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
Assembly Top Foil
Cut foil to length using hacksaw.
Deburr inside edge using rat-tail file.
Prepare top foil for drilling.
Tip: Mark top foil to distinguish
from cutoff piece.
Scribe line on top of foil to mark drill
holes. Lay top foil alongside cutoff
piece and use a flat metal object
(i.e. metal ruler) to scribe top
line of foil.
MKIV Hydraulic Unit 3 13
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
3
they are 3/8" (10 mm) and 1
from top of foil.
Drill two (2) 5/32" (4 mm) holes for
trim cap.
/8" (35 mm)
!
Foil
3
Top
/8" (10 mm)
13/8" (35 mm)
Lay top foil in line with others. Slide stay
into top foil and down line of foils or slide
each foil up stay.
14 MKIV Hydraulic Unit 3
Assembly Top Foil
Install trim cap. Place each side over wire.
Push trim cap into foil to start, then tap
in using hammer.
Install trim cap screws.
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.
MKIV Hydraulic Unit 3 15
Assembly Top Foil/Connectors
Slip connector on wire, mating hook
of plastic bushing with connector.
Loading Injector with Adhesive
Tip: In cooler weather, keep sealed
adhesive in pocket to keep 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 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.
Adhesive in
lower half
16 MKIV Hydraulic Unit 3
Assembly Foils/Connectors
Start plunger into injector and immediately
hold upright so plunger is down and
applicator tip is up.
As sealant runs down towards plunger an
air pocket will form near tip. Push plunger
to evacuate air. You are now ready to begin
injecting adhesive.
Put a drop of adhesive into screw holes.
Hold plastic wedge in place with thumb
as you insert into foil. Line foil holes
with connector screw holes.
MKIV Hydraulic Unit 3 17
Assembly Foils/Connectors
Inject only a small amount of adhesive
into middle hole.
Unit Adhesive
3
1 to 1
1
/4 ml
Tip: When you see a small amount
of adhesive enter one screw
hole, stop. You have applied
enough adhesive.
Stop when you see a small
amount of adhesive enter
one screw hole.
Use “ml”
marks to
estimate 1
1
/4ml of
to 1
adhesive
Tighten screws into connector holes. Make
sure a drop of adhesive entered each screw
hole. If not, apply to screw.
Use bushings, connector, wedge and
adhesive in other screw hole and insert
1
into other foil. Use 1 to 1
18 MKIV Hydraulic Unit 3
/4 ml of adhesive.
Assembly Bottom Foil/Connectors/Halyard Swivel
Continue installing connectors and wedges.
Make sure to use adhesive in screw holes.
Continue assembly. Use 14" (356 mm)
bottom connector to assemble bottom foil.
Slide halyard swivel onto foil above feeder
window. Make sure taller “half” is up as
shown.
MKIV Hydraulic Unit 3 19
Assembly Lower Unit to Foil
Loosen foil clamp screws at top of
lower unit assembly.
Slide assembly onto foils.
Tip: Face clamp downward so it
clears foil notches during installation.
20 MKIV Hydraulic Unit 3
Assembly Rod Rigging: Rod Adapter Stud
Apply a few drops of red
®
Loctite
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.
to threads of nosepiece.
Insert two cotter pins and
®
spread. Clean excess Loctite
from terminal body using
special care to ensure that
there is no red Loctite
threaded stud.
®
on
ROD RIGGING
MKIV Hydraulic Unit 3 21
Assembly Attach Turnbuckle/Toggle
Assemble turnbuckle. Slip toggle housing
insulator onto threaded eye. Remove toggle
plate. Use crosspin to capture eye and
tottle in toggle housing.
®
Note: If using Sta-Lok
or Norseman®
stud, you must use a washer above
stud as shown below.
Make sure shallow jaw is up.
Up
Down
Install cover plate using blue Loctite®
on screws.
If stay length is set use side cutters or
needle-nose pliers to bend cotter pin
to secure turnbuckle.
22 MKIV Hydraulic Unit 3
Assembly Attach Toggle
Choose toggle orientation to match
chainplate—fore/aft or athwartships.
Line up insulator and secure toggle
assembly to lower unit using
®
blue Loctite
on screws.
Attach Hydraulic Cylinder
Slip toggle housing insulator onto eye terminal. Remove toggle plate. Use crosspin
to capture eye and toggle in housing.
Install cover plate using blue Loctite
®
on
screws.
MKIV Hydraulic Unit 3 23
Assembly Attach Hydraulic Cylinder
Position cylinder to match chainplate direction.
Chainplate Runs Fore/Aft: Position the
guide rod so it is to the port side.
Hydraulic connections will be on the aft
side. Line up insulator and secure cylinder
®
assembly to lower unit using blue Loctite
on screws.
Chainplate Runs Athwartships: Position
the calibrated guide rod so it is aft.
Hydraulic connections will be on the
starboard side.
Chainplate Fore/Aft Orientation
Chainplate Athwartships
Orientation
24 MKIV Hydraulic Unit 3
Assembly Feeder/Final
Check foil height at top, set and secure
using hex wrench.
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.
MKIV Hydraulic Unit 3 25
Commissioning 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 foil clamp screws until you can pull clamp
out to lower foils.
Lower foils.
Remove six toggle housing screws. Use halyards to securely lift
and hold foils and lower unit.
WARNING! Foils are heavy and can drop suddenly
on fingers. Only do this work at the dock, not
underway.
Adjust turnbuckle.
Replace used cotter pins and locknuts. Lower unit and install
clevis pin and new cotter pin.
Lift foils so top is 1" (25 mm) below upper terminal.
Raise lower unit and use
halyard to lift and hold it
about 5' (1.5 m). Raise foils
using second halyard and
secure. Allow room above
for turnbuckle take up.
26 MKIV Hydraulic Unit 3
Commissioning Halyard: Swivel Height/Lead Angle
Halyard Wrap
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.
To prevent wraps, the halyard must exert a slight pull to the rear.
This allows the foils to turn while halyard remains stationary.
Prevent Halyard Wraps
WARNING! Sail must be fitted to foil length before using
to prevent headstay loss which will cause an accident.
1. Halyard swivel should be within top 4 - 6" (100 - 152mm) 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.
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 will unfurl, lower
it by releasing jib halyard. Severe halyard wraps can only be cleared
by going aloft and freeing halyard.
8 - 10°
If sail will not furl or unfurl, try to remove jib sheets and manually
wrap sail around headstay.
Testing at dock does not indicate halyard angle is correct. In wave
action, halyard may wrap if lead angle is not correct. The 8-10°
diverging angle shown at right is critical.
Pendants
If the your sail luff is not long enough to position halyard swivel properly,
you must add a pendant. Pendants should be made of plastic-coated wire
and be permanently attached so sail height will be correct. Adjustablelength 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 lower unit.
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.
MKIV Hydraulic Unit 3 27
Commissioning Halyard: Restrainer/Tension
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.
On some boats halyard sheaves are located too close to headstay and
a halyard restrainer must be used.
Halyard restrainers should be used only when required by masthead
geometry. Restrainers tend to limit sail luff length and may cause
problems if not installed properly.
If your boat needs a halyard restrainer, use Harken Part No. 945 or 1988.
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 may
experience difficulty in tensioning sail luff, friction when furling, and
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.
28 MKIV Hydraulic Unit 3
Operation Halyard: Headstay Tension
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 all halyards
are clear of furling unit action.
On many boats it will not be 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 may 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 follow
instructions on page 27.
Tip: Before adjusting headstay tension, slack
mainsheet and vang.
Using Hydraulic Length Adjuster
Use reference lines on guide rod to help repeat settings. Make sure mainsheet
and vang are eased. Use Adjuster to set length especially when using two furlers
to make sure the desired furler is tensioned when the backstay is tensioned.
Backstay Adjusters
Backstay adjusters allow headstay tension to be varied to change sail shape 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
mechanical adjuster like those offered by Harken, or a hydraulic adjuster.
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 may be necessary to shorten foil slightly.
MKIV Hydraulic Unit 3 29
Operation Raise Sail/Storm Sail/Reefing
Raise Sails
1. Install prefeeder by securely tying end of line to a deck fitting or to toggle below
furler so it is 2' (610 mm) below feeder.
2. Shackle tack of sail to lower unit. 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. Attach genoa tack to Lower Unit shackle.
8. Once sail is raised, determine the direction of furling so suncover will shield sail
from UV rays when furled.
9. Suncover on port side of sail, furl clock-wise. Suncover on starboard, furl
counter-clockwise.
Tip: Once you have determined the direction of furl to match the suncover, mark
remote furler switches, i.e. “furl/unfurl” or “in /out”.
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 may 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 28.
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 jib sheets and press correct
switch to furl sail.
In very light air, it may be necessary to place
some tension on jib sheet to insure a tight furl.
To furl in a breeze, ease sheets gradually and furl
sail in smaller increments until sail is furled or
reefed.
When furling or reefing, make sure that nothing
is jammed. Review swivel height, lead angle, halyard restrainer information. Make sure operator has a good view of sail
and stops furling when sail is rolled and sheets have a wrap or two on the furled sail. Stop immediately if sheets jam or
halyard wraps. If operator does not have a good view, station a crew member with good visibility and communicate to
operator. If motor is laboring stop and check for reason. Consult the Troubleshooting Guide on page 35.
WARNING! A hydraulic furling system is very powerful and jammed parts can break suddenly at high
load. Stop furling immediately and correct problem.
30 MKIV Hydraulic Unit 3
Operation Manual Operation
Before using the system, practice manual operation in case there is a loss of power. Make sure that the emergency
handle can rotate and not hit the bow pulpit.
Cordless drill adapters work well, but there must be a fully-charged cordless drill on hand at all times. Because
a cordless drill may lose power, always have an emergency handle onboard in a secure, easy-to-find location.
Communicate location as part of safety equipment orientation for all crewmembers.
WARNING! You must have a reliable manual
drive procedure in place before using the
system.
Drill Adapter for
Manual Drive
Emergency
Handle
WARNING! You must observe all personal safety
precautions including using a harness and
secure tether and personal flotation device
(PFD) when going forward.
1. Communicate to all crewmembers that you are going
to manually rotate the furler. Practice this emergency
procedure in controlled conditions so you and your
crew are prepared in the event of a power failure.
Explain procedure for controlling the boat and have
someone ease sheets as you rotate the handle.
2. Have an emergency handle available.
3. Using all personal safety precautions including PFD,
harness and tether, go forward.
4. Position shift lever on right side as shown in photo.
5. Use the emergency handle or a cordless drill to turn
the foil until the sail is reefed or furled.
Furling or Reefing with Manual Power
In the event of power failure it is necessary to go
forward and lower sail or furl by hand.
MKIV Hydraulic Unit 3 31
Operation Reefing Tips/Secure Sail/Race Conversion
Reefing Tips
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 that 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 boat and to reduce
heeling moment. Sails may also be reefed to improve
visibility or to slow boat while sailing in congested
areas or entering or leaving harbors.
Secure Sail
When furling prior to leaving your boat in slip or on
mooring, be sure that you get a tight furl and continue
furling system until sheets wrap around rolled sail two
or three times. Some people secure sail with shock
cord or sail ties.
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, 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 lower unit. Replace feeder.
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!
32 MKIV Hydraulic Unit 3
Maintenance Clean and Lubricate/Inspect/Storage
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.
Foils may be cleaned by washing with soap and water.
A scrap of luff tape may be run up foil to scrub inside
®
grooves. Sail luff tapes may be sprayed with McLube
to reduce friction during sail changes.
®
Spray sails off boat so Mclube
spray does not contact deck.
WARNING! Decks sprayed with McLube® will
be very slippery which can lead to slipping and
falling overboard. Spray sails off boat so
®
Mclube
spray does not contact deck.
WARNING! Worn, damaged or corroded parts may
break suddenly. Periodically inspect items listed
below and any others as necessary.
Inspect
Inspect unit for signs of chafe, wear or damage.
Inspect clevis and cotter pins below and inside lower unit 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 lower unit.
Periodically inspect wire for signs of wear or unraveling.
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 lower unit extending beyond mast. Remove lower unit and halyard swivel for
storage and transport.
After Storage or Transport
After storing or transporting unit, clean thoroughly including tack and halyard swivel 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.
MKIV Hydraulic Unit 3 33
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.
Loctite® is a registered trademark of Henkel AG & Company KGaA
™
is a registered trademark of McGee Industries, Inc.
McLube
®
is a registered trademark of Sta-Lok Terminals, Ltd.
Sta-Lok
®
is a registered trademark of Ultra Safety Systems, Inc.
Tef-Gel
™
is a registered trademark of Minnesota Mining and Manufacturing Company AkA 3M CORPORATION
3M
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 with freshwater and lubricate with dry spray lubricant such as McLube
Sail full of wind. Luff completely before furling or reefing.
Sail flogging too much. Release a short length of sheet, furl a small amount and repeat.
Foil out of clamp. Reinstall foil in lower unit and tighten clamp screws.
Halyard swivel installed upside down. Remount swivel correctly.
Jib halyard is wrapping around headstay because
angle between mast and halyard is too shallow.
Jib halyard is wrapping 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 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 with freshwater and lubricate with dry spray lubricant such as McLube
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. Keep some tension on sheets when furling in light air to get a tight, secure wrap.
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. Attach a halyard and downhaul to a small section of luff tape and clean groove by raising
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.
Wrong switch used to furl sail. Unroll sail and use other switch to furl. Alternatively, rewire switch if preferred. Once
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.
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.
Check luff tape size.
and lowering.
Halyard must be routed from a point higher on mast. This may require that halyard turning
block aloft be replaced or sail shortened.
instructions.
correct one is determined, label switch "furl" and the other "Unfurl."
®
®
Online Product Registration
www.harken.com/FurlingWarranty
34 MKIV Hydraulic Unit 3
Warranty
www.harken.com/manuals
or call, write, email or fax Harken, Inc.,
Pewaukee, WI USA
Hydraulic Unit 3H Parts List
No. Description Order Part No.
Torque Tube Foil Clamp 1 H-42967
Torque Tube Screws M8 X 125 mm SHCS 4 HFS1107
1
H-42967
HFS1107
1
1
2
3
Red Ring 1 H-51510
Lower Unit 1 7413.15BASE
1 Smalley Ring 1 H-51494
2 Tack Swivel Top Washer 1 H-51493
1
3
/2" Torlon Ball 23 HBB21
4 Tack Swivel Body 1 H-51491
1
5
/2" Delrin Ball 23 HBB22
6 Tack Swivel Lower Washer 1 H-51492
4
5
6
7413.15BASE
H-51510
1
2
4
5
MKIV Hydraulic Unit 3 35
3
No. Description Order Part No.
2
2
6
7
8
9
1
Toggle Assembly Hydr
1 Toggle Plate Screws M5 X 16 mm SHCS 8 HFS982
2
2 Toggle Plate 2 H-51477
3 Toggle Housing Insulator 1 H-51475
4 Cross Pin
5 Toggle Housing
6 Toggle Housing Screws M8 X 70 mm SHCS 6 HFS1064
7 Cotter Pin
8 Clevis Pin
9 Jaw Jaw Toggle
Toggle Assembly Hydr 7/8" 1 7413.25 7/8
1 Toggle Plate Screws M5 X 16 mm SHCS 8 HFS982
2 Toggle Plate 2 H-51477
3 Toggle Housing Insulator 1 H-51475
4 Cross Pin
5 Toggle Housing
6 Toggle Housing Screws M8 X 70 mm SHCS 6 HFS1064
7 Cotter Pin
8 Clevis Pin
9 Jaw Jaw Toggle
3
/4" 1 7413.25 3/4
3
/4" 1 H-52246
3
/4" 1 H-52245
5
/32" X 1.25" 1 HFS203
3
/4" x 1.76" Grip Length 1 H-42403
3
/4" 1 H-41489
7
/8" 1 H-51476
7
/8" 1 H-51474
5
/32" X 1.25" 1 HFS203
7
/8" x 1.96" Grip Length 1 H-42404
7
/8" 1 H-41489
Hydraulic Unit 3H Parts List
No. Description Order Part No.
3
1
2
3
4
4
3
5
Hydraulic Cylinder—3/4" Pin 1 7413.26 3/4
3
1 Toggle Housing Insulator 1 H-51475
2 Cross Pin
3 Toggle Plate 2 H-51477
4 Toggle Plate Screws M5 X 16 mm SHCS 8 HFS982
5 Toggle Housing Screws M8 X 70 mm SHCS 6 HFS1064
6 Clevis Pin
7 Jaw Jaw Toggle
8 Cotter Pin
Hydraulic Cylinder—
1 Toggle Housing Insulator 1 H-51475
2 Cross Pin
3 Toggle Plate 2 H-51477
4 Toggle Plate Screws M5 X 16 mm SHCS 8 HFS982
5 Toggle Housing Screws M8 X 70 mm SHCS 6 HFS1064
6 Clevis Pin
7 Jaw Jaw Toggle
8 Cotter Pin
3
/4" 1 H-52246
3
/4" x 1.76" Grip Length 2 H-42403
3
/4" 1 H-41489
5
/32" X 1.25" 1 HFS203
7
/8" Pin 1 7413.26 7/8
7
/8" 1 H-51476
7
/8" x 1.96" Grip Length 2 H-42404
7
/8" 1 H-41489
5
/32" X 1.25" 1 HFS203
7413.26 3/4
7413.26 7/8
6
7
8
9
2
3
7426 -22
7427 -30
4
1
36 MKIV Hydraulic Unit 3
No. Description Order Part No.
Rod Adapter Stud w/Nosepiece -22 Rod 1 7426 -22
4
1 Stud (Main Body) 1 H-41812
2 Nosepiece -22 1 H-41811
3 Cotter Pin
Stud Cap
Rod Adapter Stud w/Nosepiece -30 Rod 1 7427 -30
1 Stud (Main Body) 1 H-41814
2 Nosepiece -30 1 H-41813
3 Cotter Pin
Stud Cap
3
/32" x 1.750" 2 HFG319
7
/8" ID 1 HFG303
3
/32" x 1.750" 2 HFG319
7
/8" ID 1 HFG303
Hydraulic Unit 3H Parts List
PLEASE SAVE THESE INSTRUCTIONS
HFG672
7413FOILSET
H-39916
HBB21
HBB21
HBB21
H-39916
HFG349
HFG682
H-39392
7413.30
7413.31F
H-42073
H-42074
5
Description Order Part No.
Trim Cap Set w/o Screws 1 HFG682
5
Trim Cap Screw Set 1 HFG672
Trim Cap Screw 2 HFS1127
Halyard Swivel 1 H-39392
Clip/Smally Ring for Balls 2 H-39916
Torlon Ball Bearings 88 HBB21
Foil Set 1 7413FOILSET
Foil (7'/2.13 m Luff) 10 7413.31
Foil (2'/610 mm) Bottom 1 7413.33
Foil Screw Set 1 HFG349
Foil Screw 46 HFS1106
Connector Set 1 HFG627
Connector 9 7413.31F
Bottom Connector (9
3
/4"/247 mm) 1 7413.32F
Connector Bushing Set 1 HFG297
Connector Bushing Top (Curved/Longer) 20 H-42073
Connector Bushing Bottom (Flat/Shorter) 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
7413.32F
HFG349
H-39756
HFG324
7413.33
Description Order Part No.
HFG627
MKIV HYDRAULIC JIB REEFING & FURLING
Unit 3
Installation Manual – Intended for specialized personnel or expert users
4379 12/13
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
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.
for additional safety information.
This manual may be modified without notice. See: www.harken.com/manuals for updated versions.
4379
833
945
2124
M10
HFG722
6
7
M6
M4
HFG947
M3
HFG200/HFG201
MKIV Hydraulic Unit 3 37
Instruction Manual 1 4379
6
Blue Loctite
®
1 833
5200 Adhesive Set 1 HFG725
5200 Marine Adhesive Sealant 1 HFG722
Injector 1
Prefeeder 1 947
Description Order Part No.
Halyard Restrainer (Optional) 1 945
7
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
Shackle 3 2124
Hex Wrenches
M10 1 HFG647
M6 1 HFG644
M4 1 HFG640
M3 1 HCP1089
HFG200
HFG201
Hydraulic Unit 3H Toggle Dimensions
A
B
Unit Part No.
3
7413.25
3H
C
D
7413.25 7/
/
4
8
Unit Part No.
7413.26
3H
7413.26 7/
GE
F
H
Toggle Dimensions*
A B C D E F G H
in mm in mm in mm in mm in mm in mm in mm in mm
7413.25 3/
2.08 52.83 1.739 44.17 1.024 26.01 0.744 18.90 0.814 20.68 1.746 44.35 0.468 11.89 2 50.8
7413.25 7/8, 7413.26 7/
2.662 67.61 2 50.80 1.156 29.36 0.868 22.05 0.94 23.88 1.938 49.23 0.499 12.67 2.312 58.72
*Toggle dimensions apply to standard toggle and cylinder option except A does not apply to cylinder
4,
7413.26 3/4*
8
3
/
4
8
38 MKIV Hydraulic Unit 3
Preassembly Dimensions/Sailmaker's Instructions
Luff Length
Note offsets above and below sail.
A shorter luff may be required if a halyard restrainer is used or an
C
additional toggle assembly is used to raise unit.
If luff of sail is not long enough to put halyard swivel near top of
headstay foil, a pendant must be added. See page 28.
B
Tack Setback
A
Note setback for tack shackle and cut sail accordingly.
Luff Tape Size
6
Unit 3H requires #6 (
/32" or 5 mm) luff tape.
Luff Tape Length
Cut off top of luff tape so it is 18 to 24" (450 to 600 mm) below head
of sail. This allows head to lag behind rest of sail to help flatten sail.
It will also help head to roll more smoothly.
Note feeder height and extend bottom of luff tape downward so it is
below feeder. This will prevent luff tape from catching in feeder as
sail is lowered.
Tack and Head Shackles
Make sure tack and head shackles fit sail
rings. Minimum inside dimensions of
A
standard head and tack shackles are:
7
/8" (48 mm)
D
E
F
(A) 1
13
/16" (21 mm)
(B)
Sun Cover
B
Sun covers may be installed on either side of sail. Be
sure to match other sails in the customer's inventory.
G
H
I
J
K
See page 39
for all toggle
dimensions
MKIV Hydraulic Unit 3 39
J
I
Toggle/Pin
Ø
7413.25 ¾ Std
7413.25 7/8 Std
7413.26 ¾ Cylinder
7413.26 7/8 Cylinder
Toggle/Pin
Ø
7413.25 ¾ Std 32
7413.25 7/8 Std 32
7413.26 ¾ Cylinder 49 1245 45 1142 34
7413.26 7/8 Cylinder 49
7413.25 7/8 Std
7413.26 ¾ Cylinder
7413.26 7/8 Cylinder
*Height of threaded hydraulic ports
A B C D E Max E Min
in mm in mm in mm in mm in mm in mm
5
7
/16186 115/8296 18 457
5
7
/16186 115/8296 18 457
5
7
/16186 115/8296 18 457
5
7
/16186 115/8296 18 457
F Max F Min G Max G Min
in mm in mm in mm in mm in mm in mm
5
/16821 — — 18 446 — —
7
/8836 — — 189/16472 — —
5
/81260 455/81159 351/4895 311/4794
Toggle/Pin
Ø
7413.25 ¾ Std
I Max* I Min* J Max J Min K
in mm in mm in mm in mm in mm
5
/8118
4
3
/16132
5
1
/4 540 171/4438 117/16291 77/16 189 81/4209
21
7
/8556 177/8455 121/16306 81/16205 81/4209
21
7
/898 47 1194 — —
3
7
/898 479/161209 — —
3
7
/898 635/81616 595/81515
3
7
/898 641/41632 601/41530
3
5
/8879 305/8778
— —
— —
2 51
29/1665
H Max H Min
1
/8409
16
11
/16424
16
3
/4832 283/4730
32
3
/8848 293/8747
33
— —
— —
81/4209
81/4209
— —
— —
N15W24983 Bluemound Rd, Pewaukee, WI 53072 USA
01
Web: www.harken.com • Email: harken@harken.com
1B Green Street, Brookvale, N.S.W. 2100, Australia
Telephone: (61) 2-8978-8666 • Fax: (61) 2-8978-8667
ZA Port des Minimes, BP 3064, 17032 La Rochelle Cedex 1, France
Telephone: (33) 05.46.44.51.20 • Fax: (33) 05.46.44.25.70
Via Marco Biagi, 14, 22070 Limido Comasco (CO) Italy
Telephone: (39) 031.3523511 • Fax: (39) 031.3520031
158 Beaumont Street, Westhaven, P.O. Box 90689, Victoria St. West, Auckland 1142, New Zealand
Telephone: (64) 9-303-3744 • Fax: (64) 9-307-7987
ul. Rydygiera 8, budynek 3A, lokal 101, I pi
Main Office and Harken Brandstore: Västmannagatan 81B
Telephone: (46) 0303 61875 • Fax: (46) 0303 61876
Mailing address: Harken Sweden AB, Box 64, SE -440 30 Marstrand
Bearing House, Ampress Lane, Lymington, Hampshire S041 8LW, England
Telephone: (44) 01590-689122 • Fax: (44) 01590-610274
Web: harken.co.uk • Email: enquiries@harken.co.uk
Corporate Headquarters
Telephone: (262) 691-3320 • Fax: (262) 701-5780
Harken Australia Pty, Ltd.
Web: harken.com.au • Email: info@harken.com.au
Harken France
Web: harken.fr • Email: info@harken.fr
Harken Italy S.p.A.
Web: harken.it • Email: info@harken.it
Harken New Zealand, Ltd.
Web: harken.co.nz • Email: harken@harken.co.nz
Harken Polska SP ZOO
Tel: +48 22 561 93 93 • Fax: +48 22 839 22 75
Web: harken.pl • Email: polska@harken.pl
Harken Sweden AB
SE-113 26 Stockholm Sweden
Web: harken.se • Email: harken@harken.se
Harken UK, Ltd.
ętro, 01-793 Warszawa, Poland
Please visit: http://www.harken.com/locator.aspx
to locate Harken dealers and distributors
97653 21428
Printed in USA 4379 12/13
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