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Harken MKIV Unit 3, Installation Manual

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Harken MKIV Unit 3 Installation Manual Download Page 23

 

MKIV hydraulic unit 3 

23

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

Install cover plate using blue Loctite  

on screws.

Slip toggle housing insulator onto  

eye terminal. Remove toggle plate.  

Use cross pin to capture eye and  

toggle in housing.

Loctite is a registered trademark of Henkel AG & Company KGaA.

Summary of Contents for MKIV Unit 3

Page 1: ...iptions 2 3 Sizing check 3 Parts 4 5 Rigging parts check tools 6 Hydraulic system 7 8 Toggle deductions stay into foil options 9 Top foil lengths 10 11 Short top foil 11 Confirm foil length 12 Assembly Foils connectors 13 18 Bottom foil connectors halyard swivel 19 Lower unit to foil 20 Rod rigging rod adapter stud 21 Attach turnbuckle toggle 22 23 Attach hydraulic cylinder 23 24 Feeder final 25 C...

Page 2: ...ined 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 The user must have appropriate training in order to use this product Harken accepts no responsibility for damage...

Page 3: ...ils standard Silver foils available 7 16 1 2 11 mm 12 mm Rod Ø 7413 16 MKIV hydraulic unit 3 carbon foils 22 30 9 53 mm 11 10 mm Toggle part no Description Toggle clevis Ø 7413 25 3 4 Toggle assembly 3 4 19 1 mm 7413 25 7 8 Toggle assembly 7 8 22 2 mm 7413 26 3 4 Hydraulic cylinder toggle 3 4 19 1 mm 7413 26 7 8 Hydraulic cylinder toggle 7 8 22 2 mm 18 19 D G E F B A C H See page 39 for all toggle...

Page 4: ...andard 7413 33 BLACK 1 7 2 13 m foil clear anodized special order 7413 30 CLEAR 10 2 610 mm bottom foil clear special order 7413 33 CLEAR 1 Halyard swivel H 39392 1 Emergency crank handle 7430 1 Drill adapter for manual drive 7431 1 Halyard swivel unit 3H Emergency crank handle Drill adapter for manual drive Lower unit unit 3H 2 13 m 10 7 foils Unit 3 4 2 610 mm Bottom Foil Silver foils available ...

Page 5: ...or 7413 32F 1 14 356 mm Connector bushing set HFG297 20 EA H 42073 H 42074 1 Plastic connector wedge set HFG324 22 EA H 39487 1 Foil screw set HFG349 46 EA HFS1106 1 Trim cap set HFG682 H 39751 H 39752 1 Trim cap screw set HFG672 3 EA HFS1127 1 Prefeeder 947 1 Feeder with screw and tab H 39756 1 10 mm bow shackle 2124 3 10 mm Red Loctite HFG739 2 017 oz Blue Loctite 833 1 017 oz Injector 1 oz 5200...

Page 6: ...or black tape 3 Power drill 8 Hex wrenches provided 13 Scissors 4 Drill bit 5 32 4 mm 9 Slotted Phillips screwdrivers 14 Metal straight edge 5 Hacksaw 10 Needle nose pliers 15 Hammer 16 Metric ball end hex wrenches recommended but not required 10 13 12 11 8 7 6 5 3 2 1 15 4 14 9 Toggle assembly 1 Harken toggle assembly or hydraulic cylinder required Sold separately 2 Mating turnbuckle components w...

Page 7: ...ommendation Hose type SAE 100 R8 hose Alternatively SAE 100 R2 may be used Hose size Use 6 hose 3 8 ID Long runs may require larger hoses Hose end fitting furler end Female swivel hose end to mate with adapter Note See hydraulic connection to furling unit next page Measure hydraulic hose runs Remember these important points when measuring runs 1 Short straight runs between HPU and function are bes...

Page 8: ...ure prior to disconnecting Only work on cylinder and connections if you are a hydraulic technician 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...

Page 9: ...ay Stroke length for unit 3 cylinder is 100 mm 4 Options for snaking stay into foils Toggle part no Clevis pin Ø Pin to pin length 7413 25 3 4 3 4 19 1 mm 31 4 83 mm 7413 25 7 8 7 8 22 2 mm 37 8 98 mm Hydraulic cylinder part no Clevis pin Ø Max pin to pin length Min pin to pin length 7413 26 3 4 3 4 19 1 mm 20 50 mm 16 400 mm 7413 26 7 8 7 8 22 2 mm 201 2 525 mm 161 2 420 mm WARNING Using a thread...

Page 10: ...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 20000 mm D 19202 mm 5 Result C top foil length 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 check Alternate measureme...

Page 11: ...2 mm 5 3 8 4 Under 38 mm 11 2 eliminate top foil and run foil higher in foil clamp Under 38 mm 1 1 2 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 61 1...

Page 12: ...urnbuckle will be one half 1 2 to two thirds 2 3 open to allow for rig adjustment 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 Note Position top foil so that with top cap the foil will ride 25 mm 1 below terminal If wir...

Page 13: ...il file Cut foil to length 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 cut off piece and use a flat metal object i e metal ruler to scribe top line of foil ...

Page 14: ... 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 13 8 from top of foil Drill two 2 4 mm 5 32 holes for trim cap 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 35 mm 13 8 10 mm 3 8 ...

Page 15: ...ay 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 Install trim cap Place each side over wire Push trim cap into foil to start then tap in using hammer Install trim cap screws Hook on upper half ...

Page 16: ...nit 3 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 ...

Page 17: ...or screw holes 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 three 3 hours Use cap of adhesive to break seal Remove injector tip cap and plunger Hold injector at an angle with applicator tip fa...

Page 18: ... hole and insert into other foil Use 1 to 11 4 ml of adhesive Use ml marks to estimate 1 to 11 4 ml of adhesive Stop when you see a small amount of adhesive enter one screw hole Unit Adhesive 3 1 to 11 4 ml Inject a small amount of adhesive into middle hole Tip When you see a small amount of adhesive enter one screw hole stop You have applied enough adhesive Red Loctite Loctite is a registered tra...

Page 19: ...s shown Assembly Bottom Foil Connectors Halyard Swivel Continue installing connectors and wedges Make sure to use red Loctite adhesive in screw holes Continue assembly Use 356 mm 14 bottom connector to assemble bottom foil Red Loctite Red Loctite Loctite is a registered trademark of Henkel AG Company KGaA ...

Page 20: ...KIV hydraulic unit 3 20 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 Assembly Lower Unit to Foil ...

Page 21: ...y 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 Flats will be close and may only require a small half turn to align with cotter pin holes Loctite is a registered trademark of Hen...

Page 22: ...ng Note If using Sta Lok or Norseman stud you must use a washer above stud as shown below If stay length is set use side cutters or needle nose pliers to bend cotter pin to secure turnbuckle Make sure shallow jaw is up Up Down Install cover plate using blue Loctite adhesive on screws Loctite is a registered trademark of Henkel AG Company KGaA Sta Lok is a registered trademark of Sta Lok Terminals ...

Page 23: ...or and secure toggle assembly to lower unit using blue Loctite adhesive on screws Attach hydraulic cylinder Install cover plate using blue Loctite on screws Slip toggle housing insulator onto eye terminal Remove toggle plate Use cross pin to capture eye and toggle in housing Loctite is a registered trademark of Henkel AG Company KGaA ...

Page 24: ...c connections will be on the aft side Line up insulator and secure cylinder assembly to lower unit using blue Loctite adhesive on screws Chainplate runs athwartships Position the calibrated guide rod so it is aft Hydraulic connections will be on the starboard side Chainplate fore aft orientation Chainplate athwartships orientation Loctite is a registered trademark of Henkel AG Company KGaA ...

Page 25: ...b catches under foil Tighten screw Note Screw will turn with some difficulty It is plastic coated to prevent loosening from vibration Important When removing screw loosen no more than one full turn Slide screw up and remove feeder Assembly Feeder Final Check foil height at top Set and secure using hex wrench ...

Page 26: ...ing screws Use halyards to securely lift and hold foils and lower unit Adjust turnbuckle Replace used cotter pins and locknuts Lower unit and install clevis pin and new cotter pin Lift foils so top is 25 mm 1 below upper terminal Raise lower unit and use halyard to lift and hold it about 1 5 m 5 Raise foils using second halyard and secure Allow room above for turnbuckle take up WARNING Foils are h...

Page 27: ... wraps do not force unit to turn Attempt to open sail by carefully furling in and out a little at a time If sail will unfurl lower it by releasing jib halyard Severe halyard wraps can only be cleared by going aloft and freeing halyard If sail will not furl or unfurl try removing jib sheets and manually wrapping sail around headstay Testing at dock does not indicate halyard angle is correct In wave...

Page 28: ...en under load The restrainer should deflect halyard as little as possible or you may experience difficulty in tensioning sail luff as well as friction when furling resulting in possible damage to foils To decrease deflection angles shorten sail luff Tip Boats used in charter service should have a halyard restrainer regardless of masthead geometry Halyard tension The jib halyard should be firm but ...

Page 29: ...sucked into the 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 necessary to flip both ends of spinnaker halyard behind spreaders to prevent fouling the fur...

Page 30: ...der into foil groove 6 Attach head of sail or pendant at head of sail to halyard swivel 7 Hoist sail 8 Attach genoa tack to lower unit shackle 8 Once sail is raised determine the direction of furling so suncover will shield sail from UV rays when furled 9 Suncover on port side of sail furl clockwise Suncover on starboard furl counterclockwise Tip Once you have determined the direction of furl to m...

Page 31: ... Explain procedure for controlling the boat and have someone ease sheets as you rotate the handle 2 Have an emergency handle available 3 Use all personal safety precautions including PFD harness and tether before going forward 4 Position shift lever on right side as shown in photo 5 Use the emergency handle or a cordless drill to turn the foil until the sail is reefed or furled Furling or reefing ...

Page 32: ...Slide screw up Remove feeder 3 Lower halyard swivel To Remove Feeder For Racing 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 ...

Page 33: ...crap of luff tape may be run up foil to scrub inside grooves Sail luff tapes may be sprayed with McLube to reduce friction during sail changes Spray sails off boat so McLube spray does not contact deck Maintenance Clean and Lubricate Inspect Storage Inspect Inspect unit for signs of chafe wear or damage Inspect clevis and cotter pins below and inside lower unit for signs of loosening Check headsta...

Page 34: ...turnbuckle on page 27 Foils too high binding on swage eye Lower foils See adjusting turnbuckle on page 27 Jib halyard is too tight 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 Sail will not...

Page 35: ...4 Cross pin 7 8 1 H 51476 5 Toggle housing 7 8 1 H 51474 6 Toggle housing screws M8 x 70 mm SHCS 6 HFS1064 7 Cotter pin 5 32 x 1 25 1 HFS203 8 Clevis pin 7 8 x 1 96 grip length 1 H 42404 9 Jaw jaw toggle 7 8 1 H 42562 1 2 3 4 5 2 1 6 7 8 9 No Description Order Part no Torque tube foil clamp 1 H 42967 Torque tube screws M8 x 25 mm SHCS 4 HFS1107 Red ring 1 S281680097 Lower unit reorder parts shown ...

Page 36: ...6 3 4 1 Toggle housing insulator 1 H 51475 2 Cross pin 3 4 1 H 52246 3 Toggle plate 2 H 51477 4 Toggle plate screws M5 X 16 mm SHCS 8 HFS982 5 Toggle housing screws M8 X 70 mm SHCS 6 HFS1064 6 Clevis pin 3 4 x 1 76 grip length 2 H 42403 7 Jaw jaw toggle 3 4 1 H 41489 8 Cotter pin 5 32 X 1 25 1 HFS203 Hydraulic cylinder 7 8 pin 1 7413 26 7 8 1 Toggle housing insulator 1 H 51475 2 Cross pin 7 8 1 H ...

Page 37: ...nbuckle on boat 25 Halyard swivel height lead angle 26 Halyard restrainer tension 27 Operation Spinnaker halyards headstay tension 28 Reefing secure sail 29 Manual operation 30 Race conversion 31 Maintenance Inspection Decommissioning 32 Troubleshooting Warranty 33 Appendix Component part number list 34 36 Toggle dimensions 37 Dimensions sailmaker s instructions 38 HFG349 HFG672 5 HFG682 7413 30 B...

Page 38: ... 90 0 814 20 68 1 746 44 35 0 468 11 89 2 50 8 7413 25 7 8 7413 26 7 8 2 662 67 61 2 50 80 1 156 29 36 0 868 22 05 0 94 23 88 1 938 49 23 0 499 12 67 2 312 58 72 Toggle dimensions apply to standard toggle and cylinder option A does not apply to cylinder D G E F B A C H Unit Part no 3H 7413 25 3 4 7413 25 7 8 Unit Part no 3H 7413 26 3 4 7413 26 7 8 Appendix Toggle Dimensions ...

Page 39: ...may be installed on either side of sail Be sure to match other sails in the customer s inventory A B Toggle assembly A B C D E Max E Min in mm in mm in mm in mm in mm in mm 7413 25 std 75 16 186 115 8 296 18 457 37 8 98 47 1194 7413 25 7 8 std 75 16 186 115 8 296 18 457 37 8 98 479 16 1209 7413 26 cylinder 75 16 186 115 8 296 18 457 37 8 98 635 8 1616 595 8 1515 7413 26 7 8 cylinder 75 16 186 115 ...

Page 40: ...ne Centre Westhaven Aukland 1010 New Zealand Telephone 64 9 303 3744 Fax 64 9 307 7987 Web harken co nz Email harken harken co nz Harken Polska Sp z o o ul Przasnyska 6A 01 756 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 81B SE 113 26 Stockholm Sweden Telephone 46 0303 61875 Fax 46 03...

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