Harken 7415.15S User Manual

MKIV HYDRAULIC JIB REEFING & FURLING

Unit 5

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

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

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

Assembly

Foils/Connectors 14 - 19 Bottom Foil/Connectors/Halyard Swivel 20 Lower Unit to Foil 20 Attach Toggle 21 - 22 Attach Hydraulic Cylinder 22 Feeder/Lash Halyard Swivel 23

Commissioning

Turnbuckle on Boat 24 Halyard Swivel Height/Lead Angle 25

Halyard Restrainer/Tension 26

Operation

Headstay Tension 27 Reefing/Secure Sail 28 Manual Operation 29

Maintenance

Clean and Lubricate 30 Inspect 30 Storage 30

Troubleshoot 31 Warranty 31 Appendix

Toggle Dimensions 32 Dimensions/Sailmaker Instructions 33 Parts List 34

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

Preassembly Size Check

Online Product Registration

www.harken.com/FurlingWarranty

See page 32 for all toggle dimensions.

Size Check

1. Check headstay and clevis pin dimensions in chart below.

2. Harken does not recommend drilling boat’s chainplate or toggle. Bushings may be required to fit boats with smaller clevis pin sizes.

WARNING! 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. Description Rod Ø Wire Ø

7415.15S MKIV Hydraulic Unit 5 (Small Bushings)

7415.15L MKIV Hydraulic Unit 5 (Large Bushings)

Toggle Part No. Description Toggle Clevis Ø

7415.25 1

UNIT 5

7415.26 1

‡Continuous rod only. If rod is sectional, order Unit 6

4 MKIV Hydraulic Unit 5

Toggle Assembly 11/8" 28.6 mm

Toggle Assembly 11/4" 31.8 mm

Hydraulic Cylinder/Toggle 11/8" 28.6 mm

Hydraulic Cylinder/Toggle 11/4" 31.8 mm

-48, -60, -76‡ (14.3, 16.8, 17.9 mm

—

/8" (16 mm)

/4", 7/8" (19, 22 mm)

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

Description Part 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

Preassembly Parts

Connector Bushing Set

Bottom

Connector

Connectors

Other Components

Description Part No. Qty

SMALL BORE

Connector Bushing Set/Sm (38) HFG962 1

Trim Cap Half A/Sm H-56617 1

Trim Cap Half B/Sm H-56618 1

Extra Connector Set/Sm 7415.31S 1

LARGE BORE

Connector Bushing Set/Lg (38) HFG963 1

Trim Cap Half A/Lg H-56619 1

Trim Cap Half B/Lg H-56620 1

Extra Connector Set/Lg 7415.31L 1

ALL UNITS

Connector 15.5" (398 mm) Bottom A Side H-56606 1

Connector 15.5" (398 mm) Bottom B Side H-56607 1

Connector 12" (305 mm) A Side H-55547 8*

Connector 12" (305 mm) B Side H-55548 8*

Connector Fastener Set (50) HFG964 1

Foil Fastener Set (50) HFG965 1

Trim Cap Screw HFS1127 2

Prefeeder 947 1

Feeder H-55869 1

Feeder Screws HFS1102 2

M6 Allen (Hex Key) Wrench HFG644 1

M8 Allen (Hex Key) Wrench HFG646 1

Injector, 1 oz. 5200 Adhesive HFG725 1

Adhesive-5200 Marine White 1 oz HFG722 2

Blue Loctite

*Standard Package

833 1

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

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

Unit Part 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

7415.25 11/

Hydraulic LengthAdjusting Cylinder

(Sold Separately)

Unit Part No.

7415.26 1

7415.26 11/

Tools Required

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

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. 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 pliers 15. Hammer

16. Metric ball-end allen wrench (recommended but not required)

MKIV Hydraulic Unit 5 7

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.

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.

Unit

Recommended

Flow Rate

5 10 g/m 37.8 l/m

Furling speed RPM

22.66 22.68 30.2

15.1

Flow GPM (l/min)

37.8

45.3

52.9

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

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

1000

Hydraulic pressure in LBS

2000

3000

4000

CYLINDER PULL FORCE KG

14000

12000

10000

8000

6000

4000

Cylinder Pull force in KG

2000

Hydraulic pressure in BAR

20010050 150 2500

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

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).

Deductions to Determine Stay Length

Toggle

Part No.

7415.25 1

/8 Std 11/8" (28.6 mm) 5" (126.72 mm)

/4 Std 11/4" (31.8 mm) 511/16" (143.91 mm)

Clevis Pin

Pin-to-Pin

Length

Hydraulic Cylinder

Part No.

7415.26 1

/8 Cylinder 11/8" (28.6 mm) 2711/16" (703 mm) 2111/16" (550.29 mm)

/4 Cylinder 11/4" (31.8 mm) 285/16" (720 mm) 225/16" (567 mm)

Clevis Pin ØMax. Pin-to-Pin

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 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

Preassembly Top Foil Length

Measure A and add to this chart

and length chart below

Inches mm

Make sure upper measurement points of A and Pin-to-Pin are the same.

Measurement

B 3.00 76

E 30.00 762

F 28.5 723

Total A+B+E+F+G

TOP FOIL LENGTH WORKSHEET

Result (Pin-to-Pin – ABEFG)

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.

Inches mm

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

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

Dimensions in 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 108" (2743.2 mm) E Bottom Foil 30 762 F Bottom of Foil to Top of Toggle Housing Insulator 28 723 G Top of Toggle Housing Insulator to Clevis Pin

Pin-to-Pin Length

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

G Top of Toggle Housing Insulator to Clevis Pin

Toggle

Part No. Type

7415.25 1

7415.25 11/4Toggle Assembly 11/

7415.26 11/8Hydraulic Cylinder/Toggle 11/

7415.26 11/4Hydraulic Cylinder/Toggle 11/

*Dimensions with cylinder 58% open

Cylinder Pin

MKIV Hydraulic Unit 5 11

/8Toggle Assembly 11/

G Distance (Closed) G Distance (Open)

1 11/

in mm in mm

257/

261/

647 317/ 664 321/

Clevis Pin G Distance

in mm in mm

28.6 63/

31.8 71/

28.6 2815/

31.8 295/

162

179

* 735*

* 752*

799 816

+ 25 hidden pages