Harken C7475 User Manual

Nautor Furling Installation Manual – C7475/C7550

GENERAL SPECIFICATIONS Parts List

■ MAIN COMPONENTS

Halyard Swivel C7475/C7550

Feeder, Toggle/Terminal Assembly

Drum Assembly

C7475

C7550

2 Nautor Furling December 2004

GENERAL SPECIFICATIONS Parts List

■ MISCELLANEOUS PARTS

®

Red Loctite

Foil Screws Foil Wedges

Torque Tube Screws 5 mm, 8 mm Allen Wrench

®

Prefeeder Blue Loctite

Super Bonder

■ RIGGER PARTS

C7475
1 Trim Cap
9 Connectors
1 Long Bottom Connector

C7550
1 Trim Cap
10 Connectors
1 Long Bottom Connector

■ FOILS

C7475
9 Foils
1 Special Bottom Foil

C7550

10 Foils
1 Special Bottom Foil

December 2004 Nautor Furling 3

PREPARATION Headstay Length

■ HEADSTAY CUT LENGTH

Subtract the following from the headstay length and cut the
stay at that point.

HEADSTAY CUT LENGTH CHART

Clevis Pin Size

-30 rod (11.1 mm)

-40 rod (12.7 mm) — 201 mm

22.2 mm 25.4 mm

187 mm

—

HEADSTAY CUT LENGTH

■ STRINGING CONNECTORS ON STAY

Make sure the trim cap is at the top and the correct number
of connectors are used. The long bottom connector must be
slid on the rod last.

■ ROD COLDHEAD HEIGHT

Make sure the length of coldhead does not interfere with the
drive pin.

Distance between the collet bottom and the rollpin is 6.5 mm

6.5 mm

4 Nautor Furling December 2004

PREPARATION Foil Length

■ FOIL CUT LENGTH

Foil cut length is based on pin-to-pin length as measured
from center of upper pin (attaches the stay to the mast) to
center of lower pin (attaches the furling unit to the boat).
Measurement includes the masthead toggle.
To check foil length, lay foils alongside stay before cutting
top foil.

■ TOP FOIL CUT LENGTH

Instructions For Worksheet Below:
1 Fill in total pin-to-pin length.
2 Fill in A length.
3 Add A, B, E, F, G and subtract from total pin-to-pin length.
SUM = _________
4 Choose the number from foil multiplier below closest to,
but not greater than, sum from step 3. Fill in D length.

7 x 2133.6 = 14935.2
8 x 2133.6 = 17068.8
9 x 2133.6 = 19202.4
10 x 2133.6 = 21336.0
11 x 2133.6 = 23469.6
12 x 2133.6 = 25603.2

5 Add A, B, D, E, F, G.
Subtract from pin-to-pin length for C (top foil length).

WORKSHEET: DETERMINE TOP FOIL LENGTH

C7550

-40

25.4 mm
PIn

DIMENSIONS

A Center of PIN to Bottom of

C7475

-30

22.2 mm
PIn

_____ _____

Terminal

B Bottom of Terminal to Top of Foil

20 mm

20 mm

C Top Foil _____ _____

D __?__ 84” (2133.6 mm) Foils

(Quantity)

_____

_____

E Feeder Gap 60 mm 76 mm

F Bottom Foil 610 mm 610 mm

G Clevis Pin to Foil 661 mm 674 mm

Total Pin-to-Pin Length _____ _____

December 2004 Nautor Furling 5

PREPARATION Foil Length

■ CUTTING TOP FOIL

Once you have checked the top foil length, cut the top foil.
Deburr and clean all shavings from the foil.
Important: Failure to deburr or clean the inside of the foil may

cause it to seize to a connector when installing on rod.
Rough up the top 1” (25 mm) of the foil using a file or

sandpaper.

ASSEMBLY Foils

■ ASSEMBLE FOIL

Slide the trim cap and one connector to the top of the
headstay. Tape other connectors in place or use a pusher wire
longer than foil to hold connectors back.

Slide top foil to top of stay, screw holes toward the bottom.

®

Coat the connector with red Loctite

.
Place a wedge in the indentation with the circular mold mark
towards the connector.
Push the connector into the top foil until it is recessed about

1

/2” (13 mm).

6 Nautor Furling December 2004

ASSEMBLY Foils

Use Super Bonder to glue the trim cap to the roughened
foil top.

Slide the next connector to the top of the stay.
Coat half of the connector and the indentation with

®

red Loctite

.
Place a plastic connector wedge in the indentation
closest to the top foil.

Coat foil screws with red Loctite. Screw them into the
connector until tight. Continue assembly.

Slide halyard swivel onto foil, tall end up.

December 2004 Nautor Furling 7

ASSEMBLY Foils

Install feeder screws toward bottom, using blue Loctite®
on screws.

Slide lower unit onto foils.

ASSEMBLY Attach Stay

■ ATTACHING STAY TO TOGGLE/TERMINAL ASSEMBLY

Make sure halyard swivel and drum assembly have been
slipped on the foils.

Slip the rod adapter sleeve onto the rod.
Sandwich the nosepiece over the rod and insert into the

main body, narrow end first. Jiggle the sleeve or use a small
screwdriver to push the nosepiece completely into sleeve.

Put several drops of the blue Loctite on the large threads
of the stud. Thread the stud into the main body until the
slot aligns neatly with the hole in the main body.

TIP: Sight through the pin hole to find the optimum thread
engagement. Make sure the stud is threaded far
enough so the pin is securely seated in the slot,
yet not threaded too far to block the pin.

8 Nautor Furling December 2004

ASSEMBLY Attach Stay

Hammer the pin into the main body.

®

Clean excess Loctite

from the terminal body. Tape around

sleeve to secure pin.

Lower drum assembly and slip clevis pin and cotter pin
in place.

®

Coat threads of torque tube screws with blue Loctite

.

Raise foils and insert foil screws.

ASSEMBLY Foil Length

Check the clearance between the top of the foil and top
terminal.

TIP: Check clearance when the unit is on the ground,
before raising the headstay into position.

December 2004 Nautor Furling 9

ADJUSTMENTS Halyard Wraps

■ HALYARD WRAPS

The most serious problem with furling systems occurs when
the jib halyard wraps around the headstay foil. Halyard wraps
will prevent furling or unfurling and may cause serious damage
to the unit and the halyard. In severe cases, halyard wraps
may cause headstay loss.

To prevent wraps, the halyard must exert a slight pull to
the rear. This allows the foils to turn while the halyard
remains stationary.

■ PREVENT WRAPS

WARNING: The sail must be fitted to the foils before operation.
1 Halyard swivel should be within the top 4” (100 mm)
of the foil.
2 Halyard must pull slightly to the rear (8 - 10°).
3 Halyard must be snug, but not too tight.

TIP: With the sail raised, walk away from the boat and
look at the masthead with binoculars. Use the halyard
swivel as a measurement reference. 4” (100 mm) is

1

/3 the length of the swivel. There should be less foil

exposed above the swivel than

1

/3 of the swivel.

If a halyard wraps, do not force the unit to turn. Attempt
to open the sail by alternately furling in and out slightly.

If the sail can be unfurled, lower the sail by releasing the jib
halyard. Severe halyard wraps can only be cleared by going
aloft and freeing the halyard.

If the sail will not furl or unfurl, it may be possible to remove
the jib sheets and manually wrap the sail around the headstay.

Remember: Testing at the dock does not indicate the halyard
angle is correct. In wave action, the halyard may wrap if the
lead angle is not correct. The 8-10° diverging angle
mentioned above is critical.

8 - 10°

10 Nautor Furling December 2004

ADJUSTMENTS Pendants/Halyard Restrainer

■ PENDANTS

If your sail is not long enough to position the halyard swivel prop­erly, you must add a pendant to the sail. Pendants should be plas­tic coated wire permanently attached to the sail so the height will
be correct. Adjustable length pendants are not acceptable as they
might not be adjusted correctly during a sail change.

■ INSTALL A PENDANT

1 Raise the sail, but do not attach tack shackle.
2 Position the halyard swivel correctly near the top of the
headstay and secure the halyard.
3 Secure a piece of rope to the sail tack. Lead the line through
the tack shackle on the furling drum and tension the sail.
4 Measure the distance from the tack shackle to the
sail tack and have a pendant of this length permanently
attached to the head of the sail.
5 Repeat this procedure for every jib.

TIP: Pendants are used at the head of the sail. Short
pendants may be added at the tack to improve visibility
under the genoa, but remember that visibility is
already improved by shackling to the tack swivel.
Tack pendants increase heeling moment by raising the
sail plan. You may install pendants at both the head
and tack of the sail.

■ HALYARD RESTRAINER

To prevent wraps, the jib halyard must pull slightly to the
rear. On some boats the halyard sheaves are located too
close to the headstay and a halyard restrainer must be used.

Use halyard restrainers only when required by the masthead
geometry. Restrainers tend to limit sail luff length and may
cause problems if not properly installed.

Mount the restrainer as high as possible on the face of the
mast. Position the restrainer so the foils will not hit it when
under load.

8 - 10°

The restrainer should deflect the halyard 8 - 10°. If the angle
is more than 10°, you may experience difficulty in tensioning
the sail luff, friction in furling and possible damage to the foils.
To decrease deflection angles, shorten the luff of the sail.

TIP: Boats used in charter service should consider using 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 the sail along its entire
length so halyard tension is required only to shape
sails, not to support them.
Use only enough halyard tension to remove some
wrinkles along the luff. Do not tension the halyard
enough to cause vertical wrinkles in the luff.
Use halyard tension to adjust draft position of the sail
to suit sailing conditions. Your halyard should be firm
but not tight. If in doubt, release halyard tension.
To protect the sail, ease the halyard when the boat
is not in use.

December 2004 Nautor Furling 11

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M1013/12-04