Harken Unit 1 ESP User manual

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

2 ESP Unit 0, 1
2
1
3 4
5
7
1. Leg Kit with Toggle
2. Leg Kit Collar
3. Drum Assembly
a. Neck
b. Guard Posts
c. Spool
4. Adjuster Tube Clamp Screws
5. Bow Shackle
6. Adjuster Tube Bushings
7. Adjuster Tube
8. Foil Screws
9. Connector Bushings
10. Feeder
11. Foil (2 m)
12. Connector
13. Connector Wedge
14. Top Foil
a. Trim Cap Holes
15. Halyard Swivel
16. Trim Cap Screws
17. Trim Cap
Parts Descriptions
Parts Description
8
9
11
10
12
3a
3b
9
8
3c
13
13
WARNING! Strictly follow all instructions to avoid potential
hazards that may kill or hurt you and others. See www.harken.com/
manuals for general warnings and instructions.
WARNING! This symbol alerts you to potential hazards that may kill or hurt you and others
if you don't follow instructions. The message will tell you how to reduce the
chance of injury.
Introduction
This manual gives technical information on installation and service. 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 accepts no responsibility for damage or harm caused by not observing the safety requirements and
instructions in this manual. See limited warranty, general warnings, and instructions in www.harken.com/manuals.
Purpose
Harken®Jib Reefing and Furling is designed for rolling sails on sailboats to reduce sail size or to completely roll
so wind has little effect on the sail. Use of this product for other than normal sailboat applications is not covered
by the limited warranty.
Safety Precautions
CAUTION! This symbol alerts you to potential hazards that may hurt you and others if
you do not follow instructions. The message will tell you how to reduce the
chance of injury.
6

9
9
ESP Unit 0, 1 3
14
15
17
Preassembly Specifications
11
8
9
12
16
5
14a
a. Leg Kit Collar Screw
b. Collar
c. Short, Medium or Long Leg
d. Lock Nut
e. Washers
f. Flat Hole in Plate
g. Cotter Pin
h. Spacer
i. Threaded Cross Pin
j. Clevis Pin
k. Jaw/Jaw Toggle
l. Cotter Pin
1) Leg Kit with Toggle Assembly
a
a
b
b
c
c
d
e
de
gh
g
f
f
ih
13
13
9
5
j
kl
Unit Part Numbers
Unit Unit without
Lower Toggle
Leg Kit with Toggle
Assembly – Short
Leg Kit with Toggle
Assembly – Medium
Leg Kit with Toggle
Assembly – Long
Clevis Pin
Ø
Wire
Ø
Rod
Sizes
07320.10 7320.20 — 7320.21
5
/ 16 ",
3
/ 8 "
(8 mm, 9.5 mm)
5
/ 32 ",
3
/ 16 ",
(4, 5 mm)
-4
(4.37 mm)
17321.10 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.
Online Product Registration
www.harken.com/FurlingWarranty
Unit 0 Short and Long
Unit 1 Short, Medium, Long
105/8"
(271 mm)
7321.22 Medium Leg Kit
Max Turnbuckle Length
Upper measurement
point is to adjuster
tube bushing 6.

4 ESP Unit 0, 1
Parts List Drum Box
Bow Shackles
Halyard Swivel
Description Unit 0 Unit 1
Part No. Size Length (L) Qty Part No. Size Length (L) Qty
Halyard swivel H-58632 — — 1 H-55720 — — 1
Drum assembly 7320.10BASE — — 1 7321.10BASE — — 1
Bow shackles 2110 6 mm — 3 2110 6 mm — 3
Short leg kit with toggle 7320.20
5
/ 16 ",
3
/ 8 " 2
1
/ 16 " (52 mm) 1 7321.20
7
/ 16 ",
1
/ 2 " 2
1
/ 8 " (53 mm) 1
Medium leg kit with toggle — — — 1 7321.22
7
/ 16 ",
1
/ 2 " 6
1
/ 4 " (159 mm) 1
Long leg kit with toggle 7320.21
5
/ 16 ",
3
/ 8 " 7
3
/ 16 " (183 mm) 1 7321.21
7
/ 16 ",
1
/ 2 " 11
1
/ 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 turnbuckle
Short Leg Kit
DO NOT USE with turnbuckle
Short Medium Long
Leg Kit Relative Sizes
L
L

ESP Unit 0, 1 5
Parts List Foil Set
Adjuster
tube
2 m Foils
Connector bushings
Top foil
Connectors
Foil Set
Description Unit 0 Unit 1
Part Qty Part Qty
Included
Trim cap H-58490 2 H-55976 2
Trim cap screws HFS1127 2 HFS1127 2
Adjuster tube 7320.33 1 7321.33 1
Foils (2 m) 7320.30 4 7321.30 5
Top 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 tube bushing
Foil screws
Trim cap
screws
Trim cap
Feeder
Red Loctite®
Plastic connector
wedges

6 ESP Unit 0, 1
Parts List Parts Sold Separately/Tools
Furling Line
Unit Part No. Line Ø Length (ft)
0HFG594 7 mm 55
1HFG233 7 mm 70
7404 Lead Block Kit
Includes 3 x 7403; 1 x 7401;
1 x 7402; 1 Horn Cleat
Halyard Deflector
Unit Part No.
07301
17302
Optional Parts
Rod Rigging: Harken Rod Adapter Stud Required
Rod Size
Thread
Size UNF
Part
No.
-4 4.37 mm 7/16" 7420 -4
-6 5.03 mm
7
/ 16 " 7421 -6
-8 5.72 mm
1
/ 2 " 7422 -8
-10 6.35 mm
1
/ 2 " 7423 -10
Short Leg Kit with Toggle
Do not use with turnbuckle
Medium Leg Kit with Toggle
Required for turnbuckle
Long Leg Kit with Toggle
Required for turnbuckle
Unit Part No.
Clevis
Pin Part No.
Clevis
Pin Part No.
Clevis
Pin
07320.20
5
/ 16 ,
3
/ 8 — — 7320.21
5
/ 16 ,
3
/ 8
17321.20
7
/ 16 ,
1
/ 2 7321.22
7
/ 16 ,
1
/ 2 7321.21
7
/ 16 ,
1
/ 2
Required Parts
Required parts sold separately by Harken:
• Extra foil and connector if required. See pages 7 - 8.
• Harken Short Leg Kit with toggle. Do 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 7403 if necessary. Fits 1" (25 mm) stanchions.
WARNING! Wire that is old
or damaged may break sud-
denly, causing an accident.
Headstay condition should
be checked by a professional
rigger before reusing.
Preassembly Tools Required
2
17
15
1
9
8
7
6
4
16
5
10
12
3. Long tape measure 11. Phillips screwdriver
4. Short tape measure 12. Slotted screwdriver
5. Drill bit – 1/8" (3 mm) 13. Needle-nose pliers
6. Power drill 14. Locking Pliers
7. Hacksaw 15. Center punch
8. Side cutters 16. Hammer
9. Rat-tail file 17. Electric Tape (Use to Mark Foil)
10. Straight edge 18. Vise ( Tape Jaws to Protect Foil)
3
11
13
1. Hex keys
Unit Size
0, 1 5 mm, 6 mm
2. Socket or open end wrench
Unit Size
010 mm
116 mm
12
14
18

ESP Unit 0 7
Preassembly Top Foil Length
Length Chart
Dimensions Inches mm
ACenter of Pin to Bottom of Terminal
BBottom of Terminal to Top of Foil
1.0* 25*
CTop Foil Length ** **
DNumber of Foils ________ x 78.74" (2000 mm)
EAdjuster Tube at Just Over Midpoint 24.0 609
FDrum Height 4.1 104
GTop of Leg Kit to Clevis Pin
Pin-to-Pin Length
*Add 1" (25 mm) if using a halyard deflector.
**If top foil length is 6.5" to 4" (165 to 100 mm) cut the foil at 6.75" (165 mm). If the top foil
is shorter than 4" (100 mm) do not use a cut top foil. A full length foil will be the top foil.
Measure A and add to this chart
and length chart below
Inches mm
A
B1.0* 25*
E24.0 609
F4.1 104
G
Total A+B+E+F+G
*Add 1" (25 mm) if using a halyard deflector.
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 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
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
TOP FOIL LENGTH WORKSHEET
A
C
D
E
F
Pin
to
Pin
B
G
Pin
to
Pin
UNIT 0
Tip: Check to see if the foil fits over
the marine eye. If yes, assemble foils
and lower unit following instructions.
Measure and cut the top foil after
other foils are assembled.
IMPORTANT! Identify top foil before
cutting. Use end with foil screw
holes for connector.
G Top of Leg Kit to Clevis Pin
Toggle
Part No. Type
Clevis Pin G Distance
in mm in mm
7320.20 5/16 Short Leg Kit
5
/ 16 83.0 75
7320.20 3/8 Short Leg Kit
3
/ 8 9.5 3.0 75
7320.21 5/16 Long Leg Kit
5
/ 16 88.1 206
7320.21 3/8 Long Leg Kit
3
/ 8 9.5 8.1 206

8 ESP Unit 1
Preassembly Top Foil Length
Length Chart
Dimensions Inches mm
ACenter of Pin to Bottom of Terminal
BBottom of Terminal to Top of Foil 1.1* 28*
CTop Foil Length ** **
DNumber of Foils ________ x 78.74" (2000 mm)
EAdjuster Tube at Just Over Midpoint 23.6 600
FDrum Height 4.9 124
GTop of Leg Kit to Clevis Pin
Pin-to-Pin Length
*Add 1.1" (28 mm) if using a halyard deflector.
**If top foil length is 7.75" to 5" (200 to 125 mm) cut the foil at 7.75" (200 mm). If the top foil
is shorter than 5" (125 mm) do not use a cut top foil. A full length foil will be the top foil.
Measure A and add to this chart
and length chart below
Inches mm
A
B1.1* 28*
E23.6 600
F4.9 124
G
Total A+B+E+F+G
*Add 1.1" (28 mm) if using a halyard deflector.
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 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
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
TOP FOIL LENGTH WORKSHEET
Pin
to
Pin
G Top of Leg Kit to Clevis Pin
Toggle
Part No. Type
Clevis Pin G Distance
in mm in mm
7321.20 7/16 Short Leg Kit
7
/ 16 11 3.7 93
7321.20 1/2 Short Leg Kit
1
/ 2 12.7 3.7 93
7321.22 7/16 Medium Leg Kit
7
/ 16 11 7.4 188
7322.20 1/2 Medium Leg Kit
1
/ 2 12.7 7.6 193
7321.21 7/16 Long Leg Kit
7
/ 16 11 12.3 313
7321.21 1/2 Long Leg Kit
1
/ 2 12.7 12.3 313
UNIT 1
Tip: Check to see if the foil fits over
the marine eye. If yes, assemble foils
and lower unit following instructions.
Measure and cut the top foil after
other foils are assembled.
IMPORTANT! Identify top foil before
cutting. Use end with foil screw
holes for connector.
A
C
D
E
F
Pin
to
Pin
B
G

ESP Unit 0, 1 9
Preassembly Toggle Deductions/Stay Into Foil Options
Options for Snaking Stay into Foils
WARNING! Using a threaded nosepiece with only adhesive at the upper rod eye terminal may result in
headstay system failure. Use Harken rod adapter stud. See www.harken.com/manuals for additional
safety information.
Unit
Leg Kit Toggle
Assembly
Clevis Pin
Ø
Pin-to-Pin (P-P)
Length
Type Part No. in mm in mm
0
Short 7320.20 5/16
5
/ 16 8 1
1
/ 16 27
Long 7320.21 5/16
Short 7320.20 3/8
3
/ 8 10 1
1
/ 4 32
Long 7320.21 3/8
1
Short 7321.20 7/16
7
/ 16 11 1
7
/ 16 37Medium 7321.22 7/16
Long 7321.21 7/16
Short 7321.20 1/2
1
/ 2 13 1
5
/ 8 42Medium 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
Rigger supplied: Eye at lower end of stay or turnbuckle to mate with toggle. Use dimensions of Harken toggle
below to build stay to correct length.
Tip: Turnbuckles should be one-half to two-thirds open to allow shortening for new wire stretch and for fine-tuning
mast rake.

10 ESP Unit 0, 1
Preassembly Confirm Foil Length
Confirm foil length by laying foils alongside stay with turnbuckle components. Pull stay straight. Attach Harken
toggle to bottom of stay. Adjust turnbuckle, if used, so that length of stay with Harken toggle will fit boat. Ideally,
turnbuckle will be one-half to two-thirds open to allow for rig adjustment. Temporarily clamp short or long leg kit
to bottom of unit. Line up:
A. Bottom of full length foil with holes in adjuster tube. Set adjuster tube just above the mid-point of adjustment
range.
B. Holes at lower end of adjust tube with drum assembly 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.
CBA
Adjuster Tube
Full-Length Foil
Actual adjuster tube will have 12 to 14 adjuster holes. Line up the foil so it is just above the midpoint of adjustment.
Tip: Check to see if the foil fits over the marine eye. If yes, assemble all foils and lower unit following
instructions. Measure and cut the top foil when all other foils are assembled.
Feeder
Unit
Deflector No Deflector
in mm in mm
0250 125
12.1 53 1.1 28

ESP Unit 0, 1 11
Assembly Cutting/Drilling Top Foil
Deburr inside edge using a file.
Use tape to mark foil. Cut foil to length.
Label top foil and identify which end will
be at the top when installed. You will be
drilling each side near the top.
Lay top foil alongside cutoff piece. Use
locking pliers to clamp foils together at
the interior flat surfaces opposite the
sail grooves.
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.
Top Foil
Foil screw holes
for connector
Trim Cap Holes
Cut off this end with trim cap hole. Hole is
only used with full length 783/4" (2000 mm)
foil as top foil.
Tool: hacksaw
Tool: rat-tail file
Tools: straight edge, locking pliers

12 ESP Unit 0, 1
Assembly Cutting/Drilling Top Foil
Use center punch to start hole. Drill one of
two holes for trim cap.
Drill Size: 1/8" (3.2 mm)
Keeping 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
Top Foil
Tool: short tape measure
Tools: electric drill, drill bit, center
punch

ESP Unit 0, 1 13
Assembly Foils/Connectors
1. Identify special length top foil with trim
cap holes.
2. Slide top foil and 2 m foils and
connectors onto wire.
2a. Load connector so bushing cutouts
facing up towards 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. Top of Stay

14 ESP Unit 0, 1
Assembly Foils/Connectors/Halyard 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®

ESP Unit 0, 1 15
Assembly Foils/Connectors
8. Put red Loctite®in foil screw holes and
secure with foil screws.
Tool: slotted 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.

16 ESP Unit 0, 1
Assembly Foils/Connectors
10. Install connector bushings in top of
adjuster tube and 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

ESP Unit 0, 1 17
Assembly Foils/Connectors/Halyard Swivel/Feeder/Drum Assembly
13. Slide 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

18 ESP Unit 0, 1
Assembly Drum Assembly
15. Put blue Loctite®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.

ESP Unit 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.

20 ESP Unit 0, 1
Assembly Leg Kit with Toggle Assembly
20. Capture legs in one of the two collars.
Tip: If the legs do not fit 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