Harken 3852 User Manual

Battcar Installation Manual

System B CB – 10mm Clevis Pin

System B Slider Cars

WARNING!: Strictly follow all instructions to avoid an
accident, damage to your vessel, personal injury or death.
See www.harken.com for additional safety information.

CB/Slider Systems Parts List

Thank you for puchasing Harken's B Battcar system. Please read manual before assembling system.

Headboard Cars (Assembly)

Headboard Cars (Assembly)

Batten Cars without Receptacles

3856/3857 – CB

3834/3835 – Slider

3861

CB–Web-On

Intermediate

Cars

Standard

3863 CB

Universal Battcar

Reef Car

3862
CB Web-On
Square Top

3852

CB

Track Mounting Kit

3845, 3846

Screwpin Endstop Kits

3847,3848

3833

Slider

Endstop Kits

3850, 3851

3836 Slider

3859 – CB

3860 – CB

Tools You Will Need:

f

c

b

a

g

f

i

j

2

1

4

3

h

h

c

CB System Parts

CB System

Part No.

3861

3862

CB/Slider Parts

CB System

Part No.

3852 3833

3863 3836

3856 3834

3857 3835

3859 —

3860 —

Standard web-on headboard See sailmaker instructions, page 12 - 14

Square top web-on headboard See sailmaker instructions, page 12 - 14

Slider System

Part No.

c

d

Description

Headboard cars 3852 must use 3861 or 3862 headboard.

Intermediate cars If battens are close enough intermediate cars are not needed.

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

Batten car 12mm Threaded stud. Purchase batten receptacle separately.

Universal Battcar Purchase batten receptacle and threaded stud separately.

Reef Tack car Double up track screws at reefed car position.

j

Description

k

l

Comments

Comments

1. Tape measure 6. Hammer 11. File

2. Allen wrench 5mm 7. Hacksaw

3. Power drill (screwdriver) 8. Center punch

4. Drill bit -

5. Phillips screwdriver 10. Putty knife

Mast-up installation: stepladder secured to boat
Work height : 7' (2.13m) above boom

(Mounting Slug Type)

9

8

9

17

/64" (6.5mm) 9. Tape

Track

3844

11/16" (27mm)

10

11

12

7

Slider Cars

Only

(Drill and Tap Type)

9

/16"

(14mm)

11/16" (27mm)

Track and Accessories

Part No. Description Includes

3845, 3846

3847
3848

3850, 3851

3844

1616

2 System B (CB/Slider) 11-14-08

Track Mounting Kit (a) 19 mounting slugs

Screwpin
Endstop Kit

Endstop Kit (c) 1 tube blue Loctite®; (f) 2 stop slugs 1

Track (slug type) Section length: 6'9

Track (drill and
tap t ype)

(c) 1 tube blue Loctite®; (f) 1 top stop slug 1
30mm; (i) 2 mounting slugs

Use for mast s without grooves or when slugs will not fit. Purchase stainless steel
Do not use 3844 track. It requires mounting slugs. See page 8 for drill /tap sizes and mounting instructions.

7

/8" (22mm); (b) 1 connector slug 3" (76mm); (c) 2 Tubes Blue Loctite

7

7

/8" (22mm); (j) 1 top ends top 1522 A; (k) pin stop ; (l) 1 end track

1

/8" (2.06m). Number of track sections depends on luff length of your mainsail.

/16" (36mm); (g) 3 HFS321 flathead screws 6 x 20mm; (h) 2 HFS1037 flathead screws 6 x

7

/16" (36mm); (h) 4 HFS1037 flathead screws 6 x 30mm; (j) 2 endstops 1522A

®;

(d) 21 HFS321 Flathead screws 6 x 20mm.

1

/4" (6mm) screws separately.

6

5

12. Nut driver 10mm
or open/box-end
wrench

Track

1616

CB/Slider Systems Sizing/Sail Modifications

3852

Sizing

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

Maximum Sail Area

Monohull Multihull

CB System

2

900 ft

83 m

2

700 ft

65 m

Slider System

2

900 ft

83 m

2

700 ft

65 m

Headboard Cars

2

2

2

2

Part No.

3852 3856, 3857 3863

3833 3834, 3835 3836

Part No.
Battcars

Part No.

Intermediate Cars

Sail Modifications (See page 12)

CB Headboard

Web on headboard.

Slider Headboard

Drill holes in headboard for new halyard
location and coupler attachment. See
page 13.

Batten receptacle on sail to accept 10 mm ot
12 mm threaded stud. Note: Harken does

not supply receptacle.

Becket spacer on sail for 3863 (CB)
or 3836 (slider) intermediate cars.

CB/Slider Systems Track Length

1

10"

254 mm

Number of Track Sections

Botton endstop track and variable
length top track included.

Track Length

41'6" to 48'2"

12.649m to 14.681m

48'3" to 54'11"

14.707m to 16.739m

Number of

1

6'9

/8" (2.06m)

Track Sections

7

8

55'0" to 61'8"

16.764m to 18.796m

61'9" to 68'5"

18.821m to 20.853m

68'6" to 75'2"

20.879m to 22.911m

1

2

CB System

10"

254mm

Determine Track Length

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

9

10

11

1. Upper End—10" (254 mm) 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, Using 3847, 3848—Bottom
of track will be approximately 3/8" (10 mm)

above gooseneck fitting. When installed,
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 above.

3850, 3851 Endstop Kit—Cut a 93/8"
(238 mm) piece from finished end of one

of the 6'91/8" (2.06 m) 3844 tracks. You will

2

Slider System

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.

3-07 System B (CB/Slider) 3

CB/Slider Systems Top Track Length

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

NOTE: Chart is based on using a 9

3

/8" (238 mm) or 91/2" (241 mm) lower end track.

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

41' 6" 12.649 m 48' 3" 14.707 m 55' 0 " 16.764 m 61' 9 " 18.821 m 68' 6" 20.879 m 11/2" 38 mm

3

41' 7" 12.675 m 48' 4" 14.732 m 55' 1" 16.789 m 61' 10" 18.847 m 68' 7" 20.904 m 2

41' 8" 12.700 m 48' 5" 14.757 m 55' 2" 16.815 m 61' 11" 18.872 m 68' 8" 20.930 m 3" 76 mm

41' 10 " 12.751 m 48' 7" 14.808 m 55' 4" 16.866 m 62' 1" 18.923 m 68' 10" 20.980 m 5" 127 mm

42' 0" 12.80 2 m 48' 9" 14.859 m 55' 6" 16.916 m 62' 3" 18.974 m 69' 0" 21.031 m 7" 178 mm

42' 2" 12.852 m 48' 11" 14.910 m 55' 8" 16.967 m 62' 5" 19.025 m 69' 2" 21.082 m 9" 229 mm

42' 4" 12.903 m 49' 1" 14.961 m 55' 10 " 17. 01 8 m 62' 7" 19.075 m 69' 4" 21.13 3 m 11" 279 mm

42' 6" 12.954 m 49' 3" 15.0 11 m 56' 0" 1 7.0 6 9 m 62' 9" 19 .126 m 69' 6" 21.18 4 m 1' 1" 330 mm

42' 8" 13.005 m 49' 5" 15.062 m 56' 2" 17.120 m 62' 11" 19 .177 m 69' 8" 21.23 4 m 1' 3" 381 mm

42' 10" 13.056 m 49' 7" 15.113 m 56' 4" 17.170 m 63' 1" 19.228 m 69' 10" 21.28 5 m 1' 5" 432 mm

43' 0" 13 .106 m 49' 9" 15.164 m 56' 6" 17. 22 1 m 63' 3" 19.279 m 70' 0" 21.3 36 m 1' 7 " 483 mm

43' 2" 13.157 m 49' 11" 15.215 m 56' 8" 17. 27 2 m 63' 5" 19.329 m 70' 2" 21.3 87 m 1' 9 " 533 mm

43' 4" 13.208 m 50' 1" 15.265 m 56' 10" 17. 3 23 m 63' 7" 19.38 0 m 70' 4" 21.438 m 1' 11" 584 mm

43' 6" 13.259 m 50' 3" 15.316 m 57' 0" 1 7.3 74 m 63' 9" 19.431 m 70' 6" 21.488 m 2' 1" 635 mm

43' 8" 13.310 m 50' 5" 15.367 m 57' 2" 17. 4 24 m 63' 11" 19.482 m 70' 8" 21.539 m 2' 3" 686 mm

43' 10" 13.360 m 50' 7" 15.418 m 57' 4" 17.47 5 m 64' 1" 19.533 m 70' 10" 21.59 0 m 2' 5" 737 mm

44' 0" 13.411 m 50' 9" 15.469 m 57' 6" 1 7.5 2 6 m 64' 3" 19.583 m 71' 0 " 21.641 m 2' 7" 787 mm

44' 2" 13.462 m 50 ' 11" 15.519 m 57' 8" 17. 57 7 m 64' 5" 19.634 m 71' 2" 21.692 m 2' 9" 838 mm

44' 4" 13.513 m 51' 1" 15.570 m 57' 10" 17.6 28 m 64' 7" 19.685 m 71' 4" 21.742 m 2' 11" 889 mm

44' 6" 13.564 m 51' 3" 15.621 m 58' 0" 1 7.6 78 m 64' 9" 19.73 6 m 71' 6" 21.793 m 3' 1" 940 mm

44' 8" 13.614 m 51' 5" 15.672 m 58' 2" 17. 7 29 m 64' 11" 19.787 m 71' 8 " 21.8 44 m 3' 3" 991 mm

44' 10" 13.665 m 51' 7" 15.723 m 58' 4" 17.7 8 0 m 65' 1" 19.837 m 71' 10" 21.895 m 3' 5" 1.041 m

45' 0" 13.716 m 51' 9" 15.7 73 m 58' 6" 1 7.8 3 1 m 65' 3" 19.888 m 72' 0" 21.946 m 3' 7" 1.092 m

45' 2" 13.767 m 51' 11" 15.824 m 58' 8" 17.8 82 m 65' 5" 19.939 m 72' 2" 21.996 m 3' 9" 1.14 3 m

45' 4" 13.818 m 52' 1" 15.875 m 58' 10 " 17. 93 2 m 65' 7" 19.990 m 72' 4" 22.047 m 3' 11" 1.19 4 m

45' 6" 13.868 m 52' 3" 15.926 m 59' 0" 1 7.9 8 3 m 65' 9" 20.041 m 72' 6" 22.098 m 4' 1" 1.245 m

45' 8" 13.919 m 52' 5" 15.977 m 59' 2" 18.034 m 65' 11" 20.091 m 72' 8" 2 2.14 9 m 4' 3" 1.295 m

45' 10" 13.970 m 52' 7" 16.027 m 59' 4" 18.085 m 66' 1" 20.1 42 m 72' 10" 22.200 m 4' 5" 1.346 m

46' 0" 14.021 m 52' 9" 16.078 m 59' 6" 18 .136 m 66' 3" 2 0.19 3 m 73' 0" 22.250 m 4' 7" 1.397 m

46' 2" 14.072 m 52' 11" 16.129 m 59' 8" 18.186 m 66' 5" 20.244 m 73' 2" 22.301 m 4' 9" 1.448 m

46' 4" 14.12 2 m 53' 1" 16 .180 m 59' 10" 18.237 m 66' 7" 20.295 m 73' 4" 22.352 m 4' 11" 1.499 m

46' 6" 14.17 3 m 53' 3" 16.231 m 60' 0" 18.28 8 m 66' 9" 20.345 m 73' 6" 22.403 m 5' 1" 1.549 m

46' 8" 14.224 m 53' 5" 16.281 m 60' 2" 18.339 m

46' 10" 14.275 m 53' 7" 16.332 m 60' 4" 18.390 m 67' 1" 20.447 m 73' 10" 22.504 m 5' 5" 1.651 m

47' 0" 14.326 m 53' 9" 16.383 m 60' 6" 18.4 40 m 67' 3" 20.498 m 74' 0" 22.555 m 5' 7" 1.702 m

47' 2" 14.376 m 53' 11" 16.434 m 60' 8" 18.491 m 67' 5" 20.549 m 74' 2" 22.606 m 5' 9" 1.753 m

47' 4" 14.427 m 54' 1" 16.485 m 60' 10" 18.5 42 m 67' 7" 20.599 m 74' 4" 22.657 m 5' 11" 1.80 3 m

47' 6" 14.478 m 54' 3" 16.535 m 61' 0 " 18.593 m 67' 9" 20.650 m 74' 6 " 22.708 m 6' 1" 1.85 4 m

47' 8" 14.529 m 54' 5" 16.586 m 61' 2" 18.64 4 m 6 7' 11" 20.701 m 74' 8" 22.758 m 6' 3" 1.905 m

47' 10" 14.580 m 54' 7" 16.637 m 61' 4" 18.69 4 m 6 8' 1" 20.752 m 74' 10" 22.809 m 6' 5" 1.9 56 m

48' 0" 14.6 30 m 54' 9" 16.68 8 m 61' 6" 18.74 5 m 68' 3" 20.803 m 75' 0" 22.860 m 6' 7" 2.007 m

48' 2" 14.6 81 m 5 4' 11" 16.739 m 6 1' 8" 18.796 m 68' 5" 20.853 m 75' 2" 22.911 m 6' 91/8" 2.060 m

66' 11" 20.396 m 73' 8" 22.454 m 5' 3" 1.600 m

/8" 60 mm

4 System B (CB/Slider) 6-06

5 or

more

Slug

Slug

CB/Slider Systems Cut Top Track to Length

13/16"

(30 mm)

5

/

16

" (8 mm)

1. Cut special length top track from 6'91/8"
(2.06m) track.

2. Deburr cut.

Slightly round track corners that will slide
against mast.

3. Drill two 17/64" (6.5mm) holes in cut
end of track. Center at 5/16" (8mm) and
13/16" (30mm)

Short top track lengths

1

1

/2" (38mm) Use existing hole. Do not

drill second hole.

3

2

/8" (60mm) Use existing hole, drill hole

5

/16" (8mm) from cut end.

CB/Slider Systems Check Fit of Mounting Slugs & Car

Will Tighten

Will Not Tighten

Test track: Put mounting slug in groove,
track section on mast. Tighten with screw.

CB Cars 23/4" (70mm)

Slider Cars 1

11

/16" (42mm)

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

Check Fit

3" (76mm) connector slug must fit feeder
opening. File opening to make longer.

Use halyard with retrieval line to run
3" (76mm) connector slug up mast
to check for burrs in groove.

Mast prebend: May require straightening
before installation.

09/01/09 System B (CB/Slider) 5

longer screws.

Warning!: Avoid personal injury
or death. Screws need minimun

5 threads (turns) engaged to
hold track to mast.

Turn screw 360° five times after
threads engage slug.

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

Aft face of mast must be flat or convex.

CB/Slider Systems Install Track

1. Slip top track slugs into mast groove.
Use 17/16" (36mm) mounting slug for top
stop.

Short top track lengths Top slug

1

1

/2" (38 mm) 3" (76 mm)

3

2

/8" (60 mm)

7

/8" (22 mm)

Install 3" (76 mm) connector slug at
bottom.

Mast up: Tape 17/16" (36 mm) slug even
with top of upper track. Tape other slugs
in place.

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

3. Thread a 6 x 30 mm screw through
endstop, track, and into endstop slug.

Short top track lengths

1

1

/2" (38mm) Use one screw in stop

3

2

/8" (60mm) Use both screws

5. Loosen top screw. Slide top track up and
position next 6'91/8" (2.06m) track.

4. Slide slugs into place with putty knife.
Loosely install 6 x 20mm screws.

Mast up: Remove tape.
TIP: Use putty knife to see if screws

are loose enough to slide in groove.

REMEMBER: Tracks may stick when

Mast up: Tighten bottom screw to hold

track.

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

Mast up: Tape in place.

Put one drop blue Loctite® into each hole.

reaching a spliced area on mast.

6 System B (CB/Slider) 6-06

CB/Slider Systems 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 6 x 20mm 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.

NOTE: If bottom full-length track blocks

feeder gap, load bottom track slugs before
installing track.

10. Raise tracks so 91/2" (241mm) bottom
feeder track fits.

3850, 3851 Endstop Kit—leave
bottom 93/8" (238mm) track off
untill cars are installed.

11. Install bottom feeder track with stop.

07-01/09 System B (CB/Slider) 7

CB/Sliders Systems Install Track by Drilling and Tapping

Required Parts

1616 Track

Determine Track Length.

Bottom track must be short enough to
remove easily. Use 18" to 24" (457mm
to 609 mm) length. Do not use 3844
track for drilling and tapping.

1

/4" (6mm) Flathead Screws (not

included)

10 fasteners/meter of track

1619 Splices
1522 Endstop Set

Drill and Tap sizes

U.S. Imperial Metric

Drill
Tap

13

/64" 5mm

1

/4–20 m6 x 1

Removing Old Track

Track on mast: Before removing, scribe
pencil line down either side of track.

Track off mast: Attach string to mast to
line up track during installation.

1616

1619

1522

1. Drilling, tapping, screwing: 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 hole in center of track hole.

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

8 System B (CB/Slider) 6-06

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

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

IMPORTANT: Use blue Loctite® instead
of oil for tapping lubricant.

3. Align track at joints: Use 1619 splice
pieces and round rods or dowels to align
track during installation. Hold in place
with spring or “C" clamps until track
is secured.

Load all cars before installing bottom
track and endstop.

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 car: Hold car so
clevis pin head faces up. Align
car on guide section of loader
track and gently roll onto upper
tracks. If cars stick, realign
and roll onto track.

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

Mast up: Use halyard to
hold cars.

3. Install pinstop. 3850, 3851 Endstop Kit—

Remove bottom 9

1

/2" (241mm)

track and install cars.

TIP: Use halyard to hold
cars up

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

CB System Lost Balls

Consult ball chart below to find number of balls for each car. To load balls, 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 Length Bearing Quantity Ball ø

Number Car Type in mm Color Material per Car Part No. Balls/Set in mm

3852 Headboard Cars (2) 5

3863 Intermediate Car 29/16 68 Brown Torlon® 28 1526 25 5/16 8
3856 Battcar w/10mm Threaded Stud 41/4 108 Brown Torlon® 40 1526 25 5/16 8
3857 Battcar w/12mm Threaded Stud 41/4 108 Brown Torlon® 40 1526 25 5/16 8
3859 Universal Car 41/4 108 Brown Torlon® 40 1526 25 5/16 8
3860 Reef Car 53/16 132 Brown Torlon® 60 1526 25 5/16 8

3

/16 132 Brown Torlon® 60 1526 25 5/16 8

Slider System Load Cars on Track

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

Line up car on guide portion of loader.
Press car towards 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.

3-07 System B (CB/Slider) 9

Slider System Load Sail on Cars

1. Beginning with lower cars, use 5mm
allen wrench and 10mm 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.

4. Attach head of sail to headboard

car with clevis pin and cotter pin.

3. Load toggle using 5mm allen wrench
and 10 mm wrench or nut driver. Tighten
locknut. Do not over tighten. Make sure

toggle can pivot.

CB System Load Sail on Cars

Attach sail to system
beginning with lowest
car. Line up toggle and
insert clevis pin.

If it is a “no wind” day,
start at headboard and
hoist mainsail as you
attach sail to cars.

10 System B (CB/Slider) 3-07

H

A

R

K

E

N

H

A

R

K

E

N

Slider System Removing SailCB System Removing Sail

Press quick release
button and push
up on bottom of pin.
Remove clevis pin.

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

CB System Battcar Operating Precautions CB System Car Maintenance

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.

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.

For thorough cleaning, remove sail
then remove cars from track. Clean
as above. Once dry, apply a single
drop of McLube™ ball conditioner.
Circulate balls using a small
screwdriver.

Inspect Battcar fittings for loose
locknuts. Replace. Inspect batten
receptacles for loose screws.

CB/Slider Systems Lazy Jacks

Lazy Jacks

Use shock cord to hold lazy jacks open
so battcars and battens will not catch on
them. 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.

07/07/09 System B (CB/Slider) 11

CB/Sliders Systems Sailmakers Instructions

CB

3859/3860,

3863

A

B

D

Slider

3836

E

A

A

Headboard Not

Included

A

E

CB

3852

Slider

3833

E

B

C

D

B

C

B

C

D

Dimensions (measured from aft face of mast)

E F
Part A B C D Pin Ø Stud Ø
No. Description in mm in mm in mm in mm in mm mm

System B CB

3852 Headboard car assembly 101/2 267 19/16 39 31/16 78 41/16 102
3863 Intermediate car 2
3856 Battcar/10mm stud 4
3857 Battcar/12mm stud 4
3859 Universal Battcar 4
3860 Reef car 5

9

/16 68 19/16 39 — —

1

/4 109 19/16 39 31/16 78 43/8 111

1

/4 108 19/16 39 31/16 78 43/8 111

1

/4 108 19/16 39 — — 1 26

3

/16 132 19/16 39 — — 1 26

3

/4 19

System B Slider

3833 Headboard car assembly 71/2 190 11/4 32 21/4 57 43/16 107
3834 Battcar/10mm stud 2
3835 Battcar/12mm stud 2
3836 Intermediate car 2

3

/16 56 11/4 32 21/4 57 39/16 91

3

/16 56 11/4 32 21/4 57 33/4 96

3

/16 56 11/4 32 — — — —

3

/8 10 —

1

/4 6 —

3

/8 10 10

3

/8 10 12

3

/8 10 —

3

/8 10 —

1

/4 6 —

1

/4 6 10

1

/4 6 12

1

/4 6 —

CB

3856/3857

Slider

3834/3835

F

E

D

12 System B (CB/Slider) 7-06

CB/Sliders Systems Sailmakers Instructions

CB System Installing Headboard Car Assembly

Use 1" (25mm) webbing. Holes
in headboard accept 416 16mm
cheek blocks for leech line. Use
4mm x 10mm fasteners.

47/8"

78mm

31/16"

78mm

3861

CB–Web-On

Standard

511/16"

145mm

31/16"

78mm

3862

CB–Web-On

Square Top

Slider System Installing Headboard Car Assembly

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

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

7

/8"

1

(48mm)

Coupler Attachment Hole

Drill 5/8" (16mm) coupler attachment hole so center
is 41/4" (108mm) from top of headboard and centered
17/8" (48mm) from front edge of boltrope:

Leave at least 3/4" (19mm) between front of headboard
plate and front edge of 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 21/2" (63.5mm)
aft of existing hole.

3-07 System B (CB/Slider) 13

CB/Slider Systems Sailmaker's Instructions

Distance Between
Attachment Points

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

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

NOTE: Adding battens may reduce
stack height by eliminating
intermediate 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 a tack fitting. Diagram B

DIAGRAM A

CORRECT

DIAGRAM B

INCORRECT

CB/Slider Systems Attaching Sail to Intermediate Cars

Sail setback from luff tape to intermediate car clevis pin:

All CB Cars 3863 11/2" (38mm)
All Slider Cars 3836 1" (25mm)

Plastic spacers come with 3839 and 3836 intermediate cars.
Seize spacer to webbing by stitching just behind plastic spacer.
Seize webbing to sail by stitching up against sail.

Combining Intermediate Slider Cars with CB Battcars

Sail setback from luff tape to intermediate car clevis pin:

Slider with CB Cars 3836 13/4" (45mm)

If you combine 3836 Slider Intermediate cars with 3856, 3857
CB cars use the 13/4" (45mm) CB setback shown above.

Setback

3863, 3836

14 System B (CB/Slider) 11-14-08

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.

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

Track will not slide up mast.

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

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

CB/Slider cars do not fit on track.

CB cars do not fit on track.

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

Track and cars are not the same size. Contact your dealer or Harken.

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

Make sure the anodized end is towards 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.

Operation Troubleshooting

Problem Probable Cause Solution

Dirt in cars.

Cars bind.

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

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

Nut on Battcar is not holding. Locknut has been used too many times. Get new 6 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.

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.

Use detergent and fresh water to flush dirt out of
cars; move cars up/down do circulate; follow with
high pressure water; clean track grooves.

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

®

equipment is designed for minimal maintenance, but some maintenance is required for optimum and safest possible operation and to comply with the Harken® limited

Harken
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 the blocks and clean with detergent and fresh water. Lubrication is not required, but lubricants which will

not attract dirt may be used like McLube®.
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 or the Harken® catalog.

4286/6-06 System B (CB/Slider) 15

Corporate Headquarters

1251 East Wisconsin Avenue, Pewaukee, Wisconsin 53072 USA

Telephone: [phone]

Web: www.harken.com

• Fax: [phone] • Cable: Harken Pewaukee

• Online Catalog: www.harkenstore.com

Email: [e-mail]

Harken France

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

Telephone: [phone]

• Fax: [phone]

Web: www.harken.fr

Email: [e-mail]

Harken Italy S.P.A.

Via Marco Biagi, 14, 22070 Limido Comasco, (CO), Italy

Telephone: [phone]

• Fax: [phone]

Web: www.harken.it

Email: [e-mail]

Harken UK Ltd.

Bearing House, Ampress Lane

Lymington, Hampshire S041 8LW, England

Telephone: [phone]

• Fax: [phone]

Web: www.harken.co.uk

Email: [e-mail]

Harken Poland

ul. Lisa Kuli 4 Lok.1, 01-512 Warszawa, Polska

Telephone: [phone]

Web: www.harken.com

Email: [e-mail]

Harken Sweden

Mjölkekilsgatan 8, Box 64

S-440 30 Marstrand, Sweden

Telephone: [phone]

• Fax: [phone]

Web: www.harken.se

Email: [e-mail]

Harken Adriatik d.o.o.

Obala 107

6320 Portoroz, Slovenia

Telephone/Fax: [phone]

Web: www.harken.si

Email: [e-mail]

Harken Australia, Pty, Ltd.

1B Green Street

Brookvale, N.S.W. 2100, Australia

Telephone: [phone]

• Fax: [phone]

Web: www.harken.com.au
Email: info.harken.com.au

Harken New Zealand, Ltd.

30-36 Fanshawe Street

Auckland 1001, New Zealand

Telephone: [phone]

• Fax: [phone]

Web: www.harken.co.nz

Email: [e-mail]

Please visit: http://www.harken.com/dealers/dealers.php

for an up-to-date list of Harken dealers and distributors

Printed in USA 4286/7-09