Harken C8436 User Manual

NAUTOR MKIV

Jib Reefing & Furling

Installation Manual

C8436/C8437

Parts

2' (610mm)
Bottom Foil

Halyard Swivel

Bottom

Connector

Connectors

Bow

Shackles

7' (2.13m) Foils

Connector Bushings

Plastic

Connector

Wedges

Feeder

Foil Screws

Trim Cap

Prefeeder

3,4, 6, 10mm

Allen Wrenches

Toggle/Terminal Assembly

Drum Assembly

Main Components

Part No. Quantity Description

HFG293 1

H-39392 1

Foils (Standard Package)

Part No. Quantity Description

7413.30

7413.33 1 2'(610mm) Botton foil (shipped in drum box)

Tools

Quantity Description

1 Each 3, 4, 6, 10mm Allen wrenches

4/18/07 Nautor MKIV Furling 3

C8436 (9)

C8437 (10)

Drum assembly with clamp

Halyard swivel

7' ( 2.13m) Foil

Other Components

Part No. Quantity Description

7413.31

7413.32 1 14" (356mm) Bottom connector

HFG297 1 Connector bushing set (20 each H-42073/H-42074)

HFG324 1 Plastic connector wedge set (22 39487)

HFG349 1 Foil screw set (44 HFS1106)

HFG682 1 Trim cap set (H-39751/H-39752)

947 1 Prefeeder

H-39756 1 Feeder with screw and tab

2124 3 10mm Bow shackle

HFG725 1 Injector

HFG722 1 1 oz. 5200 Adhesive

833 1 Blue Loctite

C8436 (8)

C8437 (9)

9.75" (248mm) Connector

Blue Loctite

®

®

Injector

5200

Adhesive

Preassembly 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 22.2mm 25.4mm

-30 rod (11.1 mm) 185mm —

-40 rod (12.7 mm) — 229mm

HEADSTAY CUT LENGTH

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 MKIV Furling 4/18/07

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 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
Subtract from pin-to-pin length for C (top foil length).

E

WORKSHEET: DETERMINE TOP FOIL LENGTH

C8436

-30

DIMENSIONS

A

Center of PIN to Bottom of Terminal

B

Bottom of Terminal to Top of Foil

C

Top Foil

D

__?__ 84" (2133.6mm) Foils (Quantity)

E

Bottom Foil 610mm 610mm

F

Clevis Pin to Foil 533mm 577mm

Total Pin-to-Pin Length _________ _______

22.2mm PIn

_______ _______

20mm

_______ _______

_______ _______

C8437

-40

25.4mm PIn

20mm

F

4/18/07 Nautor MKIV Furling 5

Assembly Top Foil

Cut foil to length using a hacksaw.

Deburr inside edge using a rat-tail file.

Tip: Mark top foil to distinguish from
cutoff piece.

Lay top foil alongside cutoff piece and
use a flat metal object (i.e. metal ruler)
to scribe top line of foil.

6 Nautor MKIV Furling 4/18/07

Assembly Top Foil

Cut out template at right. Line template up
with top of foil and scribed line. Tape in
place. Use a center-punch to mark holes.

Check center-punch marks to confirm

3

they are 3/8" (10mm) and 1
from top of foil.

Drill two 5/32" (4mm) holes for
trim cap.

/8" (35mm)

!

Foil

3

Top

/8" (10mm)

13/8" (35mm)

Lay top foil in line with others. Slide stay
into top foil and down the line of foils or
slide each foil up stay.

4/18/07 Nautor MKIV Furling 7

Assembly Top Foil

Install trim cap. Place each side over wire.
Push trim cap into foil to start then tap in
using hammer.

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 isolator
with hook on upper half.

8 Nautor MKIV Furling 4/18/07

Assembly Top Foil/Connectors

Slip 9.75" (248mm) 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 the lower
half of the injector is full as shown. Keep
tip free of sealant to let air inside.

Adhesive in
lower half

4/18/07 Nautor MKIV Furling 9

Assembly Foils/Connectors

Start plunger into injector and immediately
hold upright so plunger is down and tip
applicator is up.

As sealant runs down towards the plunger
an air pocket will form near the tip. Push
plunger to evacuate the 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.

10 Nautor MKIV Furling 4/18/07

Assembly Foils/Connectors

Inject only a small amount. A Unit 3 will

1

only take 1 to 1

/4 ml graduation mark.

Tip: When you see a small amount of
adhesive enter one of the screw holes
stop. You have applied enough adhesive.

Use “ml”
marks to

estimate 1

1

/4 ml of

to 1

Stop when you see a small
amount of adhesive enter
one of the sdrew holes.

adhesive

Tighten screws into connector holes. Make
sure that a drop of adhesive was put in
screw holes. If not, apply to screw.

Use bushings, connector, wedge and
adhesive in other screw hole and

1

insert into other foil. Use 1 - 1

/4 ml

of adhesive.

4/18/07 Nautor MKIV Furling 11

Assembly Bottom Foil/Connectors/Halyard Swivel

Continue installing connectors and wedges.
Make sure to use adhesive in screw holes.

Continue assembly. Use 14" (356mm)
bottom connector to assemble bottom foil.

Slide halyard swivel onto foil above feeder
window. Make sure taller “half” is up as
shown.

12 Nautor MKIV Furling 4/18/07

Assembly Lower Unit

Loosen foil clamp screws at top of
lower unit.

Slide drum assembly onto foils.

Tip: Face clamp downwards so it
clears foil notches when installing.

Slide lower unit onto foils.

4/18/07 Nautor MKIV Furling 13

Assembly Toggle/Terminal

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.

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.

®

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.

14 Nautor MKIV Furling 4/18/07

Assembly Complete Unit Assembly

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.

Check foil height at top, set and secure
using Allen wrench.

4/18/07 Nautor MKIV Furling 15

Assembly Attach Feeder/Final Foil Assembly

Tip: Do not remove foil clamp screws
to adjust foil. Loosen screws, hold foils
and bring clamp away from foils. Adjust
and reclamp.

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 has plastic coating so it does not vibrate
loose.

Important—When removing screw,
loosen no more than one full turn.
Slide screw up and remove feeder.

Assembly Check Top Foil Clearance

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.

16 Nautor MKIV Furling 4/18/07

Commissioning Through Deck Installation/Race Conversion

Installation of Lower Unit in Deck Hole

1) Use 10mm Allen wrench provided to
remove 2 screws on bottom of guard
assembly and remove two halves.
Be careful—screws are not captive.

2) Use a 3mm Allen wrench to loosen
four screws in plastic cover and flange.

3) Insert unit through deck.

4) Put halves of flange together over

®

octagonal groove. Put blue Loctite
on screw holes and secure using
screws.

5) Put halves of cover together over

®

octagonal groove. Put blue Loctite

in

screw holes and scrure using screws.

6) Put halves of line guard together so
clamp ring is in groove. Secure with
screws.

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

Loosen screw one revolution only. Slide screw up and hold.

To Remove
Feeder For

Racing

feeder carefully—bottom end first. Don’t
lose the feeder overboard! Lower swivel

onto torque tube. Replace feeder.

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!

4/18/07 Nautor MKIV Furling 17

Commissioning Halyard Wrap

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.
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.

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
of the swivel. There should be less foil exposed above the
swivel than

1

/3 of the swivel.

1

/3 the length

8 - 10°

18 Nautor MKIV Furling 4/18/07

Commissioning 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

8 - 10°

the restrainer so the foils will not hit it when under load.
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.

4/18/07 Nautor MKIV Furling 19

Corporate Headquarters

N15W24983 Bluemound Rd, Pewaukee, WI 53072 USA

Telephone: [phone] • Fax: [phone]

Web: www.harken.com • Email: [e-mail]

Harken Australia Pty, Ltd.

1B Green Street, Brookvale, N.S.W. 2100, Australia

Telephone: [phone] • Fax: [phone]

Web: harken.com.au • Email: [e-mail]

Harken France

ZA Port des Minimes, BP 3064, 17032 La Rochelle Cedex 1, France

Telephone: [phone] • Fax: [phone]

158 Beaumont Street, Westhaven, P.O. Box 90689, Victoria St. West, Auckland 1142, New Zealand

ul. Rydygiera 8, budynek 3A, lokal 101, I pi

Mailing address: Harken Sweden AB, Box 64, SE -440 30 Marstrand

Bearing House, Ampress Lane, Lymington, Hampshire S041 8LW, England

Web: harken.fr • Email: [e-mail]

Harken Italy S.p.A.

Via Marco Biagi, 14, 22070 Limido Comasco (CO) Italy

Telephone: [phone] • Fax: [phone]

Web: harken.it • Email: [e-mail]

Harken New Zealand, Ltd.

Telephone: [phone] • Fax: [phone]

Web: harken.co.nz • Email: [e-mail]

Harken Polska SP ZOO

ętro, 01-793 Warszawa, Poland

Tel: [phone] • Fax: [phone]

Web: harken.pl • Email: [e-mail]

Harken Sweden AB

Main Office and Harken Brandstore: Västmannagatan 81B

SE-113 26 Stockholm Sweden

Telephone: [phone] • Fax: [phone]

Web: harken.se • Email: [e-mail]

Harken UK, Ltd.

Telephone: [phone] • Fax: [phone]

Web: harken.co.uk • Email: [e-mail]

Please visit: http://www.harken.com/locator.aspx

to locate Harken dealers and distributors

M1014/04-07