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

Preassembly Cut Top Track to Length

30 mm

(13/16" )

5

8 mm (

/

16

")

1. Cut special length top track from

2.08 m (6'9 15/16") track.

2. Deburr cut.

Slightly round track corners that will
slide against mast.

3. Drill two 8.5 mm (21/64") holes in cut
end of track. Center at 9.5 mm (3/8") and
36 mm (17/16").

Short top track lengths

54 mm (2
drill second hole.

81 mm (3

9.5 mm (

1

/8") Use existing hole. Do not

3

/16") Use existing hole, drill hole

3

/8") from cut end.

Check Fit of Mounting Slugs & Car

85 mm (3 3/8")

Will tighten

Test track: Put mounting slug in groove,

track section on mast. Tighten with screw.

Mounting screw must be long enough for
mast groove.

Check fit

Will not tighten

Slug

105 mm (41/8") connector slug must fit
feeder opening. File opening to make longer.

Use halyard with retrieval line to run
105 mm (41/8") connector slug up mast
to check for burrs in groove.

Mast prebend: May require straightening
before installation.

5 or

more

Warning!: Avoid personal injury
or death. Screws need minimum
five (5) threads (turns) engaged
to hold track to mast.

Turn screw 360° five (5) times after
threads engage slug.

6

System C CB

Slug

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

Aft face of mast must be flat or convex.

Assembly Install Track

1. Slip top track slugs into mast groove.
Use 51 mm (2") mounting slug for top stop.

Short top track lengths Top slug

54 mm (2
81 mm (3

1

/8") 105 mm (41/8")

3

/16") 25 mm (1")

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

Mast up: Tape 51 mm (2") slug even with
top of upper track. Tape other slugs in place.

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

3. Thread a 8 x 40 mm screw through
endstop, track, and into endstop slug.

Short top track lengths

54 mm (2
81 mm (3

1

/8") Use one screw in stop.

3

/16") Use both screws.

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

5. Loosen top screw. Slide top track up
and position next 2.08 m (6'9 15/16") track.

4. Slide slugs into place with putty knife.
Loosely install 8 x 25 mm screws.

Mast up: Tighten bottom screw to
hold track.

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.

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

System C CB

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

Mast up: Tape in place.

Put one drop blue Loctite into each hole.

7

Assembly 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 8 x 25 mm 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
until 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 all full-length tracks installed.

Note: If bottom full-length track blocks

feeder gap, load bottom track slugs before
installing track.

10. Raise tracks so 432 mm (17") bottom
feeder track fits.

11. Install bottom feeder track with stop.

8

System C CB

3855 endstop kit—leave bottom 432 mm
(17" ) track off until cars are installed.

Preassembly Drill and Tap Track

Required Parts

R32 track

Determine track length.

Bottom track must be short enough to
remove easily. Use 457 mm to 609 mm
(18" to 24") length. Do not use 3853
track for drilling and tapping.

3

10 mm (
included)

/8") flathead screws (not

10 fasteners/meter of track

R32

3153

3153 splices
548 endstop set

Drill and tap sizes

Metric U.S. Imperial

Drill 8.5 mm

Tap m10 x 1.5

5

/16"

3

/8" - 16"

548

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.

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.

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

System C CB

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

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 3153 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.

9

Assembly 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 fast 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 screw stop.

3855 endstop kit—Remove

bottom 432 mm (17" ) 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 coupler assembly.

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

No. Car type

3867

Headboard cars (2) 9

3868

Battcar w/12 mm threaded stud 5

3869

Battcar w/14 mm threaded stud 5

3870

Battcar w/16 mm threaded stud 5

3871

Intermediate car 3

3872

Universal car 5

3873

Reef car 9

Torlon is a registered trademark of Solvay Advanced Polymers L. L. C.

Load Sail on Cars

Length

in mm in mm

1

/8 231 Brown 90 Torlon 547 253/8 10

3

/8 136 Brown 50 Torlon 547 253/8 10

3

/8 136 Brown 50 Torlon 547 253/8 10

3

/8 136 Brown 50 Torlon 547 253/8 10

3

/4 95 Brown 32 Torlon 547 253/8 10

3

/8 136 Brown 50 Torlon 547 253/8 10

1

/8 231 Brown 90 Torlon 547 253/8 10

Color

Qty/
car

Bearing

material

Part
No.

Balls/

set

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

Ball Ø

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

10

System C CB

H

A

R

K

E

N

H

A

R

K

E

N

Operation Remove Sail

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

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.

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 shockcord is long enough so
boom can swing out all the way without
damaging spreaders.

Maintenance

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.

Inspect Battcars for wear. Inspect batten receptacles for
loose fasteners.

System C CB

11

Sailmakers Instructions Dimensions

3871/3872,

3873

A

B

Headboard not

included

D

E

A

E

3876

B

C

D

Dimensions (measured from aft face of mast)

Part

No. Car Type

3867

Headboard cars (2) 18

3868

Battcar w/12 mm threaded stud 5

3869

Battcar w/14 mm threaded stud 5

3870

Battcar w/16 mm threaded stud 5

3871

Intermediate car 3

3872

Universal car 5

3873

Reef car 9

A B C D E (Pin Ø) F (Stud Ø)

in mm in mm in mm in mm in mm mm

5

/8 473 2 51 35/8 92 5 126

3

/8 136 2 51 35/8 92 51/16 128

3

/8 136 2 51 35/8 92 51/16 128

3

/8 136 2 51 35/8 92 51/16 128

3

/4 95 2 51 — — 1 26

3

/8 136 2 51 — — 15/16 33

1

/8 231 2 51 — — 15/16 33

3868/3869

3870

A

E

B

C

D

F

1

/2 12 —

1

/2 12 12

1

/2 12 14

1

/2 12 16

3

/8 10 —

1

/2 12 —

1

/2 12 —

Installing Headboard Car Assembly

Use 45 mm (13/4") webbing. Holes
in headboard accept 416 16 mm

173 mm

613/16"

cheek blocks for leech line.
Use 4 mm x 10 mm fasteners.

If more reinforcement is
necessary, web through
lightening holes.

92 mm

35/8"

12

System C CB

3867

web-on

standard

92 mm

35/8"

180 mm

73/32"

3877

web-on

Square top

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

NOTE: Adding battens can reduce
stack height by eliminating
intermediate cars.

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

INCORRECTCORRECT

DIAGRAM B

Attaching Sail to Intermediate Cars

Sail setback from luff tape to intermediate car clevis pin:

Intermediate car 3871 92 mm (15/8")

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.

41 mm (15/8")

3863, 3836

System C CB

13

Installation Troubleshooting

Problem Probable Cause Solution

Cut end of top or bottom track 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 toward 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.

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.

Stud threaded too tightly into receptacle. Back off threaded stud two (2) turns.

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

Use detergent and fresh water to flush dirt out of
cars; move cars up/down to 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

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 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.

McLube is a registered trademark of McGee Industries, Inc.
OneDrop is a trademark of McLube, a Division of McGee Industries.

®

OneDrop™ ball bearing lubricant and conditioner.

Warranty

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

14

System C CB

Corporate Headquarters

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

Main Office and Harken Brandstore: Västmannagatan 81B

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

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

Telephone: [phone] • Fax: [phone]

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

SE-113 26 Stockholm Sweden

Telephone: [phone] • Fax: [phone]

Web: harken.se • Email: [e-mail]

Harken UK, Ltd.

Web: harken.co.uk • Email: [e-mail]

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

to locate Harken dealers and distributors

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