Harken 3867 User Manual

BATTCAR INSTALLATION MANUAL

System C CB

Installation Manual – Intended for specialized personnel or expert users

Introduction

Safety precautions 2

Preassembly

Parts and tools 3
Sizing/sail modifications 4
Cut track 5 - 6
Check fit of cars and slugs 6

Assembly

Install slug mount track 7 - 8
Install drill/tap style track 9

Load cars on track 10
Load sail on cars 10

Operation

Operating precautions 11
Removing sail and maintenance 11
Lazy Jacks 11

Sailmaker's instructions 12 - 13

Troubleshooting 14

General maintenance and warrenty 15

4637 11/14

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 can 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 can 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 can 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 can kill or hurt you
and others: www.harken.com/manuals for general warnings and instructions.

2

System C CB

Preassembly Parts List

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

Headboard cars (assembly)

3876

web-on

standard

3868, 3869, 3870

batten cars with

threaded stud

Reef car

Intermediate

cars

3871

3867

Track mounting kit

3854

b

a

c

3877

web-on

square top

d

Screwpin endstop kits

3875

f

c

g

i

h

j

k

l

Universal Battcar

3872

Endstop kit

3855

f

c

3873

24 mm

15

/16" )

(

61 mm (

27/16")

3858 flanged track

Track

(mounting slug type)

19 mm

(3/4" )

3853

30 mm (

j

m

Tools you will need:

13/16")

h

1

2

Track

(drill and tap type)

R32

30 mm (

13/16")

4

Parts

Part No. Description Comments

3867

3871

3868

3869

3870

3872

3873

3876

3877

Headboard cars 3867 must use 3876 or 3877 headboard.

Intermediate cars Consult sailmaker for quantity required.

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

Batten car 14 mm threaded stud. Purchase batten receptacle separately.

Batten car 16 mm 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.

Standard web-on headboard See sailmaker instructions, page 12 - 13.

Square-top web-on headboard See sailmaker instructions, page 12 - 13.

Track and Accessories

Part No. Description Includes

3854

3875

3855

3853

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

System C CB

Track mounting (a) 19 mounting slugs 25 mm (1"); (b) 1 connec tor slug 105 mm (4

Pinstop end kit (c) 1 tube blue Loctite; (f) 1 top stop slug 51 mm (2" ); (g) 4 HFS319 flathead screws 8 x 25 mm; (h) 2 HFS323 flathead screws 8 x 40 mm;

Endstop kit (c) 1 tube blue Loctite; (f) 2 stop slugs 51 mm (2"); (h) 4 HFS323 flathead screws 8 x 40 mm; (j) 1 endstop 548A; (m) 1 HBB185 high-load endstop.

Track (slug type) Section length: 2.08 m (6'9

R32

Track (drill and
tap type)

(i) 2 mounting slugs 25 mm (1" ); (j) 1 top endstop 548A; (k) pinstop; (l) 1 end track.

15

/16"). Number of track sec tions depends on luff length of mainsail.

Use for masts without grooves or when slugs will not fit. Purchase stainless steel 10 mm or
See page 8 for drill/tap sizes and mounting instructions.

1

/8"); (c) 2 tubes blue Loctite

3

8

9

10

7

1.Tape measure 7. Hacksaw

2. Tape 8. Center punch

3. Power drill (screwdriver) 9. File

4. Drill bit -8.5mm (21/64") 10. Putty knife

5. Phillips screwdriver 11. Welders clamp

6. Hammer

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

®

adhesive; (d) 21 HFS319 flathead screws 8 x 25 mm.

3

/8" screws separately. 3853 track requires mounting slugs.

5

11

3154 Track

only

6

3

Preassembly Sizing/Sail Modifications

Sizing

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

Maximum sail area

Monohull Multihull

139 m

1500 ft

2

2

116 m

1250 ft

2

Headboard cars

2

Part No.

3867

Part No.
Battcars

3868, 3869,

3870

Part No.

Intermediate cars

3871

Sail Modifications (See page 12)

Headboard

Web-on headboard.

Batten receptacle on sail to accept 12, 14
or 16 mm threaded stud. Note: Harken

does not supply receptacle.

Becket spacer on sail for 3871
intermediate cars.

CB/Slider Systems Track Length

Number of Track Sections

Bottom 432 mm (17") endstop track and
variable length top track included. Extra track
may be required if using 3855 endstop kit.

Track Length

17.120 m to 19.152 m
56'2" to 62'10"

19.202 m to 21.234 m

63'0" to 69'8"

Number of

2.08 m (6'9
Track Sections

9

10

15

/16")

21.285 m to 23.317 m
69'10" to 76'6"

23.368 m to 25.400 m

76'8" to 83'4"

25.451 m to 27.483 m

83'6" to 90'2"

27.534 m to 29.566 m

1

90'4" to 97'0"

11

12

13

14

Determine Track Length

305 mm

12"

3852

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

1. Upper end— 305 mm (12") 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 3875—Bottom
of track will be approximately 13 mm (1/2")

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.

2

4

System C CB

CB system

3855, 3851 endstop kit—Cut a 432 mm (17")

piece from finished end of one of the 2.08 m
(6'9 15/16") 3853 tracks. You will remove this
track when loading cars so it can be lower
on mast. See page 8, step 11. Drill lower
hole for stop. See page 6, step 3.

Preassembly Top Track Length

or 3154 track for use with 3855 stop.

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

Note: Chart is based on using a 3853 tack—length 2.08 m (81

62' 10" 19.152 m 69' 8" 21.234 m 76' 6" 23.317 m 83' 4" 25.400 m 90' 2" 27.483 97' 0" 29.566

62' 8" 19.101 m 69' 6" 21.184 m 76' 4" 23.266 m 83' 2" 25.349 m 90' 0" 27.432 96' 10" 29.515

62' 6" 19.050 m 69' 4" 21.133 m 76' 2" 23.216 m 83' 0" 25.298 m 89' 10" 27.381 96' 8" 29.464

62' 4" 18.999 m 69' 2" 21.082 m 76' 0" 23.165 m 82' 10" 25.248 m 89' 8" 27.330 96' 6" 29.413

62' 2" 18.948 m 69' 0" 21.031 m 75' 10" 23.114 m 82' 8" 25.197 m 89' 6" 27.280 96' 4" 29.362

62' 0" 18.898 m 68' 10" 20.980 m 75' 8" 23.063 m 82' 6" 25.146 m 89' 4" 27.229 96' 2" 29.312

61' 10" 18.847 m 68' 8" 20.930 m 75' 6" 23.012 m 82' 4" 25.095 m 89' 2" 27.178 96' 0" 29.261

61' 8" 18.796 m 68' 6" 20.879 m 75' 4" 22.962 m 82' 2" 25.044 m 89' 0" 27.127 95' 10" 29.210

61' 6" 18.745 m 68' 4" 20.828 m 75' 2" 22.911 m 82' 0" 24.994 m 88' 10" 27.076 95' 8" 29.159

61' 4" 18.694 m 68' 2" 20.777 m 75' 0" 22.860 m 81' 10" 24.943 m 88' 8" 27.026 95' 6" 29.108

61' 2" 18.644 m 68' 0" 20.726 m 74' 10" 22.809 m 81' 8" 24.892 m 88' 6" 26.975 95' 4" 29.058

61' 0" 18.593 m 67' 10" 20.676 m 74' 8" 22.758 m 81' 6" 24.841 m 88' 4" 26.924 95' 2" 29.007

60' 10" 18.542 m 67' 8" 20.625 m 74' 6" 22.708 m 81' 4" 24.790 m 88' 2" 26.873 95' 0" 28.956

60' 6" 18.440 m 67' 4" 20.523 m 74' 2" 22.606 m 81' 0" 24.689 m 87' 10" 26.772 94' 8" 28.854

60' 8" 18.491 m 67' 6" 20.574 m 74' 4" 22.657 m 81' 2" 24.740 m

60' 4" 18.390 m 67' 2" 20.472 m 74' 0" 22.555 m 80' 10" 24.638 m 87' 8" 26.721 94' 6" 28.804

60' 2" 18.339 m 67' 0" 20.422 m 73' 10" 22.504 m 80' 8" 24.587 m 87' 6" 26.670 94' 4" 28.753

60' 0" 18.288 m 66' 10" 20.371 m 73' 8" 22.454 m 80' 6" 24.536 m 87' 4" 26.619 94' 2" 28.702

59' 10" 18.237 m 66' 8" 20.320 m 73' 6" 22.403 m 80' 4" 24.486 m 87' 2" 26.568 94' 0" 28.651

59' 8" 18.186 m 66' 6" 20.269 m 73' 4" 22.352 m 80' 2" 24.435 m 87' 0" 26.518 93' 10" 28.600

59' 6" 18.136 m 66' 4" 20.218 m 73' 2" 22.301 m 80' 0" 24.384 m 86' 10" 26.467 93' 8" 28.550

59' 4" 18.085 m 66' 2" 20.168 m 73' 0" 22.250 m 79' 10" 24.333 m 86' 8" 26.416 93' 6" 28.499

59' 2" 18.034 m 66' 0" 20.117 m 72' 10" 22.200 m 79' 8" 24.282 m 86' 6" 26.365 93' 4" 28.448

59' 0" 17.983 m 65' 10" 20.066 m 72' 8" 22.149 m 79' 6" 24.232 m 86' 4" 26.314 93' 2" 28.397

58' 10" 17.932 m 65' 8" 20.015 m 72' 6" 22.098 m 79' 4" 24.181 m 86' 2" 26.264 93' 0" 28.346

58' 8" 17.882 m 65' 6" 19.964 m 72' 4" 22.047 m 79' 2" 24.130 m 86' 0" 26.213 92' 10" 28.296

58' 6" 17.831 m 65' 4" 19.914 m 72' 2" 21.996 m 79' 0" 24.079 m 85' 10" 26.162 92' 8" 28.245

58' 4" 17.780 m 65' 2" 19.863 m 72' 0" 21.946 m 78' 10" 24.028 m 85' 8" 26.111 92' 6" 28.194

58' 2" 17.729 m 65' 0" 19.812 m 71' 10" 21.895 m 78' 8" 23.978 m 85' 6" 26.060 92' 4" 28.143

58' 0" 17.678 m 64' 10" 19.761 m 71' 8" 21.844 m 78' 6" 23.927 m 85' 4" 26.010 92' 2" 28.092

57' 10" 17.628 m 64' 8" 19.710 m 71' 6" 21.793 m 78' 4" 23.876 m 85' 2" 25.959 92' 0" 28.042

57' 8" 17.577 m 64' 6" 19.660 m 71' 4" 21.742 m 78' 2" 23.825 m 85' 0" 25.908 91' 10" 27.991

57' 6" 17.526 m 64' 4" 19.609 m 71' 2" 21.692 m 78' 0" 23.774 m 84' 10" 25.857 91' 8" 27.940

57' 4" 17.475 m 64' 2" 19.558 m 71' 0" 21.641 m 77' 10" 23.724 m 84' 8" 25.806 91' 6" 27.889

57' 2" 17.424 m 64' 0" 19.507 m 70' 10" 21.590 m 77' 8" 23.673 m 84' 6" 25.756 91' 4" 27.838

57' 0" 17.374 m 63' 10" 19.456 m 70' 8" 21.539 m 77' 6" 23.622 m 84' 4" 25.705 91' 2" 27.788

56' 10" 17.323 m 63' 8" 19.406 m 70' 6" 21.488 m 77' 4" 23.571 m 84' 2" 25.654 91' 0" 27.737

56' 8" 17.272 m 63' 6" 19.355 m 70' 4" 21.438 m 77' 2" 23.520 m 84' 0" 25.603 90' 10" 27.686

56' 6" 17.221 m 63' 4" 19.304 m 70' 2" 21.387 m 77' 0" 23.470 m 83' 10" 25.552 90' 8" 27.635

56' 4" 17.170 m 63' 2" 19.253 m 70' 0" 21.336 m 76' 10" 23.419 m 83' 8" 25.502 90' 6" 27.584

56' 3" 17.145 m 63' 1" 19.228 m 68' 11" 21.006 m 76' 9" 23.393 m 83' 7" 25.476 90' 5" 27.559

56' 2" 17.120 m 63' 0" 19.202 m 69' 10" 21.285 m 76' 8" 23.368 m 83' 6" 25.451 90' 4" 27.534

15

/16") and a 432 mm (17") 3875 pinstop end track. Chart will also work with 432 mm (17") piece cut from 3853

88' 0" 26.822 94' 10" 28.905

6' 10" 2.083 m

System C CB

6' 6" 1.981 m

6' 8" 2.032 m

6' 4" 1.930 m

6' 0" 1.829 m

6' 2" 1.880 m

5' 10" 1.778 m

5' 8" 1.727 m

5' 4" 1.626 m

5' 6" 1.676 m

5' 0" 1.524 m

5' 2" 1.575 m

4' 10" 1.473 m

4' 8" 1.422 m

4' 4" 1.321 m

4' 6" 1.372 m

4' 0" 1.219 m

4' 2" 1.270 m

3' 10" 1.168 m

3' 8" 1.118 m

3' 4" 1.016 m

3' 6" 1.067 m

3' 0" 914 mm

3' 2" 965 mm

2' 10" 864 mm

2' 8" 813 mm

2' 4" 711 mm

2' 6" 762 mm

2' 0" 610 mm

2' 2" 660 mm

1' 10" 559 mm

1' 8" 508 mm

1' 4" 406 mm

1' 6" 457 mm

1' 0" 305 mm

1' 2" 356 mm

0' 10" 254 mm

0' 8" 203 mm

0' 4" 102 mm

0' 6" 152 mm

3 3/16" 81 mm

2 1/8" 54 mm

5