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

Tighten screws into connector holes. Make
sure that a drop of adhesive was put in
screw holes. If not, apply to screw.
Use bushings, connector, wedge and
adhesive in other screw hole and
insert into other foil. Use 1 - 11/4ml
of adhesive.
Inject only a small amount. A Unit 3 will
only take 1 to 11/4ml graduation mark.
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
to 11/4ml of
adhesive
Stop when you see a small
amount of adhesive enter
one of the sdrew holes.
Assembly Foils/Connectors
12 Nautor MKIV Furling 4/18/07

Continue installing connectors and wedges.
Make sure to use adhesive in screw holes.
Continue assembly. Use 14" (356mm)
bottom connector to assemble bottom foil.
Slide halyard swivel onto foil above feeder
window. Make sure taller “half” is up as
shown.
Assembly Bottom Foil/Connectors/Halyard Swivel
4/18/07 Nautor MKIV Furling 13

Loosen foil clamp screws at top of
lower unit.
Slide drum assembly onto foils.
Tip: Face clamp downwards so it
clears foil notches when installing.
Slide lower unit onto foils.
Assembly Lower Unit
14 Nautor MKIV Furling 4/18/07

Make sure halyard swivel and drum assem-
bly have been slipped on the foils.
Slip the rod adapter sleeve onto the rod.
Sandwich the nosepiece over the rod and
insert into the main body, narrow end first.
Jiggle the sleeve or use a small screwdriver
to push the nosepiece completely into
sleeve.
TIP: Sight through the pin hole to find the
optimum thread engagement. Make sure
the stud is threaded far enough so the
pin is securely seated in the slot, yet
not threaded too far to block the pin.
Put several drops of the blue Loctite®on
the large threads of the stud. Thread the
stud into the main body until the slot aligns
neatly with the hole in the main body.
Assembly Toggle/Terminal
4/18/07 Nautor MKIV Furling 15

Lower drum assembly and slip clevis pin and
cotter pin in place.
Check foil height at top, set and secure
using Allen wrench.
Hammer the pin into the main body.
Clean excess Loctite® from the terminal
body. Tape around sleeve to secure pin.
Assembly Complete Unit Assembly
16 Nautor MKIV Furling 4/18/07

Check the clearance between the top of the
foil and top terminal.
TIP: Check clearance when the unit is on
the ground, before raising the headstay
into position.
Slide halyard swivel above feeder. Place
feeder in foil recess. Push screw down
so tab catches under foil. Tighten screw.
Note: Screw will turn with some difficulty.
It has plastic coating so it does not vibrate
loose.
Important—When removing screw,
loosen no more than one full turn.
Slide screw up and remove feeder.
Tip: Do not remove foil clamp screws
to adjust foil. Loosen screws, hold foils
and bring clamp away from foils. Adjust
and reclamp.
Assembly Attach Feeder/Final Foil Assembly
Assembly Check Top Foil Clearance
4/18/07 Nautor MKIV Furling 17

Race Conversion
Race conversion allows use of both
grooves for sail changes and tacking
genoas on deck for use of maximum
luff length genoas.
Halyard Swivel Below Feeder
Use halyard to lift halyard swivel up, away
from feeder. Loosen screw one revolution
only. Slide screw up and hold. Remove
feeder carefully—bottom end first. Don’t
lose the feeder overboard! Lower swivel
onto torque tube. Replace feeder.
Installation of Lower Unit in Deck Hole
1) Use 10mm Allen wrench provided to
remove 2 screws on bottom of guard
assembly and remove two halves.
Be careful—screws are not captive.
2) Use a 3mm Allen wrench to loosen
four screws in plastic cover and flange.
3) Insert unit through deck.
4) Put halves of flange together over
octagonal groove. Put blue Loctite®
on screw holes and secure using
screws.
5) Put halves of cover together over
octagonal groove. Put blue Loctite®in
screw holes and scrure using screws.
6) Put halves of line guard together so
clamp ring is in groove. Secure with
screws.
Loosen screw one revolution only. Slide screw up and hold.
Carefully remove feeder–bottom
end first. Don't drop the feeder
overboard!
1.
2.
1. Loosen screw
one revolution only.
2. Slide screw up.
Remove feeder.
3. Lower halyard
swivel.
To Remove
Feeder For
Racing
Commissioning Through Deck Installation/Race Conversion
18 Nautor MKIV Furling 4/18/07

HALYARD WRAPS
The most serious problem with furling systems occurs
when the jib halyard wraps around the headstay foil.
Halyard wraps will prevent furling or unfurling and may
cause serious damage to the unit and the halyard. In
severe cases, halyard wraps may cause headstay loss.
To prevent wraps, the halyard must exert a slight pull to
the rear. This allows the foils to turn while the halyard
remains stationary.
8 - 10°
PREVENT WRAPS
WARNING: The sail must be fitted to the foils before
operation.
1 Halyard swivel should be within the top
4" (100 mm) of the foil.
2 Halyard must pull slightly to the rear (8 - 10°).
3 Halyard must be snug, but not too tight.
If a halyard wraps, do not force the unit to turn. Attempt
to open the sail by alternately furling in and out slightly.
If the sail can be unfurled, lower the sail by releasing the
jib halyard. Severe halyard wraps can only be cleared by
going aloft and freeing the halyard.
If the sail will not furl or unfurl, it may be possible to
remove the jib sheets and manually wrap the sail around
the headstay.
Remember: Testing at the dock does not indicate the
halyard angle is correct. In wave action, the halyard may
wrap if the lead angle is not correct. The 8-10° diverging
angle mentioned above is critical.
TIP: With the sail raised, walk away from the boat and look
at the masthead with binoculars. Use the halyard swivel
as a measurement reference. 4” (100 mm) is
1
/ 3 the length
of the swivel. There should be less foil exposed above the
swivel than
1
/ 3 of the swivel.
Commissioning Halyard Wrap
4/18/07 Nautor MKIV Furling 19

PENDANTS
If your sail is not long enough to position the halyard swivel properly, you
must add a pendant to the sail. Pendants should be plastic coated wire
permanently attached to the sail so the height will be correct. Adjustable
length pendants are not acceptable as they might not be adjusted correctly
during a sail change.
INSTALL A PENDANT
1 Raise the sail, but do not attach tack shackle.
2 Position the halyard swivel correctly near the top of the headstay and secure
the halyard.
3 Secure a piece of rope to the sail tack. Lead the line through the tack shackle
on the furling drum and tension the sail.
4 Measure the distance from the tack shackle to the sail tack and have a
pendant of this length permanently attached to the head of the sail.
5 Repeat this procedure for every jib.
TIP: Pendants are used at the head of the sail. Short pendants may be
added at the tack to improve visibility under the genoa, but remember
that visibility is already improved by shackling to the tack swivel. Tack
pendants increase heeling moment by raising the sail plan. You may
install pendants at both the head and tack of the sail.
HALYARD RESTRAINER
To prevent wraps, the jib halyard must pull slightly to the rear. On some
boats the halyard sheaves are located too close to the headstay and a
halyard restrainer must be used.
Use halyard restrainers only when required by the masthead geometry.
Restrainers tend to limit sail luff length and may cause problems if not
properly installed.
Mount the restrainer as high as possible on the face of the mast. Position
the restrainer so the foils will not hit it when under load.
The restrainer should deflect the halyard 8 - 10°. If the angle is more than
10°, you may experience difficulty in tensioning the sail luff, friction in
furling and possible damage to the foils. To decrease deflection angles,
shorten the luff of the sail.
8 - 10°
HALYARD TENSION
The jib halyard should be firm, but not too tight.
TIP: The luff foil system supports the sail along its entire
length so halyard tension is required only to shape sails, not
to support them. Use only enough halyard tension to remove
some wrinkles along the luff. Do not tension the halyard
enough to cause vertical wrinkles in the luff. Use halyard
tension to adjust draft position of the sail to suit sailing
conditions. Your halyard should be firm but not tight. If
in doubt, release halyard tension. To protect the sail,
ease the halyard when the boat is not in use.
TIP: Boats used in charter service should consider using a
halyard restrainer, regardless of masthead geometry.
Commissioning Halyard Restrainer
20 Nautor MKIV Furling 4/18/07

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Nautor MKIV Furling 4385 03/10/11