Harken NAUTOR MKIV C8436 User manual

NAUTOR MKIV
Jib Reefing & Furling
Installation Manual
C8436/C8437

Bottom
Connector
Connectors
Part No. Quantity Description
7413.30 C8436 (9) 7'(2.13m) Foil
C8437 (10)
7413.33 12'(610mm) Botton foil (shipped in drum box)
Foils (Standard Package)
Quantity Description
1 Each 3, 4, 6, 10mm Allen wrenches
Tools
Bow
Shackles
Part No. Quantity Description
7413.31 C8436 (8)
C8437 (9) 9.75" (248mm) Connector
7413.32 114" (356mm) Bottom connector
HFG297 1Connector bushing set (20 each H-42073/H-42074)*
HFG324 1Plastic connector wedge set (22 39487)
HFG349 1Foil screw set (44 HFS1106)
HFG682 1Trim cap set (H-39751/H-39752)
947 1Prefeeder
H-39756 1Feeder with screw and tab
2124 310mm Bow shackle
HFG725 1Injector
HFG722 11 oz. 5200 Adhesive
833 1Blue Loctite®
*One extra H-42073 and H-42074 sent with C8437
Other Components
Trim Cap
Foil Screws
Feeder
Prefeeder
3,4, 6, 10mm
Allen Wrenches 5200
Adhesive
Injector
Parts
Plastic
Connector
Wedges
Halyard Swivel
Toggle/Terminal Assembly
Drum Assembly
Part No. Quantity Description
H-43184 1 Drum assembly with clamp
H-39392 1 Halyard swivel
Main Components
7' (2.13m) Foils
2' (610mm)
Bottom Foil
Connector Bushings
Blue Loctite®
03/10/11 Nautor MKIV Furling 3

HEADSTAY CUT LENGTH
Subtract the following from the headstay
length and cut the stay at that point.
HEADSTAY CUT LENGTH
6.5 mm
Preassembly Headstay Length
ROD COLDHEAD HEIGHT
Make sure the length of coldhead does not
interfere with the drive pin.
Distance between the collet bottom and the
rollpin is 6.5 mm
HEADSTAY CUT LENGTH CHART
Clevis Pin Size 22.2mm 25.4mm
-30 rod (11.1 mm) 185mm —
-40 rod (12.7 mm) — 229mm
4 Nautor MKIV Furling 4/18/07

FOIL CUT LENGTH
Foil cut length is based on pin-to-pin length as measured from cen-
ter of upper pin (attaches the stay to the mast) to center of lower
pin (attaches the furling unit to the boat). Measurement includes the
masthead toggle.
To check foil length, lay foils alongside stay before
cutting top foil.
TOP FOIL CUT LENGTH
Instructions For Worksheet Below:
1 Fill in total pin-to-pin length.
2 Fill in A length.
3 Add A, B, E, F and subtract from total pin-to-pin length.
SUM = _________
4 Choose the number from foil multiplier below closest to,
but not greater than, sum from step 3. Fill in D length.
7 x 2133.6 = 14935.2
8 x 2133.6 = 17068.8
9 x 2133.6 = 19202.4
10 x 2133.6 = 21336.0
11 x 2133.6 = 23469.6
12 x 2133.6 = 25603.2
5 Add A, B, D, E, F
Subtract from pin-to-pin length for C (top foil length). E
F
WORKSHEET: DETERMINE TOP FOIL LENGTH
DIMENSIONS
C8436
-30
22.2mm PIn
C8437
-40
25.4mm PIn
ACenter of PIN to Bottom of Terminal _______ _______
BBottom of Terminal to Top of Foil
20mm 20mm
CTop Foil _______ _______
D__?__ 84" (2133.6mm) Foils (Quantity) _______ _______
EBottom Foil 610mm 610mm
FClevis Pin to Foil 533mm 577mm
Total Pin-to-Pin Length _________ _______
Preparation Foil Length
4/18/07 Nautor MKIV Furling 5

Preassembly Short Top Foil
If top foil is shorter than 93/4" (248 mm), use one of the following special techniques to ensure sufficient bearing
surface for the foil in the area of the halyard swivel.
31/2" (89 mm)
3" (76 mm)
21/2" (64 mm)
2" (51 mm)
11/2" (38 mm)
93/4" (248 mm) No special treatment required.
93/4" (248 mm)
95/8"–71/8" (244–181mm) Do not use plastic bushing
above top connector.
95/8"–71/8" (244–181 mm)
7"–51/2" (178–140 mm) Do not use plastic bushing
above top connector. Shorten top of connector and if
necessary shorten trim cap.
7"–51/2" (178–140 mm)
53/8"–4" (137–102 mm) 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.
53/8"–4" (137–102 mm)
Under 11/2" (38 mm) Eliminate top foil and run foil
higher in drum assembly.
Under 11/2" (38 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
31/2"
(89 mm)
69/16"
(167 mm)
5"
(127 mm)
47/8"
(124 mm) No
3"
(76 mm)
61/16"
(154 mm)
41/2"
(114 mm)
47/8"
(124 mm) No
21/2"
(64 mm)
69/16"
(167 mm)
4"
(102 mm)
47/8"
(124 mm) No
2"
(51 mm)
51/16"
(129 mm)
31/2"
(89 mm)
43/8"
(111 mm) Yes
11/2"
(38 mm)
49/16"
(116 mm)
3"
(76 mm)
33/4"
(95 mm) Yes
31/2"–11/2" (89–38 mm) 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
6 Nautor MKIV Furling 03/10/11

Deburr inside edge using a rat-tail file.
Cut foil to length using a hacksaw.
Tip: Mark top foil to distinguish from
cutoff piece.
Lay top foil alongside cutoff piece and
use a flat metal object (i.e. metal ruler)
to scribe top line of foil.
Assembly Top Foil
4/18/07 Nautor MKIV Furling 7

Lay top foil in line with others. Slide stay
into top foil and down the line of foils or
slide each foil up stay.
Cut out template at right. Line template up
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 3/8" (10mm) and 13/8" (35mm)
from top of foil.
Drill two 5/32" (4mm) holes for
trim cap.
Foil
Top
!
13/8" (35mm)
3/8" (10mm)
Assembly Top Foil
8 Nautor MKIV Furling 4/18/07

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 isolator
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.
Push trim cap into foil to start then tap
in using hammer.
Install trim cap screws.
Assembly Top Foil
4/18/07 Nautor MKIV Furling 9

Slip 9.75" (248mm) 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 the lower
half of the injector is full as shown. Keep
tip free of sealant to let air inside.
Loading Injector with Adhesive
Adhesive in
lower half
Assembly Top Foil/Connectors
10 Nautor MKIV Furling 4/18/07

Start plunger into injector and immediately
hold upright so plunger is down and tip
applicator is up.
As sealant runs down towards the plunger
an air pocket will form near the tip. Push
plunger to evacuate the air. You are now
ready to begin injecting adhesive.
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
4/18/07 Nautor MKIV Furling 11