Harken MKIV User manual

MKIV
Jib Reefing & Furling
Installation Manual
Unit 0
WARNING!: Strictly follow all instructions
to avoid an accident, damage to your vessel,
personal injury or death. See www.harken.com
for additional safety information.

Parts Descriptions
2 MKIV Unit 0 7/16/08
Table of Contents
1
2
3
4
5
8
7
6
9
1) Toggle Assembly
2) Crosspin
3) Shackles
4) Drum Assembly
5) Foil Clamp
6) 2' (610mm) Bottom Foil
7) Feeder
8) Connector Bushing
9) Bottom Connector
10) 7' (2.13m) Foil
11) Connector Screws
12) Connector Wedge
13) Connector
14) Halyard Swivel
15) Trim Cap
16) Trim Cap Screws
Preassembly
Parts 4-5
Tools 5
Dimensions/Sailmaker's Instructions 6
Toggle Deductions/Stay Into Foil Options 7
Top Foil Length 8
Short Top Foil 9
Foil Length 10
Assembly
Foils/Connectors 11 - 17
Halyard Swivel 17
Drum Assembly 18
Rod Rigging 19
Turnbuckle 20
Toggle 20
Final 21 - 22
Commissioning
Turnbuckle 23
Line to Cockpit 24
Halyard Wrap/Prevent Halyard Wrap 25
Pendants/Halyard: Restrainer/Tension 26
Operation
Halyard/Headstay Tension 27
Raise Sails 28
Furl/Reef 28 - 29
Secure Sail 29
Race Conversion 30
Maintenance
Clean 29
Inspect 29
Replace Line 29
Storage 29
Remove Furler 29
Troubleshooting
Warranty

Sizing Check
Unit Part No. Description Wire Sizes
7410.10 MKIV Unit 0
3/16", 7/32" 5mm, 6mm
Rod Sizes
-4, -6 4.37mm, 5.03mm
Toggle Part No. Description Chainplate Clevis Pin Size
7410.20 3/8 Eye/jaw reversible 3/8" 9.5mm
7410.20 7/16 Eye/jaw reversible 7/16" 11.1mm
Chainplate Clevis Pin
7/16/08 MKIV Unit 0 3
Preassembly Sizing Check
10
11
12
13
14 15
9
16
2. Harken does not recommend drilling boat’s chainplate or toggle. In some cases bushings are available
to fit boats with smaller clevis pin sizes.
3. Will drum fit on bow? See page 6. If necessary, use an additional toggle to slightly raise unit.
Size Check
1. Check headstay and clevis pin dimensions in chart below.
WARNING!: Harken does not recommend drilling boat's chainplate
or toggle as this may result in rig failure which will cause an
accident, damage to your vessel, personal injury or death.
See www.harken.com for additional safety information.

Drum Assembly
Preassembly Parts
Line
Bow Shackles
Trim Cap
Plastic
Connector
Wedges
Foil Screws
Feeder
Prefeeder
Halyard Swivel
4 MKIV Unit 0 6/06/08
5200
Adhesive
Injector
2' (610mm)
Bottom Foil
7' (2.13m)
Foils
Bottom
Connector
Connectors
Connector Bushings
Part No. Quantity Description
HFG290 1 Drum assembly with foil clamp
H-39923 1 Halyard swivel
Main Components
Part No. Quantity Description
7410.30 5 7'(2.13m) foil
7410.33 1 2'(610mm) Botton foil
Foils (Standard Package)
Part No. Quantity Description
7410.31 4 6.5" (165mm) Connector
7410.32 1 10" (254mm) Bottom Connector
HFG294 1 Connector bushing set (10-H-42067/10-H-42068)
HFG298 1 Plastic connector wedge set (12-H-39625)
HFG341 1 Foil screw set (26-HFS1105)
HFG679 1 Trim cap set (H-37335/H-37336)
HFG629 1 Trim cap screw set (3-HFS1126)
947 1 Prefeeder
H-39713 1 Feeder with screw and tab
2110 3 6mm Bow shackles
HFG725 1 Injector, 1 oz. 5200 Adhesive (HFG722)
Part No. Quantity Description
HFG594 55' (16.7m) 7mm Single braid polyester
Line (Standard Package)
Quantity Description
1 Each 2.5, 3, 5mm Allen wrenches
Tools
Other Components
2.5, 3, 5mm
Allen Wrenches
Trim Cap Screws

Preassembly Rigging Parts Check/Tools
Tools You Will Need
MKIV Furlers are shipped with 3M 5200
adhesive. Use adhesives on dry connectors
and foils using the special injection system
described in the assembly section. Parts
may immediately be exposed to rain. Cure
is best at 70 F (22C) with 50% humidity.
Do not apply at temperatures below 40 F
(5C) and above 100F (38C).
Although adhesive has not cured it will
remain in place on foil joints whether
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 torch to heat
joints until foils can be pulled apart.
Adhesive Alert
7/16/08 MKIV Unit 0 5
1. Long tape measure 6. Side cutters 11. Center punch
2. Short tape measure 7. Rat-tail file 12. Rigging or black tape
3. Power drill 8. Allen wrenches (provided) 13. Scissors
4. Drill bit – 1/8" (3mm) 9. Slotted/phillips screwdrivers 14. Metal straight edge
5. Hacksaw 10. Needle-nose pliers 15. Hammer
10
13
12
11
8
7
6
5
3
2
1
15
4
14
9
1. Harken toggle assembly required. Sold separately.
2. Mating turnbuckle components must be purchased separately.
3. Headstay may require cutting and shortening to fit Harken toggle.
Headstay may remain uncut by replacing lower stud of turnbuckle
with stud/eye thus eliminating extra toggle.
4. Rod rigging requires Harken rod adapter stud.
5. Order Harken 7404 Lead Block Kit. Fits 1" (25mm) stanchions.
Eye/Jaw Toggle
7410.20 3/8
7410.20 7/16
ALL UNITS
Harken Toggle
(Sold Separately)
7420 -4
7421 -6
Rod Adapter Stud
ROD RIGGING
Harken Rod Adapter
Stud Required
(Sold Separately)
Includes 3 x 7403; 1 x 7401;
1 x 7402; 1 Horn Cleat
7404 Lead Block Kit
(Sold Separately)
WARNING!: Headstay condition
should be checked by a professional
rigger before reusing. Wire that is
old or damaged may break suddenly
causing an accident, damage to your
vessel, personal injury or death.
See www.harken.com for additional
safety information.

Preassembly Dimensions/Sailmaker's Instructions
6 MKIV Unit 0 9/29/09
Luff Length
Note offsets above and below sail.
A shorter luff may be required if a halyard restrainer is necessary
(page 26) or a toggle or long toggle assembly is used to raise drum.
If luff of sail is not long enough to put halyard swivel near top of
headstay foil, a pendant must be added (see page 25).
Tack Setback
Note setback for tack shackle and cut sail accordingly.
Luff Tape Size
Unit 0 requires #6 (6/32" or 5mm) luff tape.
Luff Tape Length
Cut off top of luff tape so it is 18 to 24" (450 to 600 mm) below head of
sail. This allows head to lag behind rest of sail to help flatten sail. It will
also help head to roll more smoothly.
Note feeder height and extend bottom 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.
Minimum inside dimensions of standard head
and tack shackles are:
(A) 11/16" (27mm)
(B) 1/2" (13mm)
Sun cover
Sun covers may be installed on either side of the sail.
Be sure to match other sails in customer's inventory.
97/8"
(250mm)
Min
391/2"
(1003mm)
Max
41"
(1041mm)
81/4"
(210mm)
33/4"
(96mm)
25/16"
(59mm)
61/4"
(158mm)
51/2"
(140mm)
17/8"
(47mm)
A
B

Preassembly Toggle Deductions/Stay Into Foil Options
7/16/08 MKIV Unit 0 7
Use dimensions of Harken toggle below to build stay to correct length.
Tip: Turnbuckles should be 1/2 to 2/3 open to allow shortening for new wire stretch and for fine-tuning mast rake.
Most boats have a chainplate with a single tang.
If boat has two plates forming a jaw, reverse
eye/jaw toggle so eye is down.
Important: Remove black plastic caps and install
them so crosspin will be 90 degrees to lower
clevis pin.
CrosspinCrosspin
Fork
Attachment
Tang
Attachment
For tang-down installations,
switch plugs to this position.
Tang Attachment
25/8" (66.5mm)
or
27/8" (73mm)
Fork Attachment
Crosspin Crosspin
Clevis Pin Pin-to-Pin Length
3/8" (9.5mm) 25/8" (66.5mm)
7/16" (11.1mm) 27/8" (73mm)
Options for Snaking Stay into Foils
1. Swage stud at end of wire.
2. Open end of wire and install Norseman or Sta-Lok®stud after foil is assembled.
3. Rod adapter nosepiece for Harken rod adapter stud: Threaded nosepiece must
have a positive lock of as well as adhesive. Use Harken stud with cotter pins
(see page 19).
WARNING!: Using a threaded nosepiece with only adhesive at the
upper rod eye terminal may result in headstay system failure which
can cause an accident, damage to your vessel, personal injury or
death. See www.harken.com for additional safety information.

Preassembly Top Foil Length
Length Chart
Dimensions Inches mm
ACenter of Pin to Bottom of Terminal
BBottom of Terminal to Top of Foil
.4 10
CTop Foil Length
DNumber of Foils ________ x 84" (2133.6 mm)
EBottom Foil 24 610
FBottom of Foil to Crosspin 16.25 413
GCrosspin to Clevis Pin
Pin-to-Pin Length
Measure A and add to this chart
and length chart below
Inches mm
A
B.4 10
E24 610
F16.25 413
G
Total A+B+E+F+G
A
C
D
E
F
Pin
to
Pin
B
8 MKIV Unit 0 5/30/07
Make sure upper
measurement points
of A and Pin-to-Pin
are the same.
1Pin-to-Pin Length
2Subtract ABEFG –
3Result (Pin-to-Pin – ABEFG)
4Subtract D –
To find “D” pick number from chart below that is closest 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
3 x 2133.6 = 6400.8
4 x 2133.6 = 8534.4
5 x 2133.6 = 10668
6 x 2133.6 = 12801.6
Example–If result from Step 3 is:
500 inches “D” = 420 inches 12,000mm “D” = 10,668mm
5Result (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
Measurement
Point A
Pin
to
Pin
TOP FOIL LENGTH WORKSHEET
G Toggle Distance from Lower Clevis Pin to Crosspin Hole
Toggle Part No. Type Clevis Pin G Distance
7410.20 3/8 Eye/Jaw 3/8"9.5mm 1.3" 33mm
7410.20 7/16 Eye/Jaw 7/16"11.1mm 1.4" 36mm G

5/30/07 MKIV Unit 0 9
Preassembly Short Top Foil
If top foil is shorter than 7" (177.8mm), use one of the following special techniques to ensure sufficient bearing
surface for the foil in the area of the halyard swivel.
21/2(63mm)
2" (51mm)
11/2" (38mm)
1" (25mm)
1/2" (13mm)
63/8" (162mm) No special treatment required.
63/8" (162mm)
61/4" – 45/8" (159 – 117mm) Do not use plastic bush-
ing above top connector.
61/4" – 45/8" (159 – 117mm)
41/2" - 31/2" (114 – 89mm) Do not use plastic bushing
above top connector. Shorten top of connector and if
necessary shorten trim cap.
41/2" - 31/2" (114 – 89mm)
33/8" - 25/8" (86 – 67mm) Do not use plastic bushing
above top connector. Cut connector right at cross formed
by glue dispersion channels. Use single foil screw in top
foil only.
33/8" - 25/8" (86 - 67mm)
Under 1/2" (13mm) Eliminate top foil and run foil
higher in drum assembly.
Under 1/2" (13mm)
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"
(63mm)
55/8"
(143mm)
41/16"
(103mm)
31/4"
(83mm) No
2"
(51mm)
51/8"
(130mm)
39/16"
(90mm)
31/4"
(83mm) No
11/2"
(38mm)
45/8"
(117mm)
31/16"
(78mm)
31/4"
(83mm) No
1"
(25mm)
41/8"
(105mm)
29/16"
(65mm)
3"
(76mm) Yes
1/2"
(13mm)
35/8"
(92mm)
21/16"
(52mm)
23/4"
(70mm) Yes
21/2" - 1/2" (63 – 13mm) Shorten top foil and adjoining
full length foil so two screws are used to assemble joint
instead of four. Do not use plastic bushings above top
connector.
*To allow for saw cut, position blade so upper half of
middle hole is preserved.
Cut-Offs – Do Not Use
Cut-Offs
Do Not Use
Cut-Offs
Do Not Use
Cut-Offs
Do Not Use
Cut-Off
Do Not Use

10 MKIV Unit 0 5/30/07
Preassembly Foil Length
Line up bottom foil so foil clamp is just
above or below center of notches in
bottom foil.
Confirm foil length by laying foils alongside
stay with turnbuckle components.
Pull stay out so it is straight. Attach Harken
toggle to bottom of stay. Make sure toggle
straps are straight. Adjust turnbuckle so
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 7/16" (11mm) 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.

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 cutoff
piece and use a flat metal object
(i.e. metal ruler) to scribe top
line of foil.
5/30/07 MKIV Unit 0 11

Assembly Top Foil
Cut out template at right. Line up template
with top of foil and scribed line. Tape in
place. Use a center punch to mark holes.
Check center punch marks to confirm
they are 3/16" (5mm) and .8" or 13/16"
(20mm) from top of foil.
Drill two (2) 1/8" (3.2mm) 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.
12 MKIV Unit 0 5/30/07
3/16" (5mm)
.8" or 13/16"
(20mm)
Foil
Top
!

Assembly Top Foil
Place halves of plastic bushings on stay so
hooked part of 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.
5/30/07 MKIV Unit 0 13

Assembly Top Foil/Connectors
Slip 6.5" (165mm) connector on wire,
mating hook of plastic bushing with
connector.
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 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.
14 MKIV Unit 0 5/30/07
Loading Injector with Adhesive
Adhesive in
lower half

Start plunger into injector and immediately
hold upright so plunger is down and
applicator tip is up.
As sealant runs down towards plunger an
air pocket will form near tip. Push plunger
to evacuate air. You are now ready to begin
injecting adhesive.
5/30/07 MKIV Unit 0 15
Hold plastic wedge in place with thumb
as you insert into foil. Line foil holes
with connector screw holes.
Put a drop of adhesive into screw holes.
Assembly Foils/Connectors

Assembly Foils/Connectors
16 MKIV Unit 0 2/15/10
Tighten screws into connector holes. Make
sure a drop of adhesive entered each screw
hole. If not, apply to screw.
Use bushings, connector, wedge and
adhesive in other screw hole and
insert into other foil. Use 1/4 - 1/2ml
of adhesive.
Inject only a small amount of adhesive
into middle hole. Unit 0 will only take
1/4 to 1/3 of a graduation mark. Do not
press tip of injector into hole. Back off
slightly while injecting.
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 1/4
to 1/3ml of
adhesive
Stop when you see a small
amount of adhesive enter
one of the screw holes.
Stop when you see a small
amount of adhesive enter
one of the screw holes.

Continue installing connectors and wedges.
Make sure to use adhesive in screw holes.
Continue assembly. Use 10" (254mm) bot-
tom connector to assemble bottom foil.
Slide halyard swivel onto foil above feeder
window. Make sure taller “half” is up as
shown.
5/30/07 MKIV Unit 0 17
Assembly Bottom Foil/Connectors/Halyard Swivel

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/Turnbuckle/Harken Toggle
18 MKIV Unit 0 5/30/07

ROD RIGGING
Insert two cotter pins and
spread. Clean excess Loctite®
from terminal body using
special care to ensure that
there is no red Loctite®on
threaded stud.
Assembly Rod Rigging: Rod Adapter Stud
5/30/07 MKIV Unit 0 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.

Assembly Attach Turnbuckle/Toggle
Assemble turnbuckle and attach Harken
toggle.
Note: If using Sta-Lok®or Norseman®
stud, you must use a washer above
stud as shown below.
20 MKIV Unit 0 4/13/09
Eye/Jaw Toggle Assembly
Washer