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MKIV HYDRAULIC JIB REEFING & FURLING
Installation Manual - Intended for specialized personnel or expert users
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.
Unit 3
Preassembly
PLEASE SAVE THESE INSTRUCTIONS
WARNING! Strictly follow all instructions
to avoid an accident, damage to your vessel,
personal injury or death. See www.harken.com
for additional safety information.
4379 v1 08/21
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Table of Contents
Related Manuals for Harken MKIV Unit 3
Summary of Contents for Harken MKIV Unit 3
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Page 1: Table Of Contents
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. PLEASE SAVE THESE INSTRUCTIONS... -
Page 2: Introduction And Safety Precautions
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. -
Page 3: Unit
Sizing 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. -
Page 4: Parts
Preassembly Parts 2.13 m (10 - 7') foils 2' (610 mm) Unit 3, 4 Bottom Foil Silver foils available Drill adapter for Halyard swivel manual drive unit 3H Lower unit Emergency unit 3H crank handle Main components Description Part no. Lower unit See parts list 7'(2.13 m) foil, black anodized, standard... - Page 5 Preassembly Parts Connector bushings Foil screws Trim cap Plastic connector wedges Trim cap screws Feeder Prefeeder Bottom Connectors Bow shackles connector Red Loctite ® Blue Loctite adhesive adhesive Loctite is a registered trademark of Henkel AG & Company KGaA. Other components Description Unit Part no.
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Page 6: Rigging Parts Check/Tools
2. Mating turnbuckle components with eye at lower end must be purchased separately. See page 10. Rod rigging 3. Headstay may require cutting and shortening to fit Harken toggle. Some Harken rod adapter stud required headstays may remain uncut by replacing lower stud of turnbuckle with (sold separately) stud/eye, eliminating extra toggle. -
Page 7: Hydraulic System
Pressure PSI (bar) Maximum operating pressure Set relief valve on power plant at 140 bar or 2000 PSI. Harken powerpacks 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. -
Page 8: 4379 V1
Use -6 JIC X -6 ORB adapters - Stainless steel 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. -
Page 9: Toggle Deductions/Stay Into Foil Options
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 one-half ( ) to two-thirds ( ) open to allow shortening for new wire stretch, for fine-tuning mast rake, and to help connect the stay. -
Page 10: Top Foil Lengths
Preassembly Top Foil Length Make sure upper Measure A and add to this chart measurement points and length chart below Alternate of A and pin-to-pin measurement Inches are the same. point 23.18 Top Foil Length Worksheet Pin-to-pin length Total A+B+E+F+G Subtract ABEFG –... -
Page 11: Short Top Foil
Preassembly Short Top Foil If top foil is shorter than 248 mm (9 ") , use one of the following techniques to ensure sufficient bearing surface for the foil in the area of the halyard swivel. Cut-offs Do not use 248 mm (9 ") No special treatment required. -
Page 12: Confirm Foil Length
Line up lower unit so base of unit lines up with toggle housing. Attach one (1) link plate to lower unit. Line up lower unit so link plate hole lines up with cross pin in Harken toggle. Make sure toggle is tensioned when measuring. - Page 13 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 cut off piece and use a flat metal object (i.e.
- Page 14 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 they are 10 mm (3/8") and 35 mm (1 ") from top of foil.
- Page 15 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 (shown below), place longer half of bushing with hook on upper half.
- Page 16 Assembly Top Foil/Connectors Slip connector on wire, mating hook of plastic bushing with connector. Put a drop of red Loctite adhesive into ® screw holes. Loctite is a registered trademark of Henkel AG & Company KGaA. MKIV hydraulic unit 3...
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Page 17: Assembly Foils/Connectors
Assembly Foils/Connectors Hold plastic wedge in place with thumb as you insert into foil. Line foil holes with connector screw holes. 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;... - Page 18 Assembly Foils/Connectors Inject a small amount of adhesive into middle hole. Unit Adhesive Tip: When you see a small amount of adhesive enter one screw hole, stop. You have applied Use “ml” enough adhesive. marks to estimate 1 to 1 ml of adhesive Stop when you see a small...
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Page 19: Bottom Foil/Connectors/Halyard Swivel
Assembly Bottom Foil/Connectors/Halyard Swivel Continue installing connectors and wedges. Make sure to use red Loctite adhesive in ® screw holes. Red Loctite Continue assembly. Use 356 mm (14") bottom connector to assemble bottom foil. Red Loctite Slide halyard swivel onto foil above feeder window. -
Page 20: Lower Unit To Foil
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. MKIV hydraulic unit 3... -
Page 21: Rod Rigging: Rod Adapter Stud
Assembly Rod Rigging: Rod Adapter Stud Apply a few drops of red Loctite adhesive to threads ® of nosepiece. 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. -
Page 22: Attach Turnbuckle/Toggle
Assembly Attach Turnbuckle/Toggle Assemble turnbuckle. Slip toggle housing insulator onto threaded eye. Remove toggle plate. Use cross pin to capture eye and toggle in toggle housing. Note: If using Sta-Lok or Norseman ® stud, you must use a washer above stud as shown below. -
Page 23: Attach Hydraulic Cylinder
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 adhesive on screws. ® Attach hydraulic cylinder Slip toggle housing insulator onto eye terminal. Remove toggle plate. Use cross pin to capture eye and toggle in housing. - Page 24 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 ®...
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Page 25: Feeder/Final
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 from vibration. -
Page 26: Commissioning
Commissioning Turnbuckle on Boat Have extra cotter pins and locknuts on hand to replace used Raise lower unit and use ones at base of unit and for turnbuckle. halyard to lift and hold it about 1.5 m (5'). Raise foils Hold foils and loosen foil clamp screws until you can pull clamp using second halyard and out to lower foils. -
Page 27: Halyard Swivel Height/Lead Angle
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 can cause serious damage to the unit and the halyard. -
Page 28: Halyard Restrainer/Tension
Restrainers tend to limit sail luff length and can 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. -
Page 29: Operation
They permit a very tight headstay to be eased when boat is not in use. For best performance, consider adding a backstay adjuster; a mechanical adjuster like those offered by Harken, or a hydraulic adjuster. Remember to keep headstay tight for best performance when furling or reefing. -
Page 30: Reefing/Secure Sail
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 610 mm (2') below feeder. 2. Shackle tack of sail to lower unit. Install shackle so screw pin head is on same side as sun cover. -
Page 31: Manual Operation
Operation Manual Operation Before using the system, practice manual operation in case there is a power loss. Make sure that the emergency handle can rotate and not hit the bow pulpit. A fully-charged cordless drill must be 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. -
Page 32: Race Conversion
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 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. -
Page 33: Maintenance/Inspection/Decommissioning
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 can be cleaned by washing with soap and water. A scrap of luff tape may be run up foil to scrub inside grooves. -
Page 34: Troubleshoot/Warranty
Ultravoilet cover rolls up Once correct, label switch "furl" and the other "unfurl" inside of sail McLube is a registered trademark of McGee Industries, Inc. Warranty www.harken.com/manuals or call, write, email or fax Harken, Inc., Pewaukee, WI USA MKIV hydraulic unit 3... -
Page 35: Appendix
Appendix Parts List Description Order Part no. Torque tube foil clamp H-42967 Torque tube screws M8 x 25 mm SHCS HFS1107 Red ring S281680097 H-42967 Lower unit (reorder parts shown below) 7413.15BASE HFS1107 Smalley ring H-51494 Tack swivel top washer H-51493 "... - Page 36 Appendix Parts List Description Order Part no. Hydraulic cylinder— " pin 7413.26 3/4 Toggle housing insulator H-51475 Cross pin " H-52246 Toggle plate H-51477 Toggle plate screws M5 X 16 mm SHCS HFS982 Toggle housing screws M8 X 70 mm SHCS HFS1064 Clevis pin "...
- Page 37 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. Halyard restrainer (optional) PLEASE SAVE THESE INSTRUCTIONS...
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Page 38: Toggle Dimensions
Appendix Toggle Dimensions Unit Part no. Unit Part no. 7413.25 7413.26 7413.25 7413.26 Toggle dimensions* 7413.25 7413.26 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 50.8 7413.25 , 7413.26 2.662 67.61 50.80 1.156 29.36 0.868 22.05 0.94... -
Page 39: Dimensions/Sailmaker's Instructions
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 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. - Page 40 Main Office and Harken Brandstore: Västmannagatan 81B SE-113 26 Stockholm Sweden Telephone: (46) 0303 61875 • Fax: (46) 0303 61876 Mailing address: Harken Sweden AB, Box 64, SE -440 30 Marstrand Web: harken.se • Email: harken@harken.se Harken UK, Ltd. Bearing House, Ampress Lane, Lymington, Hampshire S041 8LW, England Telephone: (44) 01590-689122 •...
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