I N S T R U MKIII C Jib Reefing & T Furling Systems I O UNIT 3.5 N M A N U A L Thanks for buying a Harken Jib Reefing and Furling System. It will give you reliable service with minimal maintenance, but does require proper assembly and basic care. This manual is an important part of the total reefing system. Please take the time to read it carefully before assembling or using your furling system. These instructions may look intimidating, but they are very simple and use photos and drawings throughout to make assembly easy. Many sections will not apply to your boat or to your installation. If you have questions which cannot be answered by the manual or your dealer, please feel free to give us a call. We’ll be happy to do anything we can to make your sailing safer and more fun. 2 Unit 3.5 MKIII January 2007 Parts 6-7 Sailmaker Instructions 8 Preparation for Assembly 10 – 12 This section tells how to measure the headstay, prepare the wire and cut foil to length if they have not been supplied ready to assemble. Assembly 13 – 20 Assembly of the unit is explained in this section Commissioning 21 – 23 Commissioning covers how to install the assembled unit on the boat and make it operational. Operation 24 – 28 This section explains system use. It also discusses tensioning the headstay and converting to racing. Troubleshooting & Repair 29 – 30 The Assembly and Operation Trouble Shooting guides explain how to correct problems. Your seven-year limited warranty is explained on page 30. January 2007 Unit 3.5 MKIII 3 11 Threaded Stud Embout fileté à sertir Gewinde-Terminal Terminale filettato Espanõl 6 Line Guard Assembly 12 Torque Tube Guide antiusure de drosse Tube de torsion Leinen-Führung Mitnehmerhülse Guida per la scotta Tubo di torsione Espanõl Espanõl 7 Furling Drum 13 Bottom Foil Extrusion Tambour Profil inférieur standard Trommel Unterstes Profil Tamburo Estruso inferiore Part Descriptions Espanõl Espanõl Désignation 3 Locking Nut 8 Turnbuckle Assembly 14 Bottom Foil Connector Die Tiele Ecrou de blocage Ridoir Connecteur inférieur Descrizione Konter-Mutter Wirbeleinheit/Spanner Unterstes Verbinder Espanõl Dado di bloccaggio Sede dell'arridatoio Connettore inferiore Espanõl Espanõl Espanõl 1. Clevis Pin 4 Restraining Washer 9 Tack Swivel 15 Feeder Axe épaulé Rondelle plate Emerillon de point d'amure Engageur Toggelbolzen Unterlagscheibe Halswirbe Einfädler Perno Rondella Girella inferiore Feeder Espanõl Espanõl Espanõl Espanõl 2 Lower Stud with Toggle 5 Locking Washer 10 Locking Collar 16 Regular Foil Extrusion Chape articulée filetée inférieure Rondelle crantée Douille filetée de blocage Profil standard (2130 mm) Gewinde mit Toggel Zahnscheibe Klemmhülse Normales Profil Perno filettato inferiore con snodo Rondella di bloccaggio Manicotto di fermo Estruso Espanõl Espanõl Espanõl Espanõl 4 Unit 3.5 MKIII January 2007 Pivot 12" Point 7 305 mm 22 /8" Max 581 mm 20" Min 7 508 mm 11 /8" 1 302 mm 19 /2" Max 495 mm 5 16 /8" Min 422 mm ■ Sizing Check 7 1 8 8 1 Unit 3.5 is available with a / " (22.2mm), 1 / " (28.57 mm) clevis pin. 11 /2" 292 mm Max Clevis Pin 5 Make sure you have the correct size pin for your boat. Contact your 7 1 8 /8", 1 /8" 8 / " 218 mm Min dealer to exchange the lower toggle stud for the correct size. Harken (19 mm, does not recommend drilling the chainplate or the integral toggle. 28.57 mm) Check to make sure the lower drum assembly will fit inside the bow pulpit. If there is an anchor locker, check to see if the drum assembly will clear. If necessary, use a toggle or link plates to raise the unit. See page 8. ■ Connector Bore Unit 3.5 connectors are available with either a large bore or a small bore hole depending on headstay diameter. Make sure you have the correct size connectors to match the headstay. Headstay Size Connector inside Diameter 5 /8", 16 mm wire, -48 Rod .719" (18.25 mm) 19 mm wire .812" (21 mm) ■ Rod Nosepiece/Coldhead Type Two types of rod adapter nosepieces are available for the #3.5. Check to make sure you have the correct part to fit either Navtec or Riggarna. Rod Type Designation/Nosepiece Navtec 48 Riggarna 143 17 Connector 19 Connector Screws 21 Top Foil Extrusion 23 Top Foil Trim Cap Connecteur Vis pour connecteurs Profil plastique pour connecteurs Capuchon plastique supérieur Verbinder Schrauben für Verbinder Top Profil Topkappe Connettore Viti di bloccaggio connettori Estruso superiore Cappuccio per estruso superiore Espanõl Espanõl Espanõl Espanõl 18 Connector Locking Wedges 20 Halyard Swivel 22 Connector 24 Upper Swage Eye Cales plastiques pour connecteurs Emérillon de drisse Connecteur Embout serti supérieur à œil Kunststoff Keile Fallwirbel Verbinder Oberes Augterminal Piastrine di bloccaggio connettori Girella superiore (Drizza) Connettore Terminale ad occhio pressato Espanõl Espanõl Espanõl Espanõl January 2007 Unit 3.5 MKIII 5 Parts You should have at least two boxes: a long box with foils and a rectangular box containing the drum and miscellaneous components. You may also have a third box containing the headstay. ■ The foil box contains: (8) 9' (2.74 m) Foil Extrusions. A standard kit has 8 foils, but one may have been cut for use as your top foil. If your headstay is longer than 76'10" (23.42 m) you should order one extra foil extrusion, Part 1079. If your headstay is over 85'16" (26.16 m) order two extras. (1) 24" (610 mm) Special Bottom Foil Extrusion. ■ The main components box contains parts packaged on the display card plus a smaller parts box. Main Components Halyard Swivel Emérillon de drisse Fallwirbel Girella Superiore Torque Tube Tube de Torsion Mitnehmerhülse Tubo di Torsione Feeder Engageur Einfädler Feeder Drum Assembly Ensemble Panier et Chape Articulée Trommeleinheit Tamburo Completo 6 Unit 3.5 MKIII January 2007 Parts Foil Connector Prefeeder Wedges Top Foil Trim Cap Torque Tube Spare Foil Screws Screws Screws Allen Wrenches Locking Collar Bottom Regular Connectors Connector Blue Loctite® Instant Red Loctite® Adhesive Rigger Components These parts are placed on the headstay before assem- bly and may be "missing" as the parts may have been placed on your headstay in advance. Miscellaneous Parts 7 1 4 /8" (124 mm) Top Bushing/Trim Cap 1 1 Bag of 26 Connector Wedges, 9 Extra Wedges 1 13 /2" (343 mm) Bottom Connector 1 Prefeeder with line 7 10" (254 mm) Regular Connectors 1 Bag of 69 Foil Screws. Contains 20 extra screws 1 Bag of four Torque Tube Screws 1 Bag of Spare Screws. Contains one spare screw for every application. They are not required for installation 1 6 mm Allen Wrench 1 8 mm Allen Wrench 1 10 mm Allen Wrench 1 Locking Collar 1 Loctite® (Blue) 1 Loctite® (Red) 1 Feeder with screw Furling Line Line is not included with furling unit. Purchase 7/16" (12 mm) low stretch Dacron double braid. The length of the line should be equal to the length of the boat plus the length of the foot of the largest genoa plus 6’ (2 m) January 2007 Unit 3.5 MKIII 7 Sailmaker Instructions Luff Tape • Tack and Head Shackles • Suncover ■ Sail Type The Harken furler will work with conventional sails or ® sails with built in shaping devices such as Aeroluff , Actual Size Pirini Luff or foam luff. Echelle 1 Tatsächliche Grösse ■ Luff Length Dimensioni Reali Espanõl Note offsets above and below the sail. Foil Profil A shorter luff may be required if a halyard restrainer is Profil necessary (page 23) or a toggle or link plates are used Estruso Espanõl below the furler to raise the drum. If the luff of the sail is not long enough to put the halyard swivel near the top of the headstay foil, make sure a pendant is added, see page 23. Halyard Shackle ■ Tack Setback Manille de Drisse Fall-Schäkel Grillo Drizza Note setback for the tack shackle and cut the sail Espanõl accordingly. 18" ■ Luff Tape Size 457 mm 6 Unit 3.5 requires number 6 ( /32" or 5 mm) 1 13 /4" luff tape. 337 mm ■ Luff Tape Length 9" Cut off the top of the luff tape so it is 24 to 36" (610 to 229 mm 915 mm) below the head of the sail. This will allow the head to lag behind the rest of the sail to help flatten Head Shackle the sail. It will also help the head to roll more smoothly. Manille de Tétière Kopf Schäkel Grillo Penna Note feeder height and extend the bottom of the luff Espanõl Feeder Entrance tape downwards so it is below the feeder. This will pre- Engougure Einfädler Öffnung vent the luff tape from catching in the feeder as the sail Feeder Espanõl is lowered. ■ Tack and Head Shackles 2" 1 Make sure tack and head shackles fit the sail rings. 51 mm 56 /2" Max 1435 mm The minimum inside dimensions of the standard 1 shackles are: 50 /2" Min 1283 mm Tack Shackle Manille d’Amure D Fuss-Schäkel Grillo Mura Espanõl Head—D Shackle (12mm): 12" 5 (A) 1 /8" (41 mm) 305 mm Pivot Point Point de Pivot Dreh-punkt (B) 1" (25 mm) Snodo Espanõl Tack— Bow Shackle (10mm): 13 7 22 /8" Max (A) 1 /16" (49 mm) 7 581 mm (B) /8" (22 mm) A Bow 20" Min 7 11 /8" 508 mm 302 mm 1 19 /2" Max 495 mm ■ Suncover B 5 16 /8" Min Suncovers may be installed on either side of the sail. 422 mm However, make sure you match other sails in the cus- tomer's inventory.