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3811
User Manual
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Harken 3811 User Manual

BATTCAR INSTALLATION MANUAL
System A CB and Slider
Installation Manual – Intended for specialized personnel or expert users
Introduction
Preassembly (Slug Mount/Drill & Tap)
Installation (Slug Mount)
Install track 8 - 10 Install screwpin endstop kit 10
Preassembly (Drill & Tap)
Installation (Drill & Tap)
Operation (Slug Mount/Drill & Tap)
Maintenance (Slug Mount/Drill & Tap)
Sailmaker's Instructions (Slug Mount/Drill & Tap)
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
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