Harken 1807, 1807HL User Manual

hanks for buying a Harken Battcar 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 your mainsail handling system. Please take the time to read it carefully before assembling or using your Battcar system.

hese 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.

f you have questions that 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.

Contents Page

Sizing and Parts List ................................ 3

Required Tools..................................... 4

Determining and Adjusting Track Length ................ 4

Cutting Top Track to Length ........................5 - 6

Checking Fit of Mounting Slugs and Cars ............... 6

Installing Track — Groove Mast .....................7 - 8

Installing Track — Drilling and Tapping................. 9

Loading Cars on Track..............................10

Attaching Sail to Cars .............................. 11

Lazy Jacks ....................................... 12

Operation and Maintenance.......................... 12

Removing Sail .................................... 12

Sailmaker’s Instructions ........................ 13 - 18

Troubleshooting — Installation & Operation ............ 19

Sizing

Make sure that you have the correct size Battcar system for your boat.

1 - Coupler

2 -

Headboard

Cars

1792

1807

Maximum Sail Area

Monohull Multihull

350 ft

33 m

425 ft

39 m

550 ft

51 m

300 ft

28 m

350 ft

32 m

475 ft

34 m

Parts List

2 -

Headboard Plates

(1792 Only)

4 - 19 mm Rings

System Headboard

Low Load

Hi-Load

/8" (22 mm)

15 - Mounting Slugs

/4" (19 mm)

/2"

(12 mm)

/2"

(12 mm)

1792HL

Part No. Battcars

1807

1792 1807

1901, 1944,

1976, 1977

1825, 1901,

1944, 1976

1825HL, 1901HL, 1944HL,

1976HL, 1977HL

1800 TRACK, 6'83/4" (2.05 m) long: Number of sections will vary according to luff length.

Make sure you have the correct size track. System A track is 7/8" (22 mm) wide.

2720 Track: for drilling and tapping

you must use 2720 track. Use 10-32 (5 mm) screws, not included.

Do not use 1800 open backed track for drilling and tapping the mast. This track must have the support of the mounting slugs.

See page 9 for mounting instructions.

Luff

Car

1777

1894

1894HL

1 -

Screw and

Nut for

1944

Receptacle

HEADBOARD ASSEMBLY

1 - Connector Slug

/8" (67 mm)

17 - Flathead Screws

5 mm x 16 mm

2 - Tubes

Blue Loctite

MOUNTING KIT

One required for each track.

LUFF CARS

Luff cars not required

if battens are close

enough to support sail.

BATTCARS

Harken fitting is shown. You may have Battslide, Rutgerson or SDA batten receptacles supplied separately.

2 - End Stops

/4" (32 mm)

2 - Rubber End Stops

4 - Flat Head Screws

5 mm x 25 mm

1 - Tube

Blue Loctite

END KIT

One required for each system.

Required Tools Determining Track Length

HARKE

USA

HARKE

USA

Phillips screwdriver Drill Tape measure Putty knife File Hacksaw Tape Hammer Socket wrench Center punch Power driven screwdriver Step Ladder: If you are installing the system with

the mast up, use a step ladder that can be secured to the boat near the mast.

You will need to work at a hand height of about 7' (2.13 m) above the gooseneck.

/64" (5.5 mm) drill bit

Note: Track length is greater than luff length of sail. The track must extend at least 8" above the point where the halyard is attached to

the Harken headboard. Allow for sail stretch. Make sure the top of the track does not interfere with the halyard exiting from the

mast.

The set back for the halyard from the aft side of the mast is 3

/4" (96 mm). See

Diagram A. Remember to leave 1/4" (6 mm) beyond each end of the track for the end stops. At the lower end, the track must extend as close to the gooseneck as possible

and ideally below the top of the boom.

Adjusting 1800 Track Length

The length of the track is matched to the mast by adjusting the number of 6'83/4" (2.05 m) track lengths and by cutting the top and bottom track pieces to length.

Consult chart below to determine how many total track pieces you will need. Consult the charts below to determine whether you need to cut your top track to

length. All mast lengths will require cutting the bottom track. A short bottom track allows

cars to be easily loaded. See page 10.

How Many 1800 Track Sections?

Use the chart below to determine the total number of full length 6'83/4" (2.05 m) track sections required for installation.

The variable length top and bottom tracks are included in this number.

Track Length of Mast

(As Described in Diagram A)

28'9" to 33'8"

(8.763 m to 10.262 m)

33'9" to 40'5"

(10.287 m to 12.319 m)

40'6" to 47'2"

(12.344 m to 14.376 m)

47'3" to 53'11"

(14.402 m to 16.434 m)

54' to 60'7"

(16.459 m to 18.466 m)

60'8" to 62'

(18.491 m to 18.898 m)

Number of 6'83/4 " (2.05 m)

Track Sections Required

DIAGRAM A: Determining Track Length

Full Length 6'83/4" (2.05m) Top Track

Round your track length to the nearest 1" (25 mm). If your track length is one of the dimensions shown below, your track system does not need a special length top track. A full length 6'83/4" (2.05 m) track is used as the top track.

28'5" (8.661 m) 35'2" (10.719 m) 41'11" (12.776 m) 48'08" (14.834 m) 55'4" (16.866 m) 28'6" (8.687 m) 35'3" (10.744 m) 42' 0” (12.802 m) 48'09" (14.859 m) 55'5" (16.891 m) 28'7" (8.712 m) 35'4" (10.770 m) 42' 1" (12.827 m) 48'10" (14.884 m) 55'6" (16.916 m)

Cutting Top Track To Length

Total Track Length (as defined on page 4) Top Track Length

28' 8" ( 8.738 m) 35' 5” (10.795 m) 42' 2" (12.852 m) 48'11" (14.910 m) 55' 7" (16.942 m) 3" ( 76 mm)

28'10" ( 8.788 m) 35' 7" (10.846 m) 42' 4" (12.903 m) 49' 1" (14.961 m) 55' 9" (16.993 m) 5" (127 mm)

29' 0“ ( 8.839 m) 35' 9" (10.897 m) 42' 6" (12.954 m) 49' 3" (15.011 m) 55'11" (17.043 m) 7" (178 mm)

29' 2" ( 8.890 m) 35'11" (10.947 m) 42' 8" (13.005 m) 49' 5" (15.062 m) 56' 1" (17.094 m) 9" (229 mm)

29' 4" ( 8.941 m) 36' 1" (10.998 m) 42'10" (13.056 m) 49' 7" (15.113 m) 56' 3" (17.145 m) 11" (279 mm)

29' 6" ( 8.992 m) 36' 3" (11.049 m) 43' 0” (13.106 m) 49' 9" (15.164 m) 56' 5" (17.196 m) 1' 1" (330 mm)

29' 8" ( 9.042 m) 36' 5" (11.100 m) 43' 2" (13.157 m) 49'11" (15.215 m) 56' 7" (17.247 m) 1' 3" (381 mm)

29'10" ( 9.093 m) 36' 7" (11.151 m) 43' 4" (13.208 m) 50' 1" (15.265 m) 56' 9" (17.297 m) 1' 5" (432 mm)

30' 0” ( 9.144 m) 36' 9" (11.201 m) 43' 6" (13.259 m) 50' 3" (15.316 m) 56'11" (17.348 m) 1' 7" (483 mm)

30' 2" ( 9.195 m) 36'11" (11.252 m) 43' 8" (13.310 m) 50' 5" (15.367 m) 57' 1" (17.399 m) 1' 9" (533 mm)

30' 4" ( 9.246 m) 37' 1" (11.303 m) 43'10" (13.360 m) 50' 7" (15.418 m) 57' 3" (17.450 m) 1'11" (584 mm)

30' 6" ( 9.296 m) 37' 3" (11.354 m) 44' 0” (13.411 m) 50' 9" (15.469 m) 57' 5" (17.501 m) 2' 1" (635 mm)

30' 8" ( 9.347 m) 37' 5" (11.405 m) 44' 2" (13.462 m) 50'11" (15.519 m) 57' 7" (17.551 m) 2' 3" (686 mm)

30'10" ( 9.398 m) 37' 7" (11.455 m) 44' 4" (13.513 m) 51' 1" (15.570 m) 57' 9" (17.602 m) 2' 5" (737 mm)

31' 0” ( 9.449 m) 37' 9" (11.506 m) 44' 6" (13.564 m) 51' 3" (15.621 m) 57'11" (17.653 m) 2' 7" (787 mm)

31' 2" ( 9.500 m) 37'11" (11.557 m) 44' 8" (13.614 m) 51' 5" (15.672 m) 58' 1" (17.704 m) 2' 9" (838 mm)

31' 4" ( 9.550 m) 38' 1" (11.608 m) 44'10" (13.665 m) 51' 7" (15.723 m) 58' 3" (17.755 m) 2'11" (889 mm)

31' 6" ( 9.601 m) 38' 3" (11.659 m) 45' 0” (13.716 m) 51' 9" (15.773 m) 58' 5" (17.805 m) 3' 1" (940 mm)

31' 8" ( 9.652 m) 38' 5" (11.709 m) 45' 2" (13.767 m) 51'11" (15.824 m) 58' 7" (17.856 m) 3' 3" (991 mm)

31'10" ( 9.703 m) 38' 7" (11.760 m) 45' 4" (13.818 m) 52' 1" (15.875 m) 58' 9" (17.907 m) 3' 5" (1.041 m)

32' 0” ( 9.754 m) 38' 9" (11.811 m) 45' 6" (13.868 m) 52' 3" (15.926 m) 58'11" (17.958 m) 3' 7" (1.092 m)

32' 2" ( 9.804 m) 38'11" (11.862 m) 45' 8" (13.919 m) 52' 5" (15.977 m) 59' 1" (18.009 m) 3' 9" (1.143 m)

32' 4" ( 9.855 m) 39' 1" (11.913 m) 45'10" (13.970 m) 52' 7" (16.027 m) 59' 3" (18.059 m) 3'11" (1.194 m)

32' 6" ( 9.906 m) 39' 3" (11.963 m) 46' 0' (14.021 m) 52' 9" (16.078 m) 59' 5" (18.110 m) 4' 1" (1.245 m)

32' 8" ( 9.957 m) 39' 5" (12.014 m) 46' 2" (14.072 m) 52'11" (16.129 m) 59' 7" (18.161 m) 4' 3" (1.295 m)

32'10" (10.008 m) 39' 7" (12.065 m) 46' 4" (14.122 m) 53' 1" (16.180 m) 59' 9" (18.212 m) 4' 5" (1.346 m)

33' 0” (10.058 m) 39' 9" (12.116 m) 46' 6" (14.173 m) 53' 3" (16.231 m) 59'11" (18.263 m) 4' 7" (1.397 m)

33' 2" (10.109 m) 39'11" (12.167 m) 46' 8" (14.224 m) 53' 5" (16.281 m) 60' 1" (18.313 m) 4' 9" (1.448 m)

33' 4" (10.160 m) 40' 1" (12.217 m) 46'10" (14.275 m) 53' 7" (16.332 m) 60' 3" (18.364 m) 4'11" (1.499 m)

33' 6" (10.211 m) 40' 3" (12.268 m) 47' 0” (14.326 m) 53' 9" (16.383 m) 60' 5" (18.415 m) 5' 1" (1.549 m)

33' 8" (10.262 m) 40' 5" (12.319 m) 47' 2" (14.376 m) 53'11" (16.434 m) 60' 7" (18.466 m) 5' 3" (1.600 m)

33'10" (10.312 m) 40' 7" (12.370 m) 47' 4" (14.427 m) 54' 1" (16.485 m) 60' 9" (18.517 m) 5' 5" (1.651 m)

34' 0” (10.363 m) 40' 9" (12.421 m) 47' 6" (14.478 m) 54' 3" (16.535 m) 60'11" (18.567 m) 5' 7" (1.702 m)

34' 2" (10.414 m) 40'11" (12.471 m) 47' 8" (14.529 m) 54' 5" (16.586 m) 61' 1" (18.618 m)

34' 4" (10.465 m) 41' 1" (12.522 m) 47'10" (14.580 m) 54' 7" (16.637 m) 61' 3" (18.669 m)

34' 6" (10.516 m) 41' 3" (12.573 m) 48' 0” (14.630 m) 54' 9" (16.688 m) 61' 5" (18.720 m)

34' 8" (10.566 m) 41' 5" (12.624 m) 48' 2" (14.681 m) 54'11" (16.739 m) 61' 7" (18.771 m)

34'10" (10.617 m) 41' 7" (12.675 m) 48' 4" (14.732 m) 55' 1" (16.789 m) 61' 9" (18.821 m)

35' 0" (10.668 m) 41' 9" (12.725 m) 48' 6" (14.782 m) 55' 3" (16.840 m) 61'11" (18.872 m)

5' 9" (1.753 m)

5'11" (1.803 m)

6' 1" (1.854 m)

6' 3" (1.905 m)

6' 5" (1.956 m)

6' 7" (2.006 m)

Cutting Top Track To Length

If your track length is shown in the chart on page 5, use a hacksaw to cut a special length of top track from a 6'83/4" (2.05 m) track.

Round your track length to the nearest 1/2" (10 mm) and extrapolate to determine the top track length.

Before You Start...will mounting slugs and cars fit?

Use a file to deburr the cut. Slightly round off the corners of the track

that will slide against the mast so it will not catch when sliding the track up the mast.

NOTE: You will cut the bottom track in Step 10.

Will Tighten

To make sure the track will tighten against mast, put a mounting slug in the groove, a track section on the mast and use a screw to test.

Also, make sure mounting screw is long enough for your mast groove.

Will Not Tighten

Drill two 13/64" (5.5 mm) holes in the cut end of the top track centered at 5/16" (8 mm) and 11/16" (27 mm) from the track end.

Slip the rubber end stop over the cut end of the top track.

Check Fit

Check to make sure the 25/8" (67 mm) long connector slug will fit in the feeder opening. If necessary, use a file to make the feeder opening longer.

Use a halyard to run the 25/8" (67 mm) long connector slug up the entire mast. Use a retrieval line. If it jams, clean the groove.

If there is prebend in the mast, you may need to straighten it out somewhat to install the battcar system.

Clear of Trysail Track?

Cars are 21/4" (57 mm) wide. Make sure they do not hit trysail track or other obstruction up the entire spar. Tracks often converge above the spreaders.

Warning! Screws must have three (3)or

more threads engaged to hold track to mast. Make sure screw makes three (3) full 360°

rotations after threads engage in slug.

+ 14 hidden pages