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Harken Unit 0 ESP, Installation Manual

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Harken Unit 0 ESP Installation Manual Download Page 1

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.

  

PLEASE SAVE THESE INSTRUCTIONS

ESP JIB REEFING & FURLING

Unit 0, 1

Installation Manual – Intended for specialized personnel or expert users

5002 05/14

Preassembly

 

Safety Precautions/Parts Descriptions 

2 – 3

 Specifications 

3

 

Parts List 

4 – 6

 Tools 

6

 

Top Foil 

7 - 8

 

Toggle Deductions/Stay Into Foil 

9

 

Confirm Foil Length 

10

 

Cutting/Drilling Top Foil 

11 - 12

Assembly

 

Foils/Connectors/Halyard Deflector 

13 – 17

 

Halyard Swivel 

17

 

Drum Assembly 

17 – 18

 

Leg Kit with Toggle Assembly 

19 – 21

 Final 

22

Commissioning

 

Line to Cockpit/Line on Drum Assembly 

23 – 24

 

Storm Sails 

24

 

Raise Sail 

25

 

Check Halyards 

26

Operation

 Check 

Halyards 27

 

Furl/Reef 

28 – 29

 

Secure Sail 

29

 

Adjust Turnbuckle 

30

Maintenance

 

Clean/Inspect 31

 Storage 

31

Troubleshoot 

32

Product Registration 

32

Online Warranty/Product Registration 

32

Appendix 
 

Dimensions/Sailmaker's Instructions 

33

Summary of Contents for Unit 0 ESP

Page 1: ...rts List 4 6 Tools 6 Top Foil 7 8 Toggle Deductions Stay Into Foil 9 Confirm Foil Length 10 Cutting Drilling Top Foil 11 12 Assembly Foils Connectors Halyard Deflector 13 17 Halyard Swivel 17 Drum Assembly 17 18 Leg Kit with Toggle Assembly 19 21 Final 22 Commissioning Line to Cockpit Line on Drum Assembly 23 24 Storm Sails 24 Raise Sail 25 Check Halyards 26 Operation Check Halyards 27 Furl Reef 2...

Page 2: ...rvice This information is destined 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 accept...

Page 3: ...bly Short Leg Kit with Toggle Assembly Medium Leg Kit with Toggle Assembly Long Clevis Pin Ø Wire Ø Rod Sizes 0 7320 10 7320 20 7320 21 5 16 3 8 8 mm 9 5 mm 5 32 3 16 4 5 mm 4 4 37 mm 1 7321 10 7321 20 7321 22 7321 21 7 16 1 2 11 12 7 mm 7 32 1 4 9 32 5 16 6 7 8 mm 6 8 10 5 03 5 72 6 35 mm Note When using a turnbuckle you must use a Medium or Long Leg Kit assembly Check max turnbuckle length above...

Page 4: ... 3 8 21 16 52 mm 1 7321 20 7 16 1 2 21 8 53 mm 1 Medium leg kit with toggle 1 7321 22 7 16 1 2 61 4 159 mm 1 Long leg kit with toggle 7320 21 5 16 3 8 73 16 183 mm 1 7321 21 7 16 1 2 111 16 280 mm 1 Adjuster tube clamp screws HFS1252 8 mm 2 HFS1252 8 mm 3 Blue Loctite 833 1 833 1 Drum Box Blue Loctite Drum Assembly Adjuster Tube Clamp Screws Medium or Long Leg Kit Required for installation with tu...

Page 5: ...p foil 7320 34 2000 1 7321 34 2000 1 Foil screws HFS384 23 HFS384 31 Connectors H 60148 4 H 59907 5 Connector bushings H 58466 10 H 55887 12 Connector wedges MP 1894 10 MP 1894 14 Feeder H 58461 1 H 55904 1 Adjuster tube bushing MP 1975 2 MP 1976 2 Red Loctite HFG739 2 HFG739 2 Order Separately Extra foil see page 7 8 7320 30 1 7321 30 1 Extra connector with bushings 7320 31 1 7321 31 1 Adjuster t...

Page 6: ...o not use with turnbuckle Harken Medium or Long Leg Kit with toggle Required for turnbuckle Rod rigging requires Harken rod adapter stud Furling line To purchase elsewhere figure length required Boat length foot length of largest sail 6 1 8 m Optional parts sold separately by Harken Halyard Deflector Use when halyard exits very close to stay attachment point 7404 Lead Block Kit and one additional ...

Page 7: ... number from chart below that is closest to but not greater than total from step 3 Inches mm 3 X 78 74 236 2 4 X 78 74 315 0 5 x 78 74 393 7 6 x 78 74 472 4 3 x 2000 6000 4 x 2000 8000 5 x 2000 10000 6 x 2000 12000 Example If result from Step 3 is 400 inches D 393 7 inches 11 500 mm D 10000 mm 5 Result C Top Foil Length After completing worksheet above fill in A C D and G below Add A through G to ...

Page 8: ... step 3 Inches mm 3 X 78 74 236 2 4 X 78 74 315 0 5 x 78 74 393 7 6 x 78 74 472 4 7 x 78 74 551 2 8 x 78 74 629 9 3 x 2000 6000 4 x 2000 8000 5 x 2000 10000 6 x 2000 12000 7 x 2000 14000 8 x 2000 16000 Example If result from Step 3 is 500 inches D 472 44 inches 11500 mm D 10000 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...

Page 9: ...20 20 3 8 3 8 10 11 4 32 Long 7320 21 3 8 1 Short 7321 20 7 16 7 16 11 17 16 37 Medium 7321 22 7 16 Long 7321 21 7 16 Short 7321 20 1 2 1 2 13 15 8 42 Medium 7321 22 1 2 Long 7321 21 1 2 Medium or Long Leg Kit with Toggle Pin to Pin Length Short Leg Kit with Toggle Pin to Pin Length Turnbuckle with Marine Eye 1 Swage Stud 2 Marine Eye 3 Wire for Mechanical Terminal 4 Harken Rod Adapter Nosepiece R...

Page 10: ...ly holes C Lower holes in leg kit line up with eye in toggle Lay all foils out alongside stay and confirm that there will be enough space between the bottom of the marine eye and the end of the top foil If necessary go to lower end reposition the adjuster tube and lower full length foil to another position Confirm that there are two holes for the foil and one for the feeder C B A Adjuster Tube Ful...

Page 11: ...es Use a flat metal object i e metal ruler to scribe lines on one side of foil Leave foils clamped for drilling Determine top foil length using charts or by laying foils alongside wire IMPORTANT Confirm that you are using the correct unit size worksheet Be sure to lay foils lower unit and leg kit alongside stay to confirm length before cutting T o p F o i l Foil screw holes for connector Trim Cap ...

Page 12: ...ping foils clamped together flip them to the other side and repeat the procedure so there is a hole on each side Measure from the end of the foil and put a mark showing hole distance from top of foil Unit Decimal in Fraction in mm 0 59 19 32 15 1 98 1 25 Top Foil T o p F o i l Tool short tape measure Tools electric drill drill bit center punch ...

Page 13: ... the top of stay Note On top foils under 10 250 mm load top connector so that cutouts for bushings face down toward the bottom of stay 2b Load onto wire from top and or bottom 3 Make sure that special length top foil with trim cap holes is at top of stay Trim Cap Holes Trim cap holes a Cutout up b Top of Stay Cutout down Top foil under 10 250 mm Reverse top connector so bushing cutout is down b To...

Page 14: ...lyard Deflector 4 Put trim cap halves together over wire and tap in place Tool hammer 5 Secure with trim cap screws Tool Phillips screwdriver 6 If using halyard deflector install above foil Use red Loctite on screws Halyard Deflector Red Loctite ...

Page 15: ...lotted screwdriver 7 Hold plastic bushing halves in cutouts and over wire and insert up into foil 7a Make sure foil and connector screw holes are facing up 7b Make sure connector and foil are aligned 7c Hold plastic wedge in place with thumb as you insert into foil Align foil holes with connector screw holes a b c ...

Page 16: ...d insert into 2 m foil 10a Make sure foil and adjuster tube screw holes are facing up 10b Make sure adjuster tube and foil are aligned 10c Do not fasten with foil screws at this time b a 9 Join lower part of connector to next foil Put red Loctite on screw holes Secure with foil screws Adjuster Tube ...

Page 17: ...feeder onto adjuster tube Do not secure with screw until later 12 Slide halyard swivel onto foil so longer part is toward top of stay Top 11 Place adjuster tube bushings over wire and insert into foils until tab snaps into holes on either side of adjuster tube Tap in place Top Tool hammer ...

Page 18: ... on screw holes Secure with adjuster tube clamp screws 16 Capture jaw jaw toggle on eye using threaded crosspin When using Harken rod adapter stud be sure to use red Loctite and cotter pins to lock nosepiece into stud 14 Slide drum assembly onto adjuster tube ...

Page 19: ...0 1 19 Assembly Leg Kit with Toggle Assembly 18 Secure using cotter pins Tools slotted screwdriver side cutters 17 Slide one spacer on either side of jaw jaw toggle 19 Slip leg and washers onto threaded crosspin ...

Page 20: ... collar loosen Locknuts at threaded crosspin 19a Make sure flat holes in leg line up with threaded crosspin flats 19b Secure using washers and locknuts If stay length is set use side cutters or needlenose pliers to bend cotter pin to secure turnbuckle Line up flats Unit Size 0 1 10 mm Tools Socket or Open End Wrench Collar ...

Page 21: ...toward the top of the stay leaving 1 25 of space between the top of the deflector or the trim cap and bottom of marine eye Align all three holes at bottom of adjuster tube Check to make sure there is space above halyard deflector or trim cap 21 Slip Leg Kit assembly onto neck of drum assembly and fit other collar Unit Approximate Space mm in 0 1 25 1 ...

Page 22: ... and tighten 25 Slide feeder to third hole and secure using foil screw and blue Loctite Tool slotted screwdriver Tools Hex Driver Unit Size 0 1 5 mm 24 Locate nearest group of three screw holes in adjuster tube two for the foil and one for the feeder Put blue Loctite in screw holes Secure adjuster tube with foil screws Tool slotted screwdriver Blue Loctite ...

Page 23: ...de stanchion Correct block position is critical to even line spooling and ease of furling 7403 Outboard Stanchion Blocks Install 7403 Outboard Stanchion Blocks so line is outside stanchions Number and placement of leads depends on boat length and number configuration of stanchions 7402 Ratchet Stanchion Block Mount 7402 Ratchet Stanchion Block as farthest aft lead to prevent line overrides in drum...

Page 24: ...sail Add Line to Drum Assembly Run line into drum assembly between guard posts and out hole in lower plate of spool Exit opening in drum assembly as shown below Tie a small overhand knot and pull it up tightly against spool IMPORTANT Do not run line through plastic opening in drum assembly Sun Cover On Turn Spool Starboard Clockwise Port Counterclockwise Turn spool until there is a tail of line in...

Page 25: ...re often stiff and may hang up at feeder during raising Do not force sail when it hangs up lower and remove twist Sails break in with use and will become easier to raise 7 Line up front of sail so it is parallel to foil and feeds smoothly when sail is hoisted 8 Put moderate tension on the halyard and secure 9 Check the top area of the furler for interference from halyards See Check Halyards 10 Pra...

Page 26: ...atch on the top of the foil Use halyard deflector to move the halyard away Check to make sure there is enough space between the trim cap and the bottom of the terminal Halyard deflector thickness Unit Part Thickness 0 7301 25 5 mm 1 1 7302 29 mm 11 8 WARNING In severe cases a halyard wrap can cause loss of control of boat and or headstay can break suddenly Make sure halyard is clear of top foil be...

Page 27: ...ard should be firm but not too tight Tip The foil 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 should be firm but not tight I...

Page 28: ...To furl or reef ease the jib sheets and pull furling line In very light breeze place some tension on jib sheet to insure a tight furl In a stronger breeze you must completely luff sail by totally slacking jib sheets before furling The furling line should pull readily The amount of force required is related to amount of wind but a unit should never require use of a winch to furl If the sail will no...

Page 29: ... damage to furler or boat A loosely rolled sail can catch wind in a storm Sheets or furling lines can loosen as winds increase and allow furler to unroll Be sure mooring lines are not placed across furling line where they may cause chafe IMPORTANT If no wraps of line are on spool the line deadend can break the spool when the boat motors through waves If you want to Add more wraps of jibsheet on fu...

Page 30: ...se a halyard to hold foils lifted tie a rolling hitch to the foils using another line or use the actual halyard if suitable See www harken com knots for tying resources CAUTION Foils have considerable weight and can drop and cut hands if placed underneath Make sure foils are securely held up while adjusting turnbuckle Carefully loosen nut enough to move legs outwards and rotate out of the way When...

Page 31: ...y have not dropped into drum assembly 4 Wire for signs of wear unraveling or loosening 5 Locknuts on leg kit for signs of loosening or missing 6 Lower toggle for signs of wear cracks or corrosion 7 Cotter pin at lower toggle to be sure it is securely splayed as shown Storage Mast Down In areas where it freezes do not store system where water can accumulate in foils When water freezes it will ruptu...

Page 32: ...e position of forward lead block to allow line to roll evenly on drum Spare halyard catching in sail as it furls Move halyards away from furling headsail as above Headstay rotates in jerks or elliptically Insufficient tension on headstay Tighten headstay and or backstay to eliminate sag in headstay Sail does not stay furled Sail not furled tightly on stay Maintain drag on sheets while furling Furl...

Page 33: ...overs may be installed on either side of sail Be sure to match other sails in the customer s inventory A B C D E F Max F Min G H I UNIT 0 7320 20 Short Leg Kit 190 mm 17 8 49 16 13 8 61 2 25 8 377 8 221 2 85 16 77 16 3 48 mm 116 mm 36 mm 166 mm 66 mm 962 mm 572 mm 211 mm 190 mm 76 mm 7320 21 Long Leg Kit 320 mm 17 8 49 16 13 8 61 2 25 8 43 275 8 137 16 129 16 81 8 48 mm 116 mm 36 mm 166 mm 66 mm 1...

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Page 36: ...nd Ltd 158 Beaumont Street Unit 11 Orams Marine 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 Stock...

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