Installation Manual – Intended for specialized personnel or expert users
4389 02/14
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
Page 2
Introduction – Who Should Use This Manual?
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. 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 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 are not covered
by the limited warranty.
Safety Definitions
The following alert symbols and signal words are used in this manual. The message following the alert will tell
you how to reduce the chance of injury or damage.
WARNING! This indication alerts you to potential hazards that may kill or seriously injure you and
others if you don't follow instructions.
CAUTION! This indication alerts you to potential hazards that may hurt you and others if you do not
follow instructions.
NOTICE! This indicates potential damage to product if you don't follow instructions.
WARNING! Strictly follow all instructions to avoid an accident, damage to your vessel, personal injury,
or death. See www.harken.com/manuals for additional safety information.
WARNING! Using hydraulic furling demands a few important precautions:
• Do not use if you are not sufficiently trained and experienced in sailing generally and in the use of
equipment in particular.
• Before using make sure that all people and objects are clear of the moving components of the system.
2 MKIV Hydraulic Unit 5
Page 3
Table of Contents Parts Descriptions
Preassembly
Parts Descriptions/Size Check 3 - 4
Parts 5 - 6
Rigging Parts Check/Tools/Adhesive 7
Hydraulic System 8 - 9
Toggle Deductions/Stay Into Foil Options 10
Top Foil Length 11
Short Top Foil 12
Foil Length 13
Toggle Dimensions 32
Dimensions/Sailmaker Instructions 33
Parts List 34
13
11
10
10
11
8
7
5
6
3
2
1
1
4
9
3
Parts Descriptions
1) Jaw/Jaw Toggle
2) Toggle Housing
3) Toggle Housing Insulator
4) Hydraulic Cylinder
MKIV Hydraulic Unit 5 3
5) Lower Unit
6) Lashing Guides
7) Foil Clamp
8) 2.5' (762 mm) Bottom Foil
9) Feeder
10) Connector Bushing
11) Bottom Connector
12) 9' (2.74 m) Foil
13) Connector Screws
14) Connector
15) Foil Screws
16) Halyard Swivel
17) Trim Cap
18) Trim Cap Screws
Page 4
Preassembly Size Check
18
12
Online Product Registration
www.harken.com/FurlingWarranty
15
16
A
B
C
D
F
See page 32 for all
toggle dimensions.
GE
17
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! Harken does not recommend drilling boat's chainplate or toggle as this may result
in rig failure.
3. If rod rigging is used check foil inside dimensions to make sure rod splices fit inside foils.
4. Will lower unit fit on bow? See page 32. If necessary, use an additional toggle to slightly raise unit.
Unit Part No.DescriptionRod ØWire Ø
7415.15SMKIV Hydraulic Unit 5 (Small Bushings)
7415.15LMKIV Hydraulic Unit 5 (Large Bushings)
Toggle Part No.DescriptionToggle Clevis Ø
7415.25 1
7415.25 1
UNIT 5
7415.26 1
7415.26 1
‡Continuous rod only. If rod is sectional, order Unit 6
4 MKIV Hydraulic Unit 5
1
/8
Toggle Assembly11/8"28.6 mm
1
/4
Toggle Assembly11/4"31.8 mm
1
/8
Hydraulic Cylinder/Toggle11/8"28.6 mm
1
/4
Hydraulic Cylinder/Toggle11/4"31.8 mm
-48, -60, -76‡ (14.3, 16.8, 17.9 mm
—
5
/8" (16 mm)
3
/4", 7/8" (19, 22 mm)
Page 5
Preassembly Parts
2.5'
(762 mm)
9 – 9' (2.74 m) Foils
Bottom Foil
Drill Adapter for
Manual Drive
Halyard Swivel
Lower Unit
Emergency
Crank Handle
Red Loctite
®
Main Components
DescriptionPart No.Qty
Lower Unit
2.5'(762 mm) Bottom Foil
9'(2.74 m) Foil
Halyard Swivel
Emergency Crank Handle
Drill Adapter for Manual Drive
Red Loctite
*Standard Package
MKIV Hydraulic Unit 5 5
®
See Parts List
7415.33
7415.31
H-56965
7430
7431
HFG739
1
1
9*
1
1
1
3
Page 6
Preassembly Parts
Connector Bushing Set
Bottom
Connector
Connectors
Other Components
DescriptionPart No.Qty
SMALL BORE
Connector Bushing Set/Sm (38)HFG9621
Trim Cap Half A/SmH-566171
Trim Cap Half B/SmH-566181
Extra Connector Set/Sm7415.31S1
LARGE BORE
Connector Bushing Set/Lg (38)HFG9631
Trim Cap Half A/LgH-566191
Trim Cap Half B/LgH-566201
Extra Connector Set/Lg7415.31L1
ALL UNITS
Connector 15.5" (398 mm) Bottom A SideH-566061
Connector 15.5" (398 mm) Bottom B SideH-566071
Connector 12" (305 mm) A SideH-555478*
Connector 12" (305 mm) B SideH-555488*
Connector Fastener Set (50)HFG9641
Foil Fastener Set (50)HFG9651
Trim Cap ScrewHFS11272
Prefeeder9471
Feeder H-558691
Feeder ScrewsHFS11022
M6 Allen (Hex Key) WrenchHFG6441
M8 Allen (Hex Key) WrenchHFG6461
Injector, 1 oz. 5200 AdhesiveHFG7251
Adhesive-5200 Marine White 1 ozHFG7222
Blue Loctite
*Standard Package
®
8331
Connector Fastener Set
Feeder
Feeder Screws
Foil Screws
Blue Loctite
®
6, 8 mm
Large Bore
Trim Cap Screws
Small Bore
Trim Cap Halves
Prefeeder
Extra Connector Set
5200
Adhesive
Injector
6 MKIV Hydraulic Unit 5
Page 7
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. Contact Harken for toggle housing dimensions to fit eye fitting.
3. On retrofits, headstay will require cutting and shortening to fit Harken toggle. Unit
is designed to fit over most turnbuckles. Contact Harken for questions on interior
housing for turnbuckle.
4. Rod rigging requires a terminal to allow rod to pass through foils. Generally
this will require a split collet design.
Assembly Housing
(Sold Separately)
WARNING! A stay that is old or damaged may break suddenly. Always
use a new stay when installing a furler or have condition 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
UnitPart No.
Use SAE straight thread O-ring male hose end fittings - 9/16-18. Hydraulic cylinder
uses a -4JIC end fitting.
Harken Toggle
7415.25 1
5H
7415.25 11/
Hydraulic LengthAdjusting Cylinder
(Sold Separately)
UnitPart No.
5H
1
/
8
4
7415.26 1
7415.26 11/
1
/
8
4
Tools Required
Adhesive Alert
MKIV Furlers are shipped with 3M 5200
adhesive. Use adhesives on dry connectors
3
12
4
1
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).
2
Although adhesive has not cured it will
remain in place on foil joints whether
8
14
10
6
9
13
15
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
16
7
1. Long tape measure 6. Side cutters11. Center punch
2. Short tape measure 7. Rat-tail file12. Rigging or black tape
3. Power drill 8. Allen wrenches (provided)13. Scissors
4. Drill bits 9. Slotted/Phillips screwdrivers 14. Metal straight edge
5. Crosscut table saw for metal 10. Needle-nose pliers15. Hammer
16. Metric ball-end allen wrench (recommended but not required)
MKIV Hydraulic Unit 5 7
11
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.
Page 8
Preassembly Hydraulic System
Furler Power Requirements
The furling unit and hydraulic tensioning cylinder will work
18000
16000
with all current Harken hydraulic power plants. They are
designed to provide 10 g/m (37.8 l/min) at load.
60
50
40
Unit
Recommended
Flow Rate
510 g/m 37.8 l/m
30
20
Furling speed RPM
10
4
22.66 22.68 30.2
15.1
6
Flow GPM (l/min)
10
37.8
12
45.3
14
52.9
16
69.4
14000
12000
10000
8000
6000
Furling torque M - LB
4000
2000
500
(35)
Pressure PSI (Bar)
1000
(70)
1500
(105)
2000
(140)
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.
CAUTION! 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.
8 MKIV Hydraulic Unit 5
Page 9
Preassembly Hydraulic System
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 5: 6" (152 mm)
Performance:
Pressure Requirements
CYLINDER PULL FORCE LBS
30000
25000
20000
15000
10000
Pull Force in LBS
5000
0
1000
0
Hydraulic pressure in LBS
2000
3000
4000
CYLINDER PULL FORCE KG
14000
12000
10000
8000
6000
4000
Cylinder Pull force in KG
2000
0
Hydraulic pressure in BAR
200100501502500
The hydraulic length adjusting cylinder requires a pressure of Max. 3,000 psi (200 Bar) to develop rated pull force on the
headstay. A pressure relief valve must be used to ensure this pressure is not exceeded. 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 substantially less than 3,000 psi (200 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! Pressurized hydraulic cylinders can be dangerous and if handled improperly may explode.
Only work on this 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 15 - 30 lbs (1 - 2 Bar).
MKIV Hydraulic Unit 5 9
Page 10
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 5 cylinder is 6" (152 mm).
2. Open end of wire and install Norseman or Sta-Lok
®
stud after foil is assembled.
3. Rod adapter fitting (not supplied by Harken).
WARNING! Using a threaded nosepiece with only adhesive at the
upper rod eye terminal may result in headstay failure. Always use
terminals with mechanical locks as specified by rod manufacturer.
10 MKIV Hydraulic Unit 5
Page 11
Preassembly Top Foil Length
Measure A and add to this chart
and length chart below
Inchesmm
A
Make sure upper
measurement points
of A and Pin-to-Pin
are the same.
Measurement
B3.0076
E30.00762
F28.5723
G
Total A+B+E+F+G
TOP FOIL LENGTH WORKSHEET
1
2
3
Result (Pin-to-Pin – ABEFG)
4
Pin-to-Pin Length
Subtract ABEFG –
Subtract D –
To find “D” pick number from chart below that is closest to, but
not greater than total from step 3.
Inchesmm
7 x 108 = 756
8 x 108 = 864
9 x 108 = 972
10 x 108 = 1080
11 x 108 = 1188
12 x 108 = 1296
13 x 108 = 1404
Example–If result from Step 3 is:
UNIT 5H
1200 inches “D” = 1180 inches 32,000 mm “D” = 30,175 mm
5
Result (C) Top Foil Length
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
Dimensionsinmm
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 108" (2743.2 mm)
E Bottom Foil30762
F Bottom of Foil to Top of Toggle Housing Insulator28723
G Top of Toggle Housing Insulator to Clevis Pin
Pin-to-Pin Length
3
Alternate
Point
7 x 2743.2 = 19202
8 x 2743.2 = 21946
9 x 2743.2 = 24689
10 x 2743.2 = 27432
11 x 2743.2 = 30175
12 x 2743.2 = 32918
13 x 2743.2 = 35662
76
A
B
A
Pin
C
to
Pin
D
Pin
to
Pin
E
F
G Top of Toggle Housing Insulator to Clevis Pin
Toggle
Part No.Type
7415.25 1
7415.25 11/4Toggle Assembly11/
7415.26 11/8Hydraulic Cylinder/Toggle11/
7415.26 11/4Hydraulic Cylinder/Toggle11/
*Dimensions with cylinder 58% open
Cylinder Pin
MKIV Hydraulic Unit 5 11
1
/8Toggle Assembly11/
G Distance (Closed)G Distance (Open)
1
11/
Ø
1
/
8
4
inmminmm
257/
261/
16
8
647317/
664321/
Clevis PinG Distance
inmminmm
8
4
8
4
28.663/
31.871/
28.62815/
31.8295/
16
8
8
162
16
179
16
*735*
8
*752*
799
816
G
G
Page 12
Preassembly Short Top Foil
If top foil is shorter than 10 5/16" (262 mm) shorten one of the lower foils and redrill the three holes.
9'2"
233 mm
2.125"
53.98 mm
3.375"
85.37 mm
Trim CapConnector Half
Ø
0.522"
13.26 mm
Ø
0.166"
4.22 mm
Ø
0.522"
13.26 mm
4.625"
117.48 mm
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.
12 MKIV Hydraulic Unit 5
Page 13
Preassembly 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.
Determine where cylinder will ride when
sailing. Shown fully closed.
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 about 3" (76 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.
MKIV Hydraulic Unit 5 13
Page 14
Assembly Foils/Connectors
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.
14 MKIV Hydraulic Unit 5
Page 15
Assembly Foils/Connectors
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
5
they are
from top of foil.
Drill two (2)
trim cap.
/8" (16 mm) and 219/32" (76 mm)
5
/32" (4 mm) holes for
!
5
/8" (16 mm)
Foil
Top
219/32" (67 mm)
Lay top foil in line with others. Slide stay
into top foil and down line of foils or slide
each foil up stay.
MKIV Hydraulic Unit 5 15
Page 16
Assembly Foils/Connectors
Install trim cap. Place each side over wire.
Push trim cap into foil to start, then tap
in using hammer.
Install trim cap screws.
Locate 12" (305 mm) Connector side A and
®
B. Put red Loctite
on screw holes in side B.
Place halves of bushings onto stay and
capture in connector sides A and B.
Assemble using connector screws.
Red Loctite
16 MKIV Hydraulic Unit 5
Side A
®
Side B
Page 17
Assembly Foils/Connectors
Insert connector into foil and put red
®
Loctite
on foil screw holes.
Red Loctite
®
Assembly 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
MKIV Hydraulic Unit 5 17
Page 18
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.
Inject only a small amount of adhesive
into middle hole.
UnitAdhesive
1
5
1
/2 ml
Tip: When you see a small amount
of adhesive enter one screw hole, stop.
You have applied
enough adhesive.
Secure foil to connector using foil screws.
®
Make sure red Loctite
is in screw holes.
If not apply to screws.
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
18 MKIV Hydraulic Unit 5
Page 19
Assembly Foils/Connectors
Secure foil to connector using foil screws.
®
Make sure red Loctite
is in screw holes.
If not apply to screws.
Assemble the 151/2" (394 mm) bottom
connector. Feeder notch is centered
so there is no connector top/bottom.
Assemble using red Loctite
®
on screws
Red Loctite
®
MKIV Hydraulic Unit 5 19
Page 20
Assembly Bottom Foil/Connectors/Halyard Swivel/Lower Unit to Foil
Slide halyard swivel onto foil above feeder
window. The halyard swivel is symmetrical.
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 5
Page 21
Assembly Attach 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.
MKIV Hydraulic Unit 5 21
Page 22
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
Isolator
Adapter
Crosspin
Cylinder
Bosses
Sockets
Install isolator and adapter to lower unit using 6 socket head cap screws. Use Tef-Gel
™
on screws.
Insert eye into cylinder. Use stay eye terminal or threaded turnbuckle eye. Insert crosspin and secure by fastening toggle
™
plate on each side of cylinder. Use Tef-Gel
on screws.
Fit cylinder bosses to one of six socket positions. Determine position based upon desired orientation of main unit and
cylinder hydraulic port.
™
Secure cylinder to lower unit using clamp. Use Tef-Gel
on screws.
22 MKIV Hydraulic Unit 5
Page 23
Assembly Feeder/Lash Halyard Swivel
Check foil height at top, set and secure
using Allen wrench.
Fasten feeder to foil gap using Loctite®
on screws.
Red Loctite
®
Commissioning Lash Halyard Swivel
Lash halyard, head of sail and tack. One very useful knot
is a triple fisherman's knot. See: www.harken.com/knot
tying resources.
MKIV Hydraulic Unit 5 23
Page 24
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 3" (75 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.
24 MKIV Hydraulic Unit 5
Page 25
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.
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
1. Halyard swivel should be within top 6 - 8" (150 - 120 mm) 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.
If sail will not furl or unfurl, try to remove jib sheets and manually
wrap sail around headstay.
8 - 10°
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 5 25
Page 26
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.
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.
26 MKIV Hydraulic Unit 5
Page 27
Operation 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 24.
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.
Remember to keep headstay tight for best performance when furling or reefing.
IMPORTANT! 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 5 27
Page 28
Operation Reefing/Secure 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 “Troubleshoot” on page 31.
WARNING! A hydraulic furling system is very powerful and jammed parts can break suddenly at high
load. Stop furling immediately and correct problem.
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.
28 MKIV Hydraulic Unit 5
Page 29
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 5 29
Page 30
Maintenance Clean/Inspect/Storage
Clean
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.
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.
30 MKIV Hydraulic Unit 5
Page 31
Troubleshoot Warranty
ProblemProbable CauseSolution
Sail will not furl or
is difficult to furl.
Jib halyard is wrapping around headstay because
angle between mast 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.
Sail will not unfurl
or will not unfurl
completely.
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
Sail will not furl
Spare halyard catching in sail as it furls.Move halyards away from furling headsail as above.
completely.
Headstay rotates in
Insufficient tension on headstay.Tighten headstay and/or backstay to eliminate sag in headstay.
jerks or elliptically.
Sail does not stay furled.
Sail will not go up.
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
Sail will not raise
completely or luff
will not tension.
Sail will not
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
come down.
Halyard swivel off foil.Sail luff too long or foil is too short or low and must be lengthened or raised.
Ultravoilet cover rolls
Wrong switch used to furl sail.Unroll sail and use other switch to furl. Alternatively, rewire switch if preferred. Once
up inside of sail.
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
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."
McLube™ is a registered trademark of McGee Industries, Inc.
®
is a registered trademark of Sta-Lok Terminals, Ltd.
Sta-Lok
®
Torlon
is a registered trademark of Solvay Advanced Polymers
Note offsets above and below sail.
A shorter luff may be required if a halyard restrainer is used or
an 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 25.
C
Tack Setback
A
B
Note setback for tack shackle and cut sail accordingly.
Luff Tape Size
6
Unit 5H requires #6 (
/32" or 5 mm) luff tape.
Luff Tape Length
Cut off top of luff tape so it is 24 to 36" (600 to 1000 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 Lashing
Choose high strength low stretch line to lash head and tack to
fittings. Use specialty knots such as a triple fisherman's knot. See
knot tying resources at www.harken.com/knots.
Sun Cover
I
Sun covers may be installed on either side of sail. Be sure to match
other sails in the customer's inventory.
D
H
I
J
K
See page 32
for all toggle
dimensions.
MKIV Hydraulic Unit 5 33
E
F
G
1
7415.25 1
7415.25 1
7415.26 1
7415.26 1
* Approximate, will vary according to rigging used. Assumes about a 80 mm offset for each lashing.
** Approximate measurement from boltrope to lashing bearing point.