Harken 7411.11 1/2.BLACK MKIV Installation Manual Download

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Please read these instructions carefully before installing, servicing, or operating the equipment.

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MKIV UNDERDECK JIB REEFING & FURLING

Unit 1, 2, 3

Installation Manual – Intended for specialized personnel or expert users

4656 v1 08/21

Preassembly

Parts

4–5

Rigging Parts Check/Tools

Dimensions/Sailmaker's Instructions

Stay Length Deductions/Stay Into Foil Options 8

Hub Assembly

Deck Flange

Install Hub Assembly in Bow

10–11

Assemble Drum Components

Underdeck Lead Block

Preassembly

Top Foil Length (Unit 1)

Top Foil Length (Unit 2)

Top Foil Length (Unit 3)

Short Top Foil (Unit 1)

Short Top Foil (Unit 2)

Short Top Foil (Unit 3)

Confirm Foil Length

Assembly

Foils/Connectors

20–26

Halyard Swivel

Torque Tube Assembly

Rod Rigging

Attach Turnbuckle/Foils to Boat

29–31

Feeder/Final

Commissioning

Turnbuckle

33–34

Lead Line to Cockpit

Halyard Swivel Height/Angle

Halyard Restrainer/Tension

Operation

Halyard/Headstay Tension

Raise Sails/Storm Sails/Reefing

39–40

Secure Sail

Race Conversion

Maintenance

Clean/Lubricate/Inspect

Confirm Deck Flange/Tack Swivel Gap

Replace Line

Storage/Transporting

Remove Furler

Troubleshooting/Warranty

Summary of Contents for 7411.11 1/2.BLACK MKIV

Page 1: ...rum Components 11 Underdeck Lead Block 12 Preassembly Top Foil Length Unit 1 13 Top Foil Length Unit 2 14 Top Foil Length Unit 3 15 Short Top Foil Unit 1 16 Short Top Foil Unit 2 17 Short Top Foil Unit 3 18 Confirm Foil Length 19 Assembly Foils Connectors 20 26 Halyard Swivel 26 Torque Tube Assembly 27 Rod Rigging 28 Attach Turnbuckle Foils to Boat 29 31 Feeder Final 32 Commissioning Turnbuckle 33...

Page 2: ...low all instructions to avoid potential hazards that may kill or hurt you and others See www harken com manuals for general warnings and instructions WARNING This symbol alerts you to potential hazards that may kill or hurt you and others if you don t follow instructions The message will tell you how to reduce the chance of injury Introduction This manual gives technical information on installatio...

Page 3: ... 172 mm 21 2 64 mm 57 16 138 5 mm 35 8 92 mm 67 8 175 mm 143 8 365 mm 161 8 410 mm 235 8 600 mm 3 4 19 1 mm 65 16 160 mm 3 7413 11 7 8 BLACK 83 16 208 mm 61 2 166 mm 63 4 172 mm 21 2 64 mm 57 16 138 5 mm 35 8 92 mm 75 16 186 mm 15 381 mm 169 16 421 mm 241 4 616 mm 7 8 22 2 m 65 16 160 mm H F G J I D E Will Drum Fit in Bow Note If length of stud does not allow attachment to chainplate link plates b...

Page 4: ...8 10 mm 5000 lb 2270 kg 7 16 12 mm Line Specifications Line Not included with Furler Note Line is not included with furler Drum of unit is smaller to allow it to fit into narrow bow sections If overlapping sails are used standard diameter line will fill up drum and jam furler To prevent this use small diameter high strength line at forward end and have a rigger add a cover at aft end where line is...

Page 5: ...1 HFG672 3 HFS1127 1 HFG672 3 HFS1127 1 Prefeeder 947 1 947 1 947 1 Feeder with screw and tab H 39683 1 H 39559 1 H 39756 1 Injector 1 oz 5200 Adhesive HFG725 1 HFG725 1 HFG725 1 Loctite Blue 833 1 833 1 833 1 Loctite Red HFG739 2 HFG739 2 HFG739 2 Other Components Unit 1 Unit 2 Unit 3 3 4 7 8 Description Part No Qty Size Part No Qty Size Part No Qty Size Connector 7411 31 5 7 177 8 mm 7412 31 7 9...

Page 6: ...eat joints until foils can be pulled apart Adhesive Alert Unit 1 2 7404 Lead Block Kit Sold Separately 1 Long tape measure 6 Side cutters 11 Center punch 16 Hole saw 2 Short tape measure 7 Rat tail file 12 Rigging or black tape 17 Deck sealant 3 Power drill 8 Hex Keys provided 13 Scissors 18 Box end wrench 4 Drill bits see chart 9 Slotted phillips screwdrivers 14 Metal straight edge 19 6 mm bolts ...

Page 7: ... 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 Shackles Make sure tack and head shackles fit sail rings The minimum inside dimensions of standard head and tack shackles are A B Unit Part No A B C D E F G 1 7411 11 1 2 43 4 120 mm 7 177 mm 115 16 49 mm 1 16 2 mm 3713 16 960 mm 35 8 92 mm 2 7412 11 5 8 55 8 143 mm 91 ...

Page 8: ...lock as well as adhesive Use Harken stud with cotter pins See page 28 Options for Snaking Stay into Foils Unit Part No A B C D 1 7411 11 1 2 1 16 2 mm 35 8 92 mm 105 8 270 mm 155 8 397 mm 2 7412 11 5 8 1 16 2 mm 41 8 104 mm 1211 16 322 mm 189 16 471 mm 3 7413 11 3 4 1 16 2 mm 53 8 136 mm 161 8 410 mm 235 8 600 mm 3 7413 11 7 8 1 16 2 mm 513 16 148 mm 169 16 421 mm 241 4 616 mm 8 MKIV Underdeck Uni...

Page 9: ...te There must be a minimum of 3 8 9 mm thread engagement into deck flange Note Deck flange angle matches a stay angle of 731 2 when compared to deck Angles can vary between 721 2 and 741 2 Once you are certain hole is located in line with chainplate and any required shimming is done drill hole 90 to deck Make sure hole is just large enough so deck flange bears against deck It is better to make hol...

Page 10: ...hreaded stud as needed Stud Length Turn Adjusting Nut Shorten Clockwise Lengthen Counter Clockwise 1 16 1 8 2 4 mm From on deck pull up on unit to check height between deck flange and tack swivel Make sure tack swivel is free to rotate when there is upward pressure on unit Check this again when stay is up and tensioned Distance between bottom of tack swivel and deck flange must be 1 16 1 8 2 4 mm ...

Page 11: ...e each screw hole towards the stern Use blue Loctite on flathead screws provided Use blue Loctite on flathead screws provided Assemble line guard so enclosed opening faces lead block Do not use Loctite on threads Tip Loosely thread both screws turning guard so it can be rotated to its final position Finish tightening final screw when enclosed opening faces lead block Tighten screws using hex key p...

Page 12: ...t 90 to line of headstay as shown Remember block will split angle and raise up slightly under load Mount thru deck block You may want to angle it toward stanchion block Mount thru deck block You may want to angle it toward stanchion lead block 12 MKIV Underdeck Unit 1 2 3 90 ...

Page 13: ...in ABEF 4 Subtract D To find D pick number from chart below that is clos est to but not greater than total from step 3 Inches mm 3 x 84 252 4 x 84 336 5 x 84 420 6 x 84 504 7 x 84 588 8 x 84 672 3 x 2133 6 6400 8 4 x 2133 6 8534 4 5 x 2133 6 10668 6 x 2133 6 12801 6 7 x 2133 6 14935 2 8 x 2133 6 17068 8 Example If result from Step 3 is 500 inches D 420 inches 12 000 mm D 10 668 mm 5 Result C Top F...

Page 14: ...n to Pin Length 2 Subtract ABEF 3 Result Pin to Pin ABEF 4 Subtract D To find D pick number from chart below that is clos est to but not greater than total from step 3 Inches mm 5 x 84 420 6 x 84 504 7 x 84 588 8 x 84 672 9 x 84 756 5 x 2133 6 10668 6 x 2133 6 12801 6 7 x 2133 6 14935 2 8 x 2133 6 17068 8 9 x 2133 6 19202 4 Example If result from Step 3 is 500 inches D 420 inches 12 000 mm D 10 66...

Page 15: ...to Pin Length 2 Subtract ABEF 3 Result Pin to Pin ABEF 4 Subtract D To find D pick number from chart below that is clos est to but not greater than total from step 3 Inches mm 7 x 84 588 8 x 84 672 9 x 84 756 10 x 84 840 11 x 84 924 7 x 2133 6 14935 2 8 x 2133 6 17068 8 9 x 2133 6 19202 4 10 x 2133 6 21336 11 x 2133 6 23470 Example If result from Step 3 is 800 inches D 756 inches 20 000 mm D 19 20...

Page 16: ... in top foil only 3 1 2 3 90 75 mm Under 1 25 mm Eliminate top foil and run foil higher in torque tube Under 1 25 mm Top Foil Length from Worksheet 1 Initial top foil cut length 2 Cut through middle hole in top foil 3 Shorten full length adjoining foil by cutting through middle hole 4 Shorten connector 5 Shorten trim cap Resulting Top Foil Length Length 21 2 64 mm 57 8 149 mm 41 8 105 mm 31 2 89 m...

Page 17: ...Under 1 25 mm Eliminate top foil and run foil higher in torque tube Under 1 25 mm Top Foil Length from Worksheet 1 Initial top foil cut length 2 Cut through middle hole in top foil 3 Shorten full length adjoining foil by cutting through middle hole 4 Shorten connector 5 Shorten trim cap Resulting Top Foil Length Length 3 76 mm 71 4 184 mm 51 8 130 mm 41 2 114 mm No 21 2 64 mm 63 4 172 mm 45 8 117 ...

Page 18: ...8 4 137 102 mm Under 11 2 38 mm Eliminate top foil and run foil higher in torque tube Under 1 1 2 38 mm Top Foil Length from Worksheet 1 Initial top foil cut length 2 Cut through middle hole in top foil 3 Shorten full length adjoining foil by cutting through middle hole 4 Shorten connector 5 Shorten trim cap Resulting Top Foil Length Length 31 2 89 mm 69 16 167 mm 5 127 mm 47 8 124 mm No 3 76 mm 6...

Page 19: ...tube assembly This point will line up with Jaw Jaw toggle pin See chart above right Note Position top foil so that with top cap the foil will ride 5 8 16 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 Unit Pin Jaw Jaw Toggle Pin to Bottom of Torque Tube Assembly 1 1 2 12...

Page 20: ...using hacksaw 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 20 MKIV Underdeck Unit 1 2 3 ...

Page 21: ... See chart below for correct drill size Lay top foil in line with others Slide stay into top foil and down line of foils or slide each foil up stay Foil Top 13 8 35 mm 3 8 10 mm 3 16 5 mm 1 25 mm Foil Top Unit 1 Foil Top 13 16 30 mm 3 8 10 mm Unit 2 Unit 3 3 4 7 8 Unit Drill Ø 1 1 8 3 mm 2 5 32 4 mm 3 3 4 7 8 5 32 4 mm Unit Center Punch Marks 1 3 16 5 mm 1 25 mm 2 3 8 10 mm 13 16 30 mm 3 3 4 7 8 3...

Page 22: ...f longer section faces out Tip With foil screw holes up as shown below place longer half of bushing with hook on upper half Install trim cap Place each side over wire Push trim cap into foil to start then tap in using hammer Install trim cap screws 22 MKIV Underdeck Unit 1 2 3 ...

Page 23: ...Assembly Top Foil Connectors Slip connector on wire mating hook of plastic bushing with connector MKIV Underdeck Unit 1 2 3 23 Put a drop of red Loctite into screw holes ...

Page 24: ...ut 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 Start plunger into injector and immediately hold upright so plu...

Page 25: ...small amount of adhesive enter one of the screw holes stop You have applied enough adhesive Use ml marks to estimate adhesive Stop when you see a small amount of adhesive enter one of the screw holes Unit Adhesive ml 1 1 3 1 2 2 3 4 1 3 3 4 7 8 1 11 4 Unit Adhesive ml 1 1 3 1 2 2 3 4 1 3 3 4 7 8 1 11 4 MKIV Underdeck Unit 1 2 3 25 Tighten screws into connector holes Make sure a drop of red Loctite...

Page 26: ...l Slide halyard swivel onto foil above feeder window Make sure taller half is up as shown Assembly Bottom Foil Connectors Halyard Swivel 26 MKIV Underdeck Unit 1 2 3 Continue installing connectors and wedges Make sure to use red Loctite in screw holes Red Loctite ...

Page 27: ...e clamp downward so it clears foil notches during installation Assembly Torque Tube Assembly MKIV Underdeck Unit 1 2 3 27 Temporarily clamp torque tube assembly to top of bottom foil leaving feeder gap partially exposed as shown at right Gap will be used to rig a foil system lifting line ...

Page 28: ...d Assembly Rod Rigging Rod Adapter Stud Apply a few drops of red Loctite 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 Flats will be close and may only require a small half turn to align with cotter pin holes 28 MKIV Underdeck Unit 1 2 3 ...

Page 29: ...om foil Assemble turnbuckle Note If using Sta Lok or Norseman stud you must use a washer above stud as shown below Taking care not to lose parts remove bearing caps from drum assembly Tip Rig a large round plastic wash basin below furler to catch any parts that may be lost overboard MKIV Underdeck Unit 1 2 3 29 ...

Page 30: ... line attached to feeder gap as shown Attach eye to jaw jaw toggle deck level using clevis pin Adjust turnbuckle Secure with cotter pin Adjust turnbuckle When stay length is set use side cutters or needle nose pliers to bend cotter pin to secure turnbuckle Secure with cotter pin 30 MKIV Underdeck Unit 1 2 3 ...

Page 31: ...ease gap between deck flange and tack swivel when turnbuckle is tightened Check to make sure there is a 1 16 1 8 2 4mm gap Loosen foil clamp while holding torque tube assembly and carefully lower into place Note Do not remove screws just loosen them Capture posts on universal posts with caps and secure with screws Do not use Loctite on screws Tip If it is hard to capture posts in cap push against ...

Page 32: ...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 due to vibration Important When removing feeder loosen screw no more than one full turn Slide screw up and remove feeder 32 MKIV Underdeck Unit 1 2 3 ...

Page 33: ...d to replace used ones at base of unit and for turnbuckle Hold foils and loosen torque tube screws until you can pull clamp part way out in order to lower foils Lower foils Rig a screw catcher Remove screws holding bearing caps and remove taking care to not lose parts Loosen but do not remove ...

Page 34: ...en the turnbuckle is tightened Reassemble Torque Tube Assembly to Hub Assembly Do not use Loctite on screws Tip If it is hard to capture posts in cap push against stay to help align universal If necessary loosen backstay Lift foils so top is 1 2 3 8 12 mm 16 mm below upper terminal Slide foil clamp into foil notches and tighten screws to secure Check to make sure there is a 1 16 1 8 2 4mm gap 34 M...

Page 35: ...re is no clicking sound lead line through block in opposite direction Lead line to Furling Line Cleat in cockpit 7402 Ratchet Stanchion Block Install so line is angled as shown Use 10 5 mm fasteners HCP168 Furling Line Cleat Run line through enclosed window in guard and into hole in bottom plate of spool Tie a small overhand knot and pull it up under drum assembly Mount Lead Blocks Furling line ca...

Page 36: ...using a secure hoisting method Inform rigger that there has been a halyard wrap so they can avoid an accident by relying on standing rigging or halyards Inspection must be done while rigger is suspended from a separate crane or mast must be lowered to perform inspection Some professionals may rig a new line through internal masthead sheaves to serve as a temporary headstay to hold mast in place Wi...

Page 37: ... 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 Halya...

Page 38: ...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 necess...

Page 39: ...shackle Install shackle so screw pin head is on same side as sun cover 3 Secure genoa sheets to clew of sail 4 Attach genoa halyard to halyard swivel 5 Pass luff tape through prefeeder and feeder into foil groove 6 Attach head of sail or pendant at head of sail to halyard swivel 7 Hoist sail Tip New sails are often stiff and may hang up on prefeeder during raising Do not force sail when it hangs u...

Page 40: ...ound on spool c Furling line securely cleated d Jib sheets securely wrapped on winch and held in self tailing jaws Furl at dock with tension on sheets to duplicate furling in high wind Remember sails furled in light wind and left loosely secured can be a problem if wind increases IMPORTANT Remove sail from furler if extreme winds are predicted especially if boat is left unattended IMPORTANT Check ...

Page 41: ...r stud unless you disassemble terminal stud Make sure you use a new Norseman Sta Lok wedge to reassemble Norseman Sta Lok fitting 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 feeder carefully bottom end first Don t lose the feeder overboard Lower swivel onto torque tube Replace feeder Remove Feede...

Page 42: ...er Occasionally lower sail and flush halyard swivel with soap and fresh water At least twice a year unit should be cleaned more thoroughly by removing line first note direction of spool and flushing bearings with soap and fresh water After unit has dried apply a dry spray lubricant such as McLube Foils may be cleaned by washing with soap and water A scrap of luff tape may be run up foil to scrub i...

Page 43: ...ight 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 Furling line is not free Free furling line Sail will not furl completely Insufficient furling line on drum Remove sheets Rotate stay wrappi...

Page 44: ... 10 w Nosepiece 1 7423 10 1 Stud Main Body 1 H 41536 2 Nosepiece 10 1 H 41535 3 Cotter Pin 3 32 x 1 2 HFG193 5 Grip Length Pin Measurements Pin measurements are Grip Length 3 7424 12 7424 17 3 7422 8 7423 10 5 1 2 4 HFG923 3 MP 118 MP 118 H 35144A MP 118 H 35144A H 35144A MP 118 MP 129 H 35144A 1 2 4 3 5 1 1 2 2 4 H 35144A 3 No Description Order Part No Torque Tube Assembly 1 HFG927 1 Clamp 1 H 42...

Page 45: ...le 33 34 Lead Line to Cockpit 35 Halyard Swivel Height Angle 36 Halyard Restrainer Tension 37 Operation Halyard Headstay Tension 38 Raise Sails Storm Sails Reefing 39 40 Secure Sail 40 Race Conversion 41 Maintenance Clean Lubricate Inspect 42 Confirm Deck Flange Tack Swivel Gap 42 Replace Line 42 Storage Transporting 42 Remove Furler 42 Troubleshooting Warranty 833 HFG739 7404 945 8 2110 349 131 7...

Page 46: ... 7424 12 1 Stud Main Body 1 H 41531 2 Nosepiece 12 1 H 41527 3 Cotter Pin 3 32 x 1 2 HFG193 Rod Adapter Stud 17 w Nosepiece 1 7425 17 1 Stud Main Body 1 H 41531 2 Nosepiece 17 1 H 41526 3 Cotter Pin 3 32 x 1 2 HFG193 5 4 HFG924 3 MP 123 MP 123 H 33860A MP 123 MP 127 H 33860A 1 2 5 1 1 2 2 4 H 33860A 3 No Description Order Part No Torque Tube Assembly 1 HFG928 1 Clamp 1 H 42346 1 Clamp Screw M6 x 1...

Page 47: ...Boat 29 31 Feeder Final 32 Commissioning Turnbuckle 33 34 Lead Line to Cockpit 35 Halyard Swivel Height Angle 36 Halyard Restrainer Tension 37 Operation Halyard Headstay Tension 38 Raise Sails Storm Sails Reefing 39 40 Secure Sail 40 Race Conversion 41 Maintenance Clean Lubricate Inspect 42 Confirm Deck Flange Tack Swivel Gap 42 Replace Line 42 Storage Transporting 42 Remove Furler 42 Troubleshoot...

Page 48: ... Screws 1 HFG690 Flange 2 H 35465C Bottom Flange Screw M5 x 8 x 12MM 2 HFS1060 Guard Assembly 1 HFG691 Guard Set 2 H 33758E Guard Screw M8 x 1 25 x 50MM SHCS 2 HFS873 1 2 2 4 H 38168 3 4 3 No Description Order Part No Torque Tube Assembly 1 HFG929 1 Clamp 1 H 42967 2 Clamp Screw M8 x 1 25 x 25MM SHCS 4 HFS1107 Hub Assembly 3 4 1 HFG925 1 Cotter Pin 5 32 x 1 250 4 HFS203 2 Clevis Pin 3 4 x 1 766 4 ...

Page 49: ...BLACK H 42074 7413 FOILSET CLEAR HFG297 HFG627 HFG324 H 39392 H 39916 H 39916 MP 128 MP 128 MP 128 MKIV furlers began shipping with black foils in April 2021 Clear anodized foils also available 7413 30 CLEAR 7413 33 CLEAR 7413 FOILSET BLACK Description Order Part No Trim cap set w o screws 1 HFG682 Trim cap screw set 1 HFG672 Trim cap screw 2 HFS1127 Halyard swivel 1 H 39392 Clip smalley ring for ...

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Page 51: ...mm 2 362 60 mm 3 464 88 mm 3 351 85 1 mm 4 54 115 4 mm 4 694 119 25 mm Ø 4 5 114 3 mm Measure this distance to verify that template printed correctly Deck Flange Diameter 3 7 94mm IMPORTANT If you print this template from a computer file measure to confirm that template is the correct size before drilling ...

Page 52: ...This Page Intentionally Left Blank ...

Page 53: ... 2 678 68 mm 3 936 100 mm 3 698 93 9 mm 5 07 128 8 mm 5 28 134 1 mm Ø 5 032 127 82 mm Measure this distance to verify that template printed correctly Deck Flange Diameter 4 2 106 5 mm IMPORTANT If you print this template from a computer file measure to confirm that template is the correct size before drilling ...

Page 54: ...This Page Intentionally Left Blank ...

Page 55: ... 140mm 3 444 87 5 mm 5 2 132 1 mm 4 665 118 5 mm 6 531 165 9 mm 6 77 172 mm Ø 6 471 164 36 mm Measure this distance to verify that template printed correctly Deck Flange Diameter 5 45 138 5 mm IMPORTANT If you print this template from a computer file measure to confirm that template is the correct size before drilling ...

Page 56: ...rken New Zealand Ltd 30 36 Fanshawe Street P O Box 1951 Auckland 1001 New Zealand Telephone 64 9 303 3744 Fax 64 9 307 7987 Web harken co nz Email harken harken co nz Harken Polska SP ZOO ul Rydygiera 8 budynek 3A lokal 101 I piętro 01 793 Warszawa Poland Tel 48 22 561 93 93 Fax 48 22 839 22 75 Web harken pl Email polska harken pl Harken Sweden AB Main Office and Harken Brandstore Västmannagatan 8...

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