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)

Preassembly – CB System (Slug Mount) Check Fit of Mounting Slugs/Cars

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

Car’s 40 mm (1 9/16") width must clear storm trysail track.
Tracks often converge above spreaders.

Aft face of mast must be flat or convex.

Will tighten

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.

Will not tighten

Check Fit

40 mm (1 9/16")

Clear of Storm Trysail Track?

11 or
more

Warning! Screws need minimun 11 threads (turns) engaged
to hold track to mast. Turn screw 360° five times after threads
engage slug.

System AA (CB) 7

Installation – CB System (Slug Mount) Install Track

1. Slip top track slugs into mast groove. Use 19 mm (3/4") mounting
slug for top stop.

Note: If top track is 30 mm (1 3/16"), use 67 mm (2 5/8") connector
slug for top stop.

Install 67 mm (2 5/8") connector slug at bottom.

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

2. Squeeze one drop blue Loctite® into each connector slug hole.

Loctite is a trademark of Henkel AG & Company KGaA

3. Thread 4 mm x 25 mm endstop screw through endstop, track, and
into endstop slug.

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

8 System AA (CB)

Installation – CB System (Slug Mount) Install Track

4. Slide slugs into place with putty knife. Loosely install 4 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 7/8") track.

Mast up: Tighten bottom screw to hold track.

6. Slide 19 mounting slugs and then the connector slug into mast groove.

Mast up: Tape in place.

One drop blue Loctite® into each hole.

Loctite is a trademark of Henkel AG & Company KGaA

System AA (CB) 9

Installation – 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 nineteen 4 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.
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 152 mm (6") bottom

track fits.

11. Install Screwpin Endstop Kit.

Note: If bottom full-length track blocks

feeder gap, load bottom track slugs
before installing track.

10 System AA (CB)

Preassembly/Installation – CB System (Drill & Tap) Parts/Remove Track/Install Track

Track and Accessories

Part No. Description Includes

Purchase from Harken

3837

2707 Track (micro CB)

Screwpin endstop
kit

(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.

®

H-45685

2711

2711 Splice links One needed for each track joint

Purchase Separately

#8 (4 mm) Flathead screws

Drill 3 mm (1/8")

Tap 8-32 (M4)

Purchase 20 fasteners/meter of track

Considerations for
Determining Track Length.

Note: Track is longer than sail luff length.

1. Upper end: Extend track 203 mm (8") above
headboard halyard attachment point to allow for
sail stretch as main ages. Track must not block
mast halyard exit.

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

Important! Be careful not to lose

the threaded backing plate.

H-34382A

H-34380A

Screwpin

endstop kit

2707

H-28411C

3837

Remove old track

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

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.

Tip: Use a narrow shaft spring-loaded machinist's center
punch with plastic centering tube or a transfer punch.

2711

System AA (CB) 11

Installation – CB System (Drill & Tap) Install Track

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

Loctite is a trademark of Henkel

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.

Load all cars before installing bottom track and endstop.

12 System AA (CB)

Installation – CB System (Slug Mount/Drill & Tap) Load Cars on Track

IMPORTANT! Keep balls captive by loading cars onto track without sail installed. Car must have 20 balls per side.

Consult chart for correct type of balls.

DO NOT MIX CARS. High-load brown Torlon

Part

No. Car Type

3813

Headboard Cars 5 3/16 132 Brown Torlon

3814

Slider Intermediate Car 1 3/4 44 — — — — — — —

3815

CB Intermediate Car 2 3/16 56 Black Delrin

3816

Batten Car w/Threaded Stud 2 3/16 56 Brown Torlon

®

balls are used in headboard and batten cars. Luff cars use low-load black Delrin® balls.

Car Length Bearings

in mm Color Material in mm

Number

per 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.

Part

No. Balls/Set

40 2708 20 3/16 5

40 HSB240 1 3/16 5
40 2708 20 3/16 5

Ball Ø

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.

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

System AA (CB) 13

Operation – CB System (Slug Mount/Drill & Tap) Load Cars on Track

Load Cars with Sail

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

Lost Balls

Consult chart for ball type: Torlon® or Delrin®. 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.

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

14 System AA (CB)

Operation – CB System (Slug Mount/Drill & Tap) Load Sail on Cars

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

2. Screw threaded stud to terminal.

3. Load toggle using 4 mm hex wrench and 8 mm wrench or nut driver.
Tighten locknut. Do not over tighten.

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

System AA (CB) 15

H

A

R

K

E

N

H

A

R

K

E

N

Maintenance – CB System (Slug Mount/Drill & Tap) Sail Removal/Lazy Jacks/Operating Precautions

Car Maintenance/Cleaning

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

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 alight machine oil. Too much attracts dirt.

Inspect

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

Removing Sail

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.

Lazy Jacks

Use shock cord to hold lazy jacks open so
battcars and battens will not catch on them
when hoisting sail. This will also help stop
slapping of lazy jacks on sail. Attach one end
to lower spreader tips and the other to lazy
jacks. Make sure shock cord 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.

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

Shock Cord

McLube is a trademark of McGee Industries, Inc.

16 System AA (CB)

Sailmaker's Instructions – CB System (Slug Mount/Drill & Tap) Dimensions/Installing Headboard Coupler Car

C

B

D

C

B

B

A

A

E

3813

E

D

3816

A

F

D

E

3815

Dimensions

A B C D

Part

No.

3813

3814

3815

3816*

in mm in mm in mm in mm

3

5

/

16

3

1

/

4

3

2

/

16

3

2

/

16

132 1 25 113/

16

46 23/

44 1 25 — —

56 1 25 — —

561 1 25 13/4 45 35/

4

3

/

4

3

/

4

16

*Batten receptacle not included

Installing 3813 Headboard Coupler Car Assembly

3813 headboard coupler attaches to standard headboards—some headboard modification required.

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

B

A

D

E

3814

E

Locknut Size

mm

70 5 —

19 5 —

19 5 —

84 5 10

Stud Size

F

mm

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.

Coupler Attachment Hole

Drill 11 mm (7/16") coupler attachment hole so
center is 101 mm (4") from top of headboard
and 25 mm (1") from front edge of boltrope.

Leave at least 9 mm between front of headboard
plate and front edge of coupler attachment hole.

System AA (CB) 17

Sailmaker's Instructions – CB System (Slug Mount/Drill & Tap) Attachment Points/Reef Points

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.

Note Batten fittings and cars cannot handle reefing outhaul or
downhaul loads. Transfer loads to tack fitting—Diagram B.

Diagram A

CORRECT

Diagram B

INCORRECT

Sailmaker's Instructions – (CB/Slider Systems) Attaching Sail to Intermediate Cars

Attach Sail to Intermediate Cars

Sail setback from luff tape to intermediate car clevis pin:

3814 – 20 mm (13/16")
3815 – 20 mm (13/16")

Plastic spacers come with 3814 and 3815 intermediate cars. Seize spacer to webbing by stitching just behind plastic spacer.
Seize webbing to sail by stitching up against sail.

See Above

18 System AA (CB)

CB System (Slug Mount/Drill & Tap) Operation Troubleshooting

Problem Probable Cause Solution

Tracks do not butt up against each other Cut end of top or bottom track is at joint. Make sure the anodized end is towards the

full length track.

Track weight pulling tracks apart. Tracks will come together when you loosen bottom

screw and push the tracks up mast.

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.

Track will not slide up mast.

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

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

Slugs catching on mast splice. Loosen screws slightly. If necessary have someone

at splice area to wiggle the slug past the splice.

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.

Balls are missing. Remove cars, load balls and slide cars back on track.

CB System (Slug Mount/Drill & Tap) Operation Troubleshooting

Problem Probable Cause Solution

Cars bind. Balls missing from car. Remove cars, load balls and slide cars back on track.

Dirt in cars. Use detergent and fresh water to flush dirt out of cars;

Nut on Battcar is not holding. Locknut has been used too many times. Get new 5 mm locknut.

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. Use topping lift or rod vang and shock cord to pull

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 loads are being transferred to batten

receptacle.

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

move cars up/down do circulate; follow with high
pressure water; clean track grooves.

lazy jacks out to shrouds.

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

General Maintenance (see specific maintenance on page 16)

Harken equipment is designed for minimal maintenance, but some maintenance is required for optimum and safest possible operation
and to comply with the Harken limited warranty. In general, the most important aspect of maintenance is to keep your equipment clean
by frequently flushing with fresh water.

In corrosive atmospheres, stainless parts may show discoloration around holes, rivets and screws. This is not serious and may be
removed with a fine abrasive.

With the exception of winches, do not use grease unless specifically recommended in the instruction sheet.

Flush blocks thoroughly with fresh water. Periodically disassemble blocks, if possible, and flush with detergent and fresh water.
Lubrication is not required.

Important! Exposure to some teak cleaners and other caustic solutions can result in discoloration of part and is not covered under
the Harken warranty.

Warranty

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

System AA (CB) 19

Corporate Headquarters

09

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

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

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

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

Main Office and Harken Brandstore: Västmannagatan 81B

SE-113 26 Stockholm Sweden

Telephone: [phone] • Fax: [phone]

Web: harken.se • Email: [e-mail]

Harken UK, Ltd.

Telephone: [phone] • Fax: [phone]

Web: harken.co.uk • Email: [e-mail]

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

to locate Harken dealers and distributors

97653 21170

Printed in USA 4247 10/14