle hole.*

4. Shorten connector

(124 mm)

(111 mm)

(95 mm)

47/8"

43/8"

33/4"

5. Shorten trim cap

Yes

/2" (178 – 140 mm)

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)

53/8" – 4" (137 – 102 mm) Do not use plastic bushing

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

+ 28 hidden pages