Harken 3811 User Manual

BATTCAR INSTALLATION MANUAL

System A CB and Slider

Installation Manual – Intended for specialized personnel or expert users

Introduction

Safety precautions 2

Preassembly (Slug Mount/Drill & Tap)

Parts 3
Tools 4
Sizing 4
Sail modifications 4
Track length (slug mount only) 4 - 5
Cutting top track to length (slug mount only) 6
Check fit of mounting slugs/cars (slug mount only) 7

Installation (Slug Mount)

Install track 8 - 10
Install screwpin endstop kit 10

Preassembly (Drill & Tap)

Parts 4, 11
Track length 11
Remove old track 11

Installation (Drill & Tap)

Drill, tap, and fasten 11

Operation (Slug Mount/Drill & Tap)

Load cars on track 12
Load cars on track with sail attached 13
Lost balls 13
Load cars on track with sail attached (slider) 14
Load sail on cars (CB/slider) 14 - 15

Maintenance (Slug Mount/Drill & Tap)

Removing sail 16
Car maintenance/cleaning/inspect 16
Lazy Jacks 16
Operating precautions 16

Sailmaker's Instructions (Slug Mount/Drill & Tap)

Dimensions 17
Installing headboard car assembly 17
Headboard plates 17
Battcars with batten receptacles 18 - 19
Distance between attachment points/reef points 20
Attaching sail to intermediate cars 21

Troubleshooting – Installation/Operation 22

Addresses 24

4248 10/14

Please read these instructions carefully before installing, servicing, or operating the equipment.

This manual may be modified without notice: www.harken.com/manuals for updated versions.

PLEASE SAVE THESE INSTRUCTIONS

Introduction

This manual gives technical information on installation and service. This information is written 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 Battcars are designed to reduce the size of, or completely drop the mainsail on a sailboat 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

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.

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.

WARNING! Strictly follow all instructions to avoid potential hazards that may kill or hurt you
and others: www.harken.com/manuals for general warnings and instructions.

System A (CB/slider)

2

CB/Slider Systems Parts

Headboard Car Assemblies

CB BALL BEARING CARS SLIDER CARS

CB BALL BEARING CARS SLIDER CARS

Intermediate Cars

3812

3883

3827

3811

Batten Cars

CB BALL BEARING CARS SLIDER CARS

3828

1777

3830

3882 3829

3881

3831

Max headboard

Part

No. Description

Length Width Weight

in mm in mm oz g in mm in mm in mm lb kg

thickness

CB Cars: Typical Boat Length: Monohulls 11.3 - 15.2 m (37 - 50 ft); Multihulls 9.1 - 12.2 m (30 - 40 ft)

3811 Headboard car assembly 8
3812 Intermediate car 2
3829 Battcar/10 mm stud** 2
3830 Battcar/40 mm receptacle 2
3881 Battcar/12 mm stud** 2
3831 Universal Battcar** 2
3882 Batten car/12 mm stud** 4
3883 Reef car 4

3

/8213 21/457 18 5189/

1

/457 21/457 4 109 — — — — — — —

7

/873 21/457 6 157 — — — — — — — 600 272

7

/873 21/457 9 253 — — 15/841

7

/873 21/457 6.4 182 — — — — — — — 600 272

7

/873 21/457 4.3 122 — — — — — — — 600 272

1

/8105 21/457 8.2 232 — — — — — — — 875 397

1

/8105 21/457 6.1 174 — — — — — — — 875 397

16

14 — — — — — 1600 725

Slider Cars: Typical Boat Length: Monohulls 11.3 - 15.2 m (37 - 50 ft); Multihulls 9.1 - 12.2 m (30 - 40 ft)

3827 Headboard car assembly 6 153 1
1777 Low-load intermediate car* 2 51 1
3828 Intermediate car 1
3802 Battcar/10 mm stud** 1
3803 Battcar/40 mm receptacle 1

3

System A (CB/slider)

3

/444 13/835 1.6 45 — — — — — — — 350 159

3

/444 13/835 2.8 80 — — — — — — — 350 159

3

/444 13/835 6.4 181 — — 15/841

1

/435 10 2699/

1

/432 1.1 32 — — — — — — — 200 91

16

14 — — — — — 1600 725

3803

3802

Max batten

Batten

5

/

8

16 Flat/round 600 272

5

/

8

16 Flat/round 350 159

Maximum

working loadWidth Ø

CB/Slider Systems Parts

Track mounting kit

3804, 3805, 3806

a b c d

Screwpin endstop kits

3824, 3825, 3826

e f g

h

Spare

car screws

Endstop kits

3808, 3809, 3810

i j k

Track (slug type) Track (drill and tap)

12.5 mm

1

/2")

(

2720

3807

22 mm (7/8")

22 mm (7/8")

Track and Accessories

Part No. Description Includes

Mounting Slug Method

3

3804, 3805

3806

3824, 3825

3826

3808, 3809

3810

3807

Drill & Tap Method

2720

Loctite is a registered trademark of Henkel AG & Company KGaA.

System A (CB/slider)

Track mounting kit

Screwpin endstop kt

Endstop kit (g) 2 endstops 263A; (i) 4 HFS320 flathead screws 5 x 25 mm; (f) 2 stop slugs 32 mm (1

Track

Track

(a) 15 mounting slugs 19 mm (
(d) 17 HFS1015 flathead screws 5 x 20 mm

(e) 1 end track with screwpin stop; (f) 1 top stop slug 32 mm (1
(i) 2 HFS320 flathead screws 5 x 25 mm; (j) 2 HFS1015 flathead screws 5 x 20 mm; (k) 1 tube blue Loctite® adhesive

Section length: 2.05 m (6'8

Use for masts without grooves or when slugs will not fit. Purchase stainless steel #10 (5 mm) screws separately.
Do not use 3807 open-backed track. It requires mounting slugs. See page 8 for drill/tap sizes and mounting instructions.

/4"); (b) 1 connector slug 67 mm (25/8"); (c) 2 tubes blue Loctite® adhesive;

7

/8"). Number of track sections will vary according to luff length of your mainsail.

1

/4"); (g) 1 top endstop 263A; (h) 1 mounting slug 19 mm (3/4");

1

/4")

4

CB/Slider Systems Sizing/Sail Modifications

R27

R27

R27

R27

R27

R27

Tools You Will Need

1.Tape measure 10. Putty knife

2. Tape 11. Hex wrench (4 mm)

3. Power drill (screwdriver) 12. Nut driver (8 mm) or open wrench

4. Drill bit 5.5 mm (

5. Phillips screwdriver 13. Spring clamp

6. Hammer 14. Spring-loaded center punch (not shown)

7. Hacksaw 15. Drill bit 4.2 mm (

8. Center punch 16. Tap 5 x .80 mm (10-32) (not shown)

9. File 17. Transfer punch (5.2 mm or .205")

Mast-Up Installation: Stepladder secured to the boat.

Work Height: 2.13 m (7') above boom

13

/64")

Drill & Tap (additional)

5

/32") (not shown)

1

5

6

9

2

3

4

8

7

11

12

13

10

17

Sizing

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

Car part numbers

Headboard Battcars Intermediate Monohull Multihull

3811 3829, 3830 3812, 3831 CB 600 ft
3827 3802, 3803 3828 Slider 600 ft256 m2500 ft246 m

— — 1777 Slider 350 ft233 m2300 ft228 m

Car

type

Sail Modifications (See page 12)

1. Mainsail headboard
A. Drill new halyard location
B. Drill attachment to accept clevis pin for 3811/3827 headboard car coupler.

Maximum sail area

2

56 m2500 ft246 m

2

2

2

1

203 mm

(

8")

2. Batten receptacle on sail to accept 10 mm threaded stud.
Note: Harken does not supply receptacle.

3. Becket spacer on sail for 1777, 3812, 3828, or 3831 intermediate cars.

Determine Track Length

Measure track length from point 1 to point 2. See diagram at left. Use this
measurement in two charts to follow.

1. Upper end: 203 mm (8") above black band. Track is longer than sail luff
length to allow for stretch as sail ages. Track must not block halyard exit.

2. Lower end: Bottom of track will be approximately 10 mm (3/8") above
gooseneck fitting. When installed 3824, 3825, 3826 endstop kit track
should be as low as possible yet you should still be able to install long
headboard cars. Test measurement by using long headboard car. See
photo at right.

3808, 3809, 3810 Endstop kit: Cut a 203 mm (8") piece from finished end of one of the

2.05 m (6'8 7/8") 3807 tracks. You will remove this track when loading cars so it can be
lower on mast. See page 7, step 11. Drill lower hole for stop. See page 5, step 3.

Number of Track
Sections

Bottom 203 mm (8")
endstop track and variable
length top track included
in measurements below.
See example below:

5

System A (CB/slider)

Track Length

8.458 m to 10.490 m
(27'9" to 34'5")

10.516 m to 12.522 m
(34'6" to 41'1")

12.548 m to 14.580 m

(41'2" to 47'10")

14.605 m to 16.637 m

(47'11" to 54'7")

16.662 m to 18.694 m
(54'8" to 61'4")

Number of

2.05 m (6'8 7/8)
Track Sections

5

6

7

8

9

Track length example

7

2.05 m (6'8

2.05 m (6'87/8")

2.05 m (6'87/8")

2.05 m (6'87/8")

2.05 m (6'87/8")

.203 m (8")

Total 10.49 m (34'5")

/8")

2

CB/Slider Systems Top Track Length – Slug Mount

Top track length chart: (use for 3807 slug mount track). Round track length to nearest 25 mm (1").
Note: Chart is based on using 8" (203 mm) end track at bottom.

Total Track Length (as defined on page 3) Top Track Length

27' 9" 8.458 m — — 41' 2" 12.548 m 47' 11" 14.605 m 54' 8" 16.662 m 1

27' 10" 8.484 m 34' 6" 10.516 m 41' 3" 12.573 m 48' 0" 14.630 m 54' 9" 16.688 m 2

27' 11" 8.509 m 34' 7" 10.541 m 41' 4" 12.598 m 48' 1" 14.656 m 54' 10" 16.713 m 3" 76 mm

28' 1" 8.560 m 34' 9" 10.592 m 41' 6" 12.649 m 48' 3" 14.707 m 55' 0" 16.764 m 5" 127 mm

28' 3" 8.611 m 34' 11" 10.643 m 41' 8" 12.700 m 48' 5" 14.757 m 55' 2" 16.815 m 7" 178 mm

28' 5" 8.661 m 35' 1" 10.693 m 41' 10" 12.751 m 48' 7" 14.808 m 55' 4" 16.866 m 9" 229 mm

28' 7" 8.712 m 35' 3" 10.744 m 42' 0" 12.802 m 48' 9" 14.859 m 55' 6" 16.916 m 11" 279 mm

28' 9" 8.763 m 35' 5" 10.795 m 42' 2" 12.852 m 48' 11" 14.910 m 55' 8" 16.967 m 1' 1" 330 mm

28' 11" 8.814 m 35' 7" 10.846 m 42' 4" 12.903 m 49' 1" 14.961 m 55' 10" 17.018 m 1' 3" 381 mm

29' 1" 8.865 m 35' 9" 10.897 m 42' 6" 12.954 m 49' 3" 15.011 m 56' 0" 17.069 m 1' 5" 432 mm

29' 3" 8.915 m 35' 11" 10.947 m 42' 8" 13.005 m 49' 5" 15.062 m 56' 2" 17.120 m 1' 7" 483 mm

29' 5" 8.966 m 36' 1" 10.998 m 42' 10" 13.056 m 49' 7" 15.113 m 56' 4" 17.170 m 1' 9" 533 mm

29' 7" 9.017 m 36' 3" 11.049 m 43' 0" 13.106 m 49' 9" 15.164 m 56' 6" 17.221 m 1' 11" 584 mm

29' 9" 9.068 m 36' 5" 11.100 m 43' 2" 13.157 m 49' 11" 15.215 m 56' 8" 17.272 m 2' 1" 635 mm

29' 11" 9.119 m 36' 7" 11.151 m 43' 4" 13.208 m 50' 1" 15.265 m 56' 10" 17.323 m 2' 3" 686 mm

30' 1" 9.169 m 36' 9" 11.201 m 43' 6" 13.259 m 50' 3" 15.316 m 57' 0" 17.374 m 2' 5" 737 mm

30' 3" 9.220 m 36' 11" 11.252 m 43' 8" 13.310 m 50' 5" 15.367 m 57' 2" 17.424 m 2' 7" 787 mm

30' 5" 9.271 m 37' 1" 11.303 m 43' 10" 13.360 m 50' 7" 15.418 m 57' 4" 17.475 m 2' 9" 838 mm

30' 7" 9.322 m 37' 3" 11.354 m 44' 0" 13.411 m 50' 9" 15.469 m 57' 6" 17.526 m 2' 11" 889 mm

30' 9" 9.373 m 37' 5" 11.405 m 44' 2" 13.462 m 50' 11" 15.519 m 57' 8" 17.577 m 3' 1" 940 mm

30' 11" 9.423 m 37' 7" 11.455 m 44' 4" 13.513 m 51' 1" 15.570 m 57' 10" 17.628 m 3' 3" 991 mm

31' 1" 9.474 m 37' 9" 11.506 m 44' 6" 13.564 m 51' 3" 15.621 m 58' 0" 17.678 m 3' 5" 1.041 m

31' 3" 9.525 m 37' 11" 11.557 m 44' 8" 13.614 m 51' 5" 15.672 m 58' 2" 17.729 m 3' 7" 1.092 m

31' 5" 9.576 m 38' 1" 11.608 m 44' 10" 13.665 m 51' 7" 15.723 m 58' 4" 17.780 m 3' 9" 1.143 m

31' 7" 9.627 m 38' 3" 11.659 m 45' 0" 13.716 m 51' 9" 15.773 m 58' 6" 17.831 m 3' 11" 1.194 m

31' 9" 9.677 m 38' 5" 11.709 m 45' 2" 13.767 m 51' 11" 15.824 m 58' 8" 17.882 m 4' 1" 1.245 m

31' 11" 9.728 m 38' 7" 11.760 m 45' 4" 13.818 m 52' 1" 15.875 m 58' 10" 17.932 m 4' 3" 1.295 m

32' 1" 9.779 m 38' 9" 11.811 m 45' 6" 13.868 m 52' 3" 15.926 m 59' 0" 17.983 m 4' 5" 1.346 m

32' 3" 9.830 m 38' 11" 11.862 m 45' 8" 13.919 m 52' 5" 15.977 m 59' 2" 18.034 m 4' 7" 1.397 m

32' 5" 9.881 m 39' 1" 11.913 m 45' 10" 13.970 m 52' 7" 16.027 m 59' 4" 18.085 m 4' 9" 1.448 m

32' 7" 9.931 m 39' 3" 11.963 m 46' 0" 14.021 m 52' 9" 16.078 m 59' 6" 18.136 m 4' 11" 1.499 m

32' 9" 9.982 m 39' 5" 12.014 m 46' 2" 14.072 m 52' 11" 16.129 m 59' 8" 18.186 m 5' 1" 1.549 m

32' 11" 10.033 m 39' 7" 12.065 m 46' 4" 14.122 m

53' 1" 16.180 m 59' 10" 18.237 m 5' 3" 1.600 m

33' 1" 10.084 m 39' 9" 12.116 m 46' 6" 14.173 m 53' 3" 16.231 m 60' 0" 18.288 m 5' 5" 1.651 m

33' 3" 10.135 m 39' 11" 12.167 m 46' 8" 14.224 m 53' 5" 16.281 m 60' 2" 18.339 m 5' 7" 1.702 m

33' 5" 10.185 m 40' 1" 12.217 m 46' 10" 14.275 m 53' 7" 16.332 m 60' 4" 18.390 m 5' 9" 1.753 m

33' 7" 10.236 m 40' 3" 12.268 m 47' 0" 14.326 m 53' 9" 16.383 m 60' 6" 18.440 m 5' 11" 1.803 m

33' 9" 10.287 m 40' 5" 12.319 m 47' 2" 14.376 m 53' 11" 16.434 m 60' 8" 18.491 m 6' 1" 1.854 m

33' 11" 10.338 m 40' 7" 12.370 m 47' 4" 14.427 m 54' 1" 16.485 m 60' 10" 18.542 m 6' 3" 1.905 m

34' 1" 10.389 m 40' 9" 12.421 m 47' 6" 14.478 m 54' 3" 16.535 m 61' 0" 18.593 m 6' 5" 1.956 m

34' 3" 10.439 m 40' 11" 12.471 m 47' 8" 14.529 m 54' 5" 16.586 m 61' 2" 18.644 m 6' 7" 2.007 m

34' 5" 10.490 m 41' 1" 12.522 m 47' 10" 14.580 m 54' 7" 16.637 m 61' 4" 18.694 m 6' 8

5

/16" 41 mm

1

/16" 52 mm

7

/8" 2.054 m

System A (CB/slider)

6

Preassembly – CB System (Slug Mount) Cut Top Track to Length

1. Cut special length top track from 2.05 m (6'8 3/4") track.

2. Deburr cut.

Slightly round track corners that will slide against mast.

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

Short top track lengths

5

41 mm (1

52 mm (2

7

System A (CB/slider)

/16") Use existing hole. Do not drill

second hole.

1

/16") Use existing hole, drill hole

5

/16" (8 mm) from cut end.

8 mm (5/

16

27 mm

(11/16")

")

CB/Slider Systems (Slug Mount) Check Fit of Mounting Slugs/Car

67 mm (2 5/8") connector slug must fit feeder opening.
File opening to make longer.

Use halyard with retrieval line to hoist 67 mm (2 5/8") connector slug up mast
to check for burrs in groove.

Mast prebend: May require straightening before installation.

Storm Trysail Track

Cars must clear storm trysail track. Tracks often converge
above spreaders.

Aft face of mast must be flat or convex.

Test track: Put mounting slug in groove, track section on mast. Tighten with
screw. Track must be drawn tightly to mast.

Mounting screw must be long enough for mast groove.
If necessary, purchase longer screws.

11 or
more

Warning! Screws need minimum of 5 threads (turns) engaged to hold
track to mast. Turn screw 360° five times after threads engage slug.

Check fit

CB cars 57 mm (21/4")

Slider cars 35 mm (13/8")

Clear of trysail track?

System A (CB/slider)

8

CB System (Slug Mount) Install Track

1. Slip top track slugs into mast groove. Use 32 mm (1 1/4") mounting slug
for top stop.

Short top track lengths Top slug

41 mm (1

52 mm (2

Mast up: Tape 32 mm (1 1/4") slug even with top of upper track. Tape other
slugs in place.

2. One drop blue Loctite® adhesive into each connector slug hole.

5

/16") 67 mm (25/8")

1

/16") 19 mm (3/4")

3. Thread 5 mm x 25 mm endstop screws through endstop, track, and into endstop slug.

Short top track lengths

41 mm (1

52 mm (2

5

/16") Use one screw in stop

1

/16") Use both screws

Mast up: Remove tape. Tighten screw to hold track.

Loctite is a registered trademark of Henkel AG & Company KGaA.

9

System A (CB/slider)

CB System (Slug Mount) Install Track

4. Slide slugs into place with putty knife.
Loosely install 5 mm x 20 mm screws.

Tip: Use putty knife to see if screws are loose enough to slide in groove.

Remember: Tracks may stick when reaching a spliced area on mast.

5. Loosen top screw. Slide top track up and position next 2.05 m (6'8 3/4") track.

Mast up: Tighten bottom screw to hold track.

6. Slide 15 mounting slugs and then the connector slug into mast groove.

Mast up: Tape in place.

One drop blue Loctite® adhesive into each hole.

Loctite is a registered trademark of Henkel AG & Company KGaA.

System A (CB/slider)

10

CB System (Slug Mount) Install Track

7. Hold full-length track piece up to mast. Loosely install top screw.

Use putty knife to slide additional slugs and connector slug into place. Loosely install all
fifteen 5 mm x 20 mm screws.

8. Slide tracks up enough to fit next track.

Mast up: Hold upper tracks. Loosen screw that holds tracks. Slide track up. If screws
bind in mast groove opening, loosen them untill track slides. Tighten new bottom screw
securely.

CAUTION! Do not let tracks drop. Severe injury to hands
and/or fingers can result.

9. Repeat until full-length tracks installed.

10. Raise tracks so 203 mm (8") bottom
track fits.

11. Install screwpin endstop kit.

3808, 3809, 3810 Endstop Kit

Leave bottom 203 mm (8") track
off untill cars are installed.

Note: If bottom full-length track blocks
feeder gap, load bottom track slugs before
installing track.

11

System A (CB/slider)

CB/Sliders Systems (Drill/Tap) Install Track

Track and Accessories

Part No. Description Includes

Purchase from Harken

Use for masts without grooves or when slugs will not fit. Purchase

2707

2724

Purchase Separately

#10 (5 mm) Flathead screws

Track (Micro CB)

Splice links One needed for each track joint

263

Endstop set

Drill 4.2 mm (5/32")

Tap 10-32 (5 x .80 mm)

stainless steel #8 (4 mm) screws separately. Do not use 3817
open-backed track. It requires mounting slugs. See page 11 for
drill/tap sizes and mounting instructions.

Purchase 10 fasteners/meter of track

Determining Track Length

Bottom track must be short enough to remove easily. Use 457 mm to 609 mm
(18" to 24") length. Do not use 3807 track for drilling and tapping.

Remove Old Track

IMPORTANT! Before removing old track, scribe pencil line down either side.

2720

2724

263

Drill, Tap, and Fasten

After old track is removed, attach string to mast to line up track
during installation.

1. Start at one end of track and work down: Do not drill and tap from both
track ends.

Clamp or duct tape track on mast. Center punch in center of track hole using
a narrow shaft spring-loaded machinist's punch with plastic centering tube or
a transfer punch. Track hole size is 2.05" or 5.2 mm.

2. Drill track hole, holding drill perpendicular to mast face.
Tap threads and install screws using blue Loctite® adhesive.

Tip: Use low speed drill with tap for cutting threads.

IMPORTANT! Use blue Loctite

3. Align track at joints. Use 2711 splice links and round rods or dowels on
outside of track to align during installation. Hold in place with spring or “C”
clamps until track is secured.

®

adhesive instead of oil for tapping lubricant.

Load all cars before installing bottom track and endstop.

Loctite is a registered trademark of Henkel AG & Company KGaA.

System A (CB/slider)

12

CB System Load Cars on Track

IMPORTANT! To keep balls captive we recommend loading cars onto track without sail installed.
Chart below shows correct number of balls for each car.

1. Headboard cars: Hold car so cap screw head faces up. Align car on guide
section of loader track and gently roll onto upper tracks. If car sticks, realign
and roll onto track.

Tip: To load headboard car assembly, angle headboard coupler, roll car
onto track. If necessary, remove headboard assembly.

2. Load intermediate car (if used). Alternate with batten cars until all cars are
loaded.

Mast up: Use halyard to hold cars up.

3. Install screwpin stop.

3808, 3809, 3810
Endstop kit

Remove bottom 203 mm (8")
track and install cars.

Tip: Use halyard to hold
tracks up.

13

System A (CB/slider)

CB System Load Cars on Track with Sail Attached

Cars with sail attached can be loaded by carefully aligning car with track and
supporting sail to keep weight off cars.

Line up car on guide portion of loader. Press car toward mast and carefully roll
car onto track. Begin with upper cars and work down.

Tip: Have another person help hold sail while you load cars.

CB System Lost Balls

Consult chart for ball type: Torlon® or Delrin® ball bearings. Place car on edge
with retaining clip in place. Insert balls one-by-one from center of clip and roll
into return race. Do not overfill car.

Part

No. Car Type

3811

Headboard cars (2) 8

3812

Intermediate car 2

3829

Batten car w/threaded stud 2

3830

Battcar w/40 mm receptacle 2

3831

Universal car 2

3881

Batten car w/12 mm threaded stud 2

3882

Batten car w/12 mm threaded stud 4

3883

Reef car 4

Car Length Bearings

in mm Color Material in mm

3

/

8

1

/

7

/

7

/

7

/

7

/

1

/

1

/

213 Brown Torlon 60 177 21 1/4 6

4

57 Brown Torlon 32 177 21 1/4 6

8

73 Brown Torlon 40 177 21 1/4 6

8

73 Brown Torlon 40 177 21 1/4 6

8

73 Brown Torlon 40 177 21 1/4 6

8

73 Brown Torlon 40 177 21 1/4 6

8

105 Brown Torlon 60 177 21 1/4 6

8

105 Brown Torlon 60 177 21 1/4 6

Delrin is a registered trademark of E. I. du Pont de Nemours and Company or its affiliates.
Torlon is a registered trademark of Solvay Advanced Polymers.

System A (CB/slider)

Number

per Car

Purchase

Part No. Balls/Set

Ball Ø

14

Slider System Load Cars on Track with Sail Attached

Slider cars can be loaded onto tracks with or without sail attached.

Line up car on guide portion of loader. Press car toward mast and
slide car onto track. Begin with upper cars and work down.

Tip: To load headboard car assembly, angle headboard. Roll car
onto tracks. If necessary, remove headboard assembly.

3883 Reef Car Load Sail on Cars

1. Beginning with lower cars, use 4 mm hex key
and 8 mm wrench or nut driver to attach sail
to cars. Tighten lock nut until bottom tip
of fastener is flush with nut.

For 3883 reef car, line up plastic
becket spacer and insert clevis pin.



3883 reef car

15

System A (CB/slider)

CB/Slider Systems Load Sail on Cars

2. Screw threaded stud to sail batten receptacle. Thread completely in and then back off
two turns. Receptacle must be allowed to rotate on stud.

3. Load toggle using 4 mm hex key and 8 mm wrench or nut driver. Tighten lock nut.
Do not over tighten. Make sure toggle can pivot.

3a. For 3881 and 3882 battcars, line up toggle and insert clevis pin.

4. Attach head of sail to headboard car with clevis pin and cotter pin.

4a. For 3881 and 3882 battcars, press quick release button and pushup on bottom of pin.
Remove clevis pin.

System A (CB/slider)

16

CB/Slider Systems Removing Sail

H

A

R

K

E

N

H

A

R

K

E

N

Removing Sail (CB System)

From cars: Remove clevis pin from head of sail. Use a 4 mm
hex wrench and a 8 mm wrench or nut driver on other cars.

Cars and sail: Keep cars lined up with track when sliding off.

Inspect cars: 20 balls per side. Replace

5 mm locknut after two removals.

Removing Sail (Slider System)

If your system has slider Battcars without ball
bearings, leave slides attached and slide cars off,
beginning at the bottom.

Car Maintenance/Cleaning (CB System)

Clean beginning of season, or if cars bind. Squirt detergent and water into ball
bearings. Circulate by moving cars up and down. Let stand. To remove deter­gent, spray water into ball bearings and circulate. Clean tracks with detergent
and water.

Use OneDrop™ Ball Conditioner (CB System)

Once dry, use only a single drop of McLube® OneDrop™ ball bearing
conditioner. Do not use spray lubricants because ball bearings may skid not
roll. Apply one to two drops of McLube OneDrop to ball contact surfaces of
track. Roll car back and forth through OneDrop several times to distribute onto
bearings. Wipe remaining OneDrop off track. OneDrop is preferred, but you
can also use one to two drops of a light machine oil. Too much attracts dirt.

McLube is a registered trademark of McGee Industries, Inc.

Inspect

Inspect Battcars for loose locknuts. Replace. Inspect batten receptacles for loose screws.

CB/Slider Systems Lazy Jacks

Use shockcord to hold Lazy Jacks open so Battcars and
battens will not catch on them when hoisting sail. This will
also help stop Lazy Jacks from slapping on sail. Attach one
end to lower spreader tips and the other to Lazy Jacks. Make
sure shockcord is long enough so boom can swing out all the
way without damaging spreaders.

Operating Precautions

When lowering sail, do not let halyard go.
Ease cars down by keeping a wrap on winch.

Shockcord

IMPORTANT! On unstayed masts, avoid
over-rotation of sail.

On boats with unstayed masts, vang must be
used to prevent over-rotation of upper part of
sail. Over-rotation can damage batten receptacles.

17

System A (CB/slider)

Halyard

attachment

hole

63.5 mm
(2 1/2")

CB/Sliders Systems Sailmakers Instructions

C

B

CB

3811

Slider

C

B

3827

A

A

E

D

Dimensions (measured from aft face of mast)

Part

No. Description

System A CB

3811 Headboard car assembly
3812 Intermediate car 2
3829 Battcar/10 mm stud 2
3830 Battcar/receptacle 2
3831 Universal Battcar 2
3881 Battcar/12 mm stud 2
3882 Long batten car/12mm stud 4
3883 Reef car 4

System A Slider

3827 Headboard car assembly
1777 Intermediate car/low-load 2 51 1
3828 Intermediate car 1
3802 Battcar/10 mm stud 1
3803 Battcar/receptacle 1

A B

in mm in mm in mm in mm in mm mm

83/

8

213 13/

1

/

4

/

8

/

8

/

8

/

8

/

8

/

8

/

4

/

4

/

4

57 13/
73 13/
73 13/
73 13/

73 13/
105 13/
105 13/

44 11/

44 11/

44 11/

7

7

7

7

1

1

6 153 11/

3

3

3

D

E

3829

Slider

3802

CB

C

B

A

F

B

, CB

3812, 1777,

A

8

35 21/4/27/8* 57/73* 4 102

8

35 — —

8

35 21/

8

35 27/

8

35 — —

8

35 23/

8

35 23/

8

35 — —

16

1

27 21/8 54 311/

/

8

28 — —

16

27 — —

16

27 21/8 54 — —

16

27 21/8 54 51/

3828, 3831

D

Slider

1777, 3828

E

C

Boltrope setback D

3

/

4

57 311/

8

4

4

73 53/

69 37/
69 37/

3

/

3

/

3

/

21

/

D

E

CB

3830

Slider

3803

E

Pin Ø

3

/

16

4

19

16

94

4

146

4

19

8

99

8

99

4

19

16

94

4

19

32

17

8

130

3

/

16

3

/

16

3

/

16

3

/

16

1

/

4

1

/

4

1

/

4

3

/

16

3

/

16

3

/

16

3

/

16

3

/

16

5 —
5 —
5 10
5 —
5 —
6 12
6 12
6 —

5 —
5 —
5 —
5 10
5 —

F

Stud Ø

CB/Slider Systems Installing Headboard Car Assembly

Headboard coupler attaches to standard headboards - some headboard modification required.

Maximum thickness of headboard plates and sail: 14 mm (9/16")

G

Center of coupler

attachment hole to

front edge of boltrope

3802

3830

3829

3803

Coupler Attachment Hole

Drill 11 mm (7/16") coupler attachment hole so center

40 mm (1

30 mm (13/16")

44 mm (13/4")

43 mm (1

9

/16")

11

/16")

is 101 mm (4") from top of headboard. Consult chart
to determine “G" based on Battcar used.

Leave at least 9 mm (3/8") between front of headboard
plate and front edge of coupler attachment hole.

System A (CB/slider)

100 mm

G

Min 9.5 mm

(3/8")

4"

Coupler

attachment

hole

Halyard Attachment Hole

Use aft hole if headboard has two.

If not, drill second hole to accept halyard shackle
pin. Locate hole approximately 63.5 mm (2 1/2") aft
of existing hole.

18

CB/Slider—Battcars with Batten Receptacles—3830 CB/3803 Slider Sailmaker Instructions

Option 1

Round battens

End batten pocket 254 mm (10") from receptacle.

Flat battens

End batten pocket 254 mm (10") from receptacle.

Option 2

Round battens

Pucker batten pocket; draw edges together before inserting batten.

Flat battens

Fit batten into receptacle. If necessary, pucker batten pocket and
draw edges together before inserting. May require optional shim.

Optional Shim

Use enclosed rubber shim so thin flat battens or small diameter round battens
fit correctly inside receptacle. To insert shim, take apart batten receptacle with
batten inside. Place rubber shim on one side of the batten. Assemble. Note:

screw and nuts are not captive.

19

System A (CB/slider)

CB/Slider—Battcars with Batten Receptacles—3830 CB/3803 Slider Sailmaker Instructions

Assembly

Place batten receptacles on same side of sail. Make sure
front of coverplate presses on swivel pin retainer that
secures swivel pin. Tighten screws and nuts.

16 mm (5/8")

maximum diameter of batten

42.88 mm (1 11/16")

6 mm (1/4") maximum thickness of batten

System A (CB/slider)

20

CB/Slider Systems

Distance Between Attachment Points

Battens and intermediate cars placed at sailmaker's discretion. Maximum
distance between attachment points is 1.2 m to 1.35 m (4' to 4'6").

Distance may be slightly greater. Contact Harken to discuss
sail reshaping to eliminate luff flutter.

Note: Adding battens may reduce stack height by eliminating luff cars.

Setting Reef Points

Space reef points halfway between sail attachment points.
Battens or reef points may need to be moved. Diagram A.

Diagram A

Note: Batten fittings and cars cannot handle reefing outhaul

or downhaul loads. Transfer loads to a tack fitting. Diagram B.

21

System A (CB/slider)

Diagram B

CB/Slider Systems— Attaching Sail to Intermediate Cars Sailmaker's Instructions

Sail setback from luff tape to intermediate car clevis pin
will vary depending upon intermediate and batten car.

Intermediate Cars Batten Cars

Setback

1777

3812

3828

3802/3803

Slider cars

Setback – Luff tape to pin

26 mm (1") 30 mm (1

— 23 mm (7/8") 37 mm (17/16")

27 mm (11/16") 30 mm (13/16") 44 mm (13/4")

3829 CB Cars

w/10 mm stud

3

/16") 44 mm (13/4")

3830 CB car

w/batten recpt.

Plastic spacers come with 1777, 3812, and 3828 intermediate cars.
Seize spacer to webbing by stitching just behind plastic spacer. Seize
webbing to sail by stitching up against sail.

1777, 3812, 3828

System A (CB/slider)

22

CB/Slider Systems Installation Troubleshooting

Problem Probable Cause Solution

Cut end of top or bottom track is at joint.

Tracks do not butt up against each other.

Track weight pulling tracks apart.

Mounting slugs do not fit. Slugs wrong size. Different size slug required. Contact your dealer.

Mounting screws will not tighten. Incorrect mounting slug used. Different size slug required. Contact your dealer.

Slugs catching on mast splice.

Track will not slide up mast.

CB/slider cars do not fit on track. Track and cars are not the same size. Contact your dealer or Harken.

CB cars do not fit on track. Balls are missing.

Sail headboard does not fit inside coupler. Ring was not pressed far enough. Take sail to sailmaker.

Corners of cut track catching. Use file to round off corners of track.

Mast has too much prebend. Ease backstay and/or straighten mast.

Paint or other material clogging mast groove. Clean out groove.

Make sure the anodized end is toward the
full-length track.

Tracks will come together when you loosen the
bottom screw and push the tracks up the mast.

Loosen screws slightly. If necessary have someone
at splice area to wiggle the slug past the splice.

Remove cars, load balls and slide cars back
on track.

CB/Slider Systems Operation Troubleshooting

Problem Probable Cause Solution

Use detergent and fresh water to flush dirt out of

Dirt in cars.

Cars bind.

Stud threaded too tightly into receptacle. Back off threaded stud two turns.

Balls missing from car.

Mounting screws will not tighten. Incorrect mounting slug used. Get new 6 mm lock nut.

Batten receptacle does not rotate. Nuts are too tight. Loosen nuts slightly.

Cars jam when raising sail. Headboard or cars are catching on lazy jacks.

Sail will not go all the way up. Sail is too tall or sheave is too far forward. Have sail shortened or move sheave aft.

Vertical post or pin on batten receptacle bending.

Reef tack fitting will not reach reef hook. Reef point too close to sail attachment. Move intermediate car sail attachment.

Reef loads are being transferred to batten recep­tacle.

cars; move cars up/down to circulate; follow with
high-pressure water; clean track grooves. Condition
balls using McLube One-Drop. See below.

Remove cars, load balls and slide cars back on
track.

Use topping lift or rod vang and shock cord to pull
lazy jacks out to shrouds.

Transfer reef downhaul and outhaul loads to mast
or boom gooseneck.

Maintenance

Clean beginning of season, or if cars bind. Squirt detergent and water into ball bearings. Circulate by moving cars up and
down. Let stand. To remove detergent, spray water into ball bearings and circulate. Clean tracks with detergent and water.

Do not use spray lubricants because ball bearings may skid, not roll. Once cars and tracks are dry, apply one to two
drops of McLube® OneDrop™ conditioner to ball contact surfaces of track. Roll car back and forth through OneDrop
several times to distribute onto bearings. Wipe remaining OneDrop off track. OneDrop is preferred, but you can also
use one to two drops of a light machine oil. Too much oil attracts dirt.

Warranty

For additional safety, maintenance, and warranty information: www.harken.com/manuals or the Harken catalog.

Loctite is a registered trademark of Henkel AG & Company KGaA.
McLube is a registered trademark of McGee Industries, Inc.
OneDrop is a trademark of McLube®, a Division of McGee Industries.

23

System A (CB/slider)

Corporate Headquarters

N15W24983 Bluemound Rd, Pewaukee, WI 53072 USA

Telephone: [phone] • Fax: [phone]

Web: www.harken.com • Email: [e-mail]

Harken Australia Pty, Ltd.

1B Green Street, Brookvale, N.S.W. 2100, Australia

Telephone: [phone] • Fax: [phone]

Web: harken.com.au • Email: [e-mail]

Harken France

ZA Port des Minimes, BP 3064, 17032 La Rochelle Cedex 1, France

Telephone: [phone] • Fax: [phone]

ul. Rydygiera 8, budynek 3A, lokal 101, I pi

Main Office and Harken Brandstore: Västmannagatan 81B

Mailing address: Harken Sweden AB, Box 64, SE -440 30 Marstrand

Bearing House, Ampress Lane, Lymington, Hampshire S041 8LW, England

Telephone: [phone] • Fax: [phone]

Web: harken.fr • Email: [e-mail]

Harken Italy S.p.A.

Via Marco Biagi, 14, 22070 Limido Comasco (CO) Italy
Telephone: [phone] • Fax: [phone]

Web: harken.it • Email: [e-mail]

Harken New Zealand, Ltd.

158 Beaumont Street

Unit 11, Orams Marine Centre

Westhaven, Aukland, 1010, New Zealand

Telephone: [phone] • Fax: [phone]

Web: harken.co.nz • Email: [e-mail]

Harken Polska SP ZOO

ętro, 01-793 Warszawa, Poland

Tel: [phone] • Fax: [phone]

Web: harken.pl • Email: [e-mail]

Harken Sweden AB

SE-113 26 Stockholm Sweden

Telephone: [phone] • Fax: [phone]

Web: harken.se • Email: [e-mail]

Harken UK, Ltd.

Web: harken.co.uk • Email: [e-mail]

Please visit: http://www.harken.com/locator.aspx

to locate Harken dealers and distributors

Printed in USA 4248 10/14