Harken 3813 User Manual

BATTCAR INSTALLATION MANUAL

System AA

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 (sug 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 - 12

Operation (slug mount/drill & tap)

Load cars on track without sail 13
Load cars on track with sail 14
Lost balls 14
Load sail on cars 15

Maintenance (slug mount/drill & tap)

Car maintenance/cleaning 16
Removing sail 16
Lazy jacks 16
Operating precautions 16

Sailmaker's instructions (slug mount/drill & tap)

Dimensions 17
Installing 3813 headboard coupler assembly 17
Headboard pates 17
Distance between atachment points/reef points 18

Attaching sail to intermediate cars 18

Troubleshooting – installation/operation

4247 10/14

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

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

PLEASE SAVE THESE INSTRUCTIONS

Introduction

This manual gives technical information on installation and service. This information is destined 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.
See www.harken.com/manuals for general warnings and instructions.

2 System AA (CB)

Preassembly – CB System (Slug Mount/Drill & Tap) Parts

Batten cars without receptacle

3813

3816

Spare car
screw/nut

3814

Screwpin endstop kit

3821, 3822, 3823

(mounting slug method)

a

b

c

d

e

f

mounting slug type

Track

Track mounting kit

3818, 3819, 3820

(mounting slug method)

a

c

12 mm

(15/32")

Screwpin endstop kit

3837

(drill & tap method)

b

a

d

d

b

c

Track

drill/tap type

9 mm

(3/8")

3815

Cars

Part No. Description Comments

3813 Headboard car

3814 Slider intermediate car If battens are close enough intermediate cars are not needed.

3815 CB intermediate car If battens are close enough intermediate cars are not needed.

3816 Batten car 10 mm Threaded stud. Purchase batten receptacle separately.

Track and Accessories

Part No. Description Includes

Mounting slug method

3818, 3819

3820

3821, 3822

3823

3817 Track Section length: 2.05 m (6'8 7/8"). Number track sections vary according to luff length of mainsail.

Drill & tap method

3837 Screwpin Endstop Kit

2707 Track (Micro CB)

System AA (CB) 3

Track Mounting Kit

Screwpin Endstop Kit

(a) 19 x mounting slugs 19 mm (3/4"); (b) 1 x connector slug 67 mm (2 5/8"); (c) 2 x tubes blue Loctite
(d) 21 x HFS1009 flathead screws 4 x 20 mm.
(a) 1 x 152 mm (6") end track with screwpin stop; (b) 1 x flathead screw HFS948 4 x 25 mm; (c) 1 x topstop;
(d) 2 x HFS1009 flathead screws 4 x 20 mm; (e) 1 x mounting slug 19 mm (3/4"); (f) 1 x tube blue Loctite

(a) 1 x 152 mm (6") end track with screwpin stop; (b) 1 x 2711 splice link; (c) 1 x H-28411C endstop (d) 1 x tube blue Loctite®

Use for masts without grooves or when slugs will not fit. Purchase stainless steel 4 mm (#8) screws separately.
Do not use 3817 open-backed track. It requires mounting slugs. See page 11 for drill/tap sizes and mounting instructions.

13 mm

(1/2")

Loctite is a trademark of Henkel AG & Company KGaA

13 mm

(1/2")

2707

®

®

.

Preassembly– CB System (Slug Mount/Drill & Tap) Tools/Sizing/Sail Modifications/Track Length

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 3/16" (4.5 mm)

5. Phillips screwdriver 13. Spring clamp

6. Hammer 14. Spring-loaded centerpunch (not shown)

7. Hacksaw 15. Drill bit 1/8" (3 mm) (not shown)

8. Center punch 16. Tap 8-32 (M4) (not shown)

9. File 17. Transfer punch

Mast-up installation: Stepladder secured to the boat.

Work height: 7' (2.13 m) above boom

Drill & tap (additional)

1

5

6

9

2

4

3

8

7

11

12

13

10

17

Sizing

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

Maximum Sail Area Part No. Part No. Part No.

Monohull Multihull Headboard Battcars Intermediate Car

2

300 ft

28 m2250 ft223 m

Sail Modifications

See page 12 - 13.

2

3813 3816 3814, 3815

1

8"

203 mm

1. Mainsail Headboard

A. Drill new halyard location
B. Drill Attachment to accept clevis pin for 3813 headboard
car coupler.

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

3. Becket spacer on sail for 3815 intermediate car, or install
3814 slider on sail.

Determine Track Length

Note: Track length is longer than sail luff length.

1. Upper End: Extend track 8" (203 mm) above headboard

halyard attachment point to allow for sail stretch as sail ages.
Track must not block mast halyard exit.

2. Lower End: Place 6" (152 mm) Screwpin Endstop track on
mast. Make sure car clears gooseneck fittings and adjust
height as necessary. Measure to lower end of track.

Number of 3817 Track Sections (Slug Mount)

Variable length top track included

Track length

6.350 m to 8.382 m
20'10" to 27'6"

8.407 m to 10.439 m
27'7" to 34'3"

10.465 m to 12.471 m
34'4" to 40'11"

12.497 m to 14.529 m

41'0" to 47'8"

4 System AA (CB)

Number of 2.05 m (6'8

track sections

5

6

7

7

/8")

2

Pre-Assembly (Slug Mount) Top Track Length

Round track length to nearest 1" (25 mm).

Note: Chart is based on using 3817 track–length 2.05m (6'8 7/8") and 3821, 3822, or 3823 Endstop Kits–length 152.4 mm (6").

Total track length (as defined on page 3) Top track length

20'10" 6.350 m 27' 7" 8.407 m 41' 0" 12.497 m 13/16" 30 mm

20'11" 6.375 m 27' 8" 8.433 m 34' 4" 10.465 m 41' 1" 12.522 m 2" 51 mm

21' 0" 6.401 m 27' 9" 8.458 m 34' 5" 10.490 m 41' 2" 12.548 m 3" 76 mm

21' 2" 6.452 m 27'11" 8.509 m 34' 7" 10.541 m 41' 4" 12.598 m 5" 127 mm

21' 4" 6.502 m 28' 1" 8.560 m 34' 9" 10.592 m 41' 6" 12.649 m 7" 178 mm

21' 6" 6.553 m 28' 3" 8.611 m 34'11" 10.643 m 41' 8" 12.700 m 9" 229 mm

21' 8" 6.604 m 28' 5" 8.661 m 35' 1" 10.693 m 41'10" 12.751 m 11" 279 mm

21'10" 6.655 m 28' 7" 8.712 m 35' 3" 10.744 m 42' 0" 12.802 m 1' 1" 330 mm

22' 0" 6.706 m 28' 9" 8.763 m 35' 5" 10.795 m 42' 2" 12.852 m 1' 3" 381 mm

22' 2" 6.756 m 28'11" 8.814 m 35' 7" 10.846 m 42' 4" 12.903 m 1' 5" 432 mm

22' 4" 6.807 m 29' 1" 8.865 m 35' 9" 10.897 m 42' 6" 12.954 m 1' 7" 483 mm

22' 6" 6.858 m 29' 3" 8.915 m 35'11" 10.947 m 42' 8" 13.005 m 1' 9" 533 mm

22' 8" 6.909 m 29' 5" 8.966 m 36' 1" 10.998 m 42'10" 13.056 m 1'11" 584 mm

22'10" 6.960 m 29' 7" 9.017 m 36' 3" 11.049 m 43' 0" 13.106 m 2' 1" 635 mm

23' 0" 7.010 m 29' 9" 9.068 m 36' 5" 11.100 m 43' 2" 13.157 m 2' 3" 686 mm

23' 2" 7.061 m 29'11" 9.119 m 36' 7" 11.151 m 43' 4" 13.208 m 2' 5" 737 mm

23' 4" 7.112 m 30' 1" 9.169 m 36' 9" 11.201 m 43' 6" 13.259 m 2' 7" 787 mm

23' 6" 7.163 m 30' 3" 9.220 m 36'11" 11.252 m 43' 8" 13.310 m 2' 9" 838 mm

23' 8" 7.214 m 30' 5" 9.271 m 37' 1" 11.303 m 43'10" 13.360 m 2'11" 889 mm

23'10" 7.264 m 30' 7" 9.322 m 37' 3" 11.354 m 44' 0" 13.411 m 3' 1" 940 mm

24' 0" 7.315 m 30' 9" 9.373 m 37' 5" 11.405 m 44' 2" 13.462 m 3' 3" 991 mm

24' 2" 7.366 m 30'11" 9.423 m 37' 7" 11.455 m 44' 4" 13.513 m 3' 5" 1.041 m

24' 4" 7.417 m 31' 1" 9.474 m 37' 9" 11.506 m 44' 6" 13.564 m 3' 7" 1.092 m

24' 6" 7.468 m 31' 3" 9.525 m 37'11" 11.557 m 44' 8" 13.614 m 3' 9" 1.143 m

24' 8" 7.518 m 31' 5" 9.576 m 38' 1" 11.608 m 44'10" 13.665 m 3'11" 1.194 m

24'10" 7.569 m 31' 7" 9.627 m 38' 3" 11.659 m 45' 0" 13.716 m 4' 1" 1.245 m

25' 0" 7.620 m 31' 9" 9.677 m 38' 5" 11.709 m 45' 2" 13.767 m 4' 3" 1.295 m

25' 2" 7.671 m 31'11" 9.728 m 38' 7" 11.760 m 45' 4" 13.818 m 4' 5" 1.346 m

25'4" 7.722 m 32' 1" 9.779 m 38' 9" 11.811 m 45' 6" 13.868 m 4' 7" 1.397 m

25' 6" 7.772 m 32' 3" 9.830 m 38'11" 11.862 m 45' 8" 13.919 m 4' 9" 1.448 m

25' 8" 7.823 m 32' 5" 9.881 m 39' 1" 11.913 m 45'10" 13.970 m 4'11" 1.499 m

25'10" 7.874 m 32' 7" 9.931 m 39' 3" 11.963 m 46' 0" 14.021 m 5' 1" 1.549 m

26' 0" 7.925 m 32' 9" 9.982 m 39' 5" 12.014 m 46' 2" 14.072 m 5' 3" 1.600 m

26' 2" 7.976 m 32'11" 10.033 m 39' 7" 12.065 m 46' 4" 14.122 m 5' 5" 1.651 m

26' 4" 8.026 m 33' 1" 10.084 m 39' 9" 12.116 m 46' 6" 14.173 m 5' 7" 1.702 m

26' 6" 8.077 m 33' 3" 10.135 m 39'11" 12.167 m 46' 8" 14.224 m 5' 9" 1.753 m

26' 8" 8.128 m 33' 5" 10.185 m 40' 1" 12.217 m 46'10" 14.275 m 5'11" 1.803 m

26'10" 8.179 m 33' 7" 10.236 m 40' 3" 12.268 m 47' 0" 14.326 m 6' 1" 1.854 m

27' 0" 8.230 m 33' 9" 10.287 m 40' 5" 12.319 m 47' 2" 14.376 m 6' 3" 1.905 m

27' 2" 8.280 m 33'11" 10.338 m 40' 7" 12.370 m

27' 4" 8.331 m 34' 1" 10.389 m 40' 9" 12.421 m 47' 6" 14.478 m 6' 7" 2.007 m

27' 6" 8.382 m 34' 3" 10.439 m 40'11" 12.471 m 47' 8" 14.529 m 6'8 7/8" 2.054 m

47' 4" 14.427 m 6' 5" 1.956 m

System AA (CB) 5

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 4.5 m (3/16") top stop hole in cut end of track.

Use existing hole if top track is 30 mm (1 3/16").

6 System AA (CB)

3/8" (10 mm)