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Harken MKIV, Installation Manual

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Harken MKIV Installation Manual Download Page 11

Assembly 

Top Foil

Deburr inside edge using rat-tail 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.

 

MKIV Unit 1 

11

Summary of Contents for MKIV

Page 1: ...ions Sailmaker s Instructions 6 Toggle Deductions Stay Into Foil Options 7 Top Foil Length 8 Short Top Foil 9 Confirm Foil Length 10 Assembly Foils Connectors 11 17 Halyard Swivel 17 Drum Assembly 18 Rod Rigging 19 Turnbuckle Toggle 20 21 Final Feeder 22 23 Commissioning Turnbuckle 24 Line to Cockpit 25 Halyard Wrap Prevent Halyard Wrap 26 Pendant Halyard Restrainer Halyard Tension 27 Operation Sp...

Page 2: ...d 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 or...

Page 3: ...s 8 10 12 5 72 mm 6 35 mm 7 14 mm Toggle Part No Description Chainplate Clevis Pin Size 7411 20 1 2 Eye jaw reversible 1 2 12 7 mm 7311 20 1 2 Jaw jaw 1 2 12 7 mm 7311 20 5 8 Stud jaw 5 8 15 9 mm 7311 21 1 2 Long link plate w toggle 1 2 12 7 mm 7311 21 5 8 Long link plate w toggle 5 8 15 9 mm Chainplate Clevis Pin MKIV Unit 1 3 Preassembly Sizing Check 10 11 12 13 14 15 9 16 Size Check 1 Check hea...

Page 4: ...ector HFG295 1 Connector bushing set 12 H 42062 12 H 42063 HFG299 1 Plastic connector wedge set 14 H 39625 HFG343 1 Foil screw set 30 HFS1105 HFG680 1 Trim cap set H 37361 H 37362 HFG629 1 Trim cap screw set 3 HFS1126 947 1 Prefeeder H 39683 1 Feeder with screw and tab 2110 3 6 mm Bow shackles HFG739 2 Red Loctite for foil screws HFG725 1 Injector 1 oz 5200 Adhesive HFG722 Other Components 2 5 4 5...

Page 5: ...er they are left on the ground or raised up on boat Foils can be raised immediately after assembly and sails fitted Note A small amount of adhesive may bulge out of injection ports If possible let system sit for a couple days before sailing If adhesive gets on sails remove using acetone For faster curing adhesive purchase 4200 Fast Cure Note Damaged foils can be repaired Use a hand held propane to...

Page 6: ...ote If a long link plate is used add the following dimensions to feeder shackle and drum height based on whether plate is used full length or shortened to one of five hole positions Do not add to halyard swivel or top terminal dimensions 1 2 12 7 mm Clevis Pin Add 131 2 to 63 8 343 mm to 162mm 5 8 15 9 mm Clevis Pin Add 111 4 to 43 8 286 mm to 111 mm Toggle Used 1 2 12 7 mm 5 8 15 9 mm 2 51mm A B ...

Page 7: ...positive lock as well as adhesive Use Harken stud with cotter pins see page 19 Options for Snaking Stay into Foils 31 4 83mm Eye Jaw Reversible 1 2 12 7 mm Clevis Pin Jaw Jaw 1 2 12 7 mm Clevis Pin Make sure your toggle looks like this 3 76 mm Use dimensions of Harken toggle below to build stay to correct length Tip Turnbuckles should be 1 2 to 2 3rds open to allow shortening for new wire stretch ...

Page 8: ...20 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 12000 mm D 10668 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 ...

Page 9: ...nly 3 1 2 3 90 75 mm Under 1 25 mm Eliminate top foil and run foil higher in drum assembly 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 mm No 2 51 mm...

Page 10: ...that length of stay with Harken toggle will fit boat Ideally turnbuckle will be half to two thirds open to allow for rig adjustment Line up drum assembly so holes below drum line up with holes in Harken toggle Make sure toggle is tensioned when measuring Note Position top foil so that with top cap the foil will ride 1 2 13 mm below terminal If wire fitting at top of stay is swage foil must ride ju...

Page 11: ...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 MKIV Unit 1 11 ...

Page 12: ...se a center punch to mark holes Check center punch marks to confirm they are 3 16 5 mm and 1 25 mm from top of foil Drill two 2 1 8 3 2 mm holes for trim cap Lay top foil in line with others Slide stay into top foil and down the line of foils or slide each foil up stay 3 16 5 mm 1 25 mm Foil Top 12 MKIV Unit 1 ...

Page 13: ...as shown below place longer half of bushing with hook on upper half Install trim cap Place each side over wire Assemble Halyard Deflector if used Push trim cap into foil to start then tap in using hammer Install trim cap screws Loctite is a registered trademark of Henkel AG Company KGaA MKIV Unit 1 13 Red Loctite Halyard Deflector ...

Page 14: ... Foil Connectors Slip 7 177 8 mm connector on wire mating hook of plastic bushing with connector 14 MKIV Unit 1 Loctite is a registered trademark of Henkel AG Company KGaA Put a drop of red Loctite into screw holes ...

Page 15: ...ot 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 plunger is...

Page 16: ...t of adhesive into middle hole Unit 1 will only take 1 3 1 2 of a 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 3 to 1 2 ml of adhesive Stop when you see a small amount of adhesive enter one of the screw holes Tighten screws into connector holes Make sure a drop of red Loctite entered each s...

Page 17: ...wivel onto foil above feeder window Make sure taller half is up as shown Loctite is a registered trademark of Henkel AG Company KGaA MKIV Unit 1 17 Assembly Bottom Foil Connectors Halyard Swivel Continue installing connectors and wedges Make sure to use red Loctite in screw holes Red Loctite ...

Page 18: ...Loosen foil clamp screws at top of drum assembly Slide drum assembly onto foils Tip Face clamp downward so it clears foil notches during installation Assembly Drum Assembly 18 MKIV Unit 1 ...

Page 19: ...registered trademark of Henkel AG Company KGaA MKIV Unit 1 19 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 R O D R I G G I N ...

Page 20: ...ch Harken toggle Note If using Sta Lok or Norseman stud you must use a washer above stud as shown below Stud Jaw Toggle Assembly Eye Jaw Toggle Assembly Make sure shallow jaw is up 20 MKIV Unit 1 STA LOK is a registered trademark of STA LOK Terminals Ltd Turnbuckle Clevis Pin Toggle Clevis Pin Crosspin ...

Page 21: ...AG Company KGaA MKIV Unit 1 21 Make sure drum assembly has four threaded holes in base Determine height of link plates to provide anchor clearance and cut to length Cut at scribe mark Deburr edges Connect eye to toggle jaw using special clevis pin Secure using cotter pin Toggle For Long Link Plates Blue Loctite WARNING Stay must attach to toggle Do not attach stay to crosspin at drum assembly beca...

Page 22: ...iers to bend cotter pin to secure turnbuckle Clevis Pin Crosspin at 90 to Clevis Pin Slide lower drum assembly over turnbuckle and attach using long crosspin Use plastic washers provided WARNING Crosspin must be 90 degrees to clevis pin that attaches unit to boat If pins run same direction toggle will fatigue and could break suddenly 7311 20 5 8 stud jaw toggle ...

Page 23: ...with some difficulty It is plastic coated to prevent loosening due to vibration Important When removing screw loosen no more than one full turn Slide screw up and remove feeder Tip Do not remove foil clamp screws to adjust foil Loosen screws hold foils and bring clamp away from foils Adjust and reclamp Assembly Feeder Final MKIV Unit 1 23 ...

Page 24: ...1 5 m Raise foils using second halyard and secure Allow room above for turnbuckle take up Adjust turnbuckle Replace used cotter pins Lower drum assembly and install clevis pin and new cotter pin Lift foils so top is 5 8 16 mm below upper terminal CAUTION Foils can drop suddenly causing injury to hands Make sure drum assembly and foils are securely lifted using a halyard before adjusting turnbuckle...

Page 25: ...on If there 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 Mount Lead Blocks Furling line can be led down either side of boat If boat is in slip consider mounting opposite dock Remove four screws on stanchion blocks Clamp blo...

Page 26: ...ng 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 Wire rod rigging termin...

Page 27: ...nsion 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 Halyard ...

Page 28: ...l slightly 28 MKIV Unit 1 On 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 externa...

Page 29: ...f sail to drum 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 ...

Page 30: ... 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 all poi...

Page 31: ...yard swivel 6 Reattach headstay to boat Remove Drum 1 Remove sail and unwind line from drum Line can remain attached to drum 2 Use 5 mm hex key provided to remove 2 screws on bottom of guard assembly and remove two halves Be careful screws are not captive 3 Use a 2 5 mm hex key to loosen four screws in plastic cover and flange Halyard Swivel Below Feeder Use halyard to lift halyard swivel up away ...

Page 32: ...evis pin and shift furler up so drum assembly can be strapped securely to mast Some people remove drum assembly and halyard swivel for storage and transport After Storage or Transport After storing or transporting unit clean thoroughly including ball bearings See instructions above Loosen Foil Clamp Before Slacking Backstay In order to prevent foils from locking against upper stay terminal when ba...

Page 33: ...yard angle Foils riding on turnbuckle Raise foils See adjusting turnbuckle on page 24 Foils too high binding on swage eye Lower foils See adjusting turnbuckle on page 24 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 detergent and ...

Page 34: ...H 42178 3 Upper Clevis Pin Custom 1 H 42170 H 42171 4 Lower Clevis Pin 1 H 42395 H 42397 5 Isolator 2 H 42182 H 42182 6 Cotter Pin 2 HFS220 HFS203 7 Nylon Locking Nut M10 2 HFS846 HFS846 8 AllenCapScrews M6x1x12MMSHCS 4 HFS876 HFS876 9 Loctite Blue 1 833 833 1 8 x 1 18 8 5 32 x 11 4 18 8 No Description Order Part No Eye Jaw Toggle Reversible 1 7411 20 1 2 1 Toggle 1 H 37675C 2 Crosspin 5 16 x 211 ...

Page 35: ...om 10 75 273 mm 1 Connector Bushing Curved Longer 2 Connector Bushing Flat Shorter 2 Connector Wedge Set 1 HFG299 Connector Wedge 14 H 39625 Feeder Set 1 H 39683 Feeder 1 H 35623B Feeder Screw 1 HFS1129 Tab 1 H 35666A HFS1126 H 39812 7404 944 10 HCP1387 HFG640 HFG643 2110 H 36125A H 36125A MP 129 MP 129 MP 129 7411 FOIL SET 7411 31 7411 32 HFG299 HFG722 947 HFG200 HFG201 HFG233 Please read these i...

Page 36: ...Harken 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...

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