Harken Unit 1 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 1 ESP

Page 1: ...ts 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 Asse...

Page 2: ...vice 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 propert...

Page 3: ...mbly Short Leg Kit with Toggle Assembly Medium Leg Kit with Toggle Assembly Long Clevis Pin Wire 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 7...

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 Ad...

Page 5: ...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 55...

Page 6: ...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 le...

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...

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...

Page 9: ...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...

Page 10: ...y 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 foi...

Page 11: ...s 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 Confir...

Page 12: ...ing 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 U...

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...

Page 14: ...yard 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 Loc...

Page 15: ...otted 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 7...

Page 16: ...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 p...

Page 17: ...eeder 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...

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 nos...

Page 19: ...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 threade...

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 needlen...

Page 21: ...oward 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 s...

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 adju...

Page 23: ...e 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...

Page 24: ...ail 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...

Page 25: ...e 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 i...

Page 26: ...tch 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...

Page 27: ...rd 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 al...

Page 28: ...o 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 slack...

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 fur...

Page 30: ...e 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...

Page 31: ...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 Cot...

Page 32: ...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 elliptica...

Page 33: ...ers 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...

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Page 36: ...d 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...

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