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BATTCAR
Installation Manual
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Harken BATTCAR Installation Manual

BATTCAR INSTALLATION MANUAL

System AA

Installation manual – Intended for specialized personnel or expert users

 

 

 

 

 

 

 

4247 

10/14

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

Spare car

screw/nut

 

3816

 

 

 

 

Screwpin endstop kit

 

 

 

 

 

 

Track mounting kit

 

 

Screwpin endstop kit

 

 

 

 

3821, 3822, 3823

 

 

3818, 3819, 3820

 

 

3837

 

 

 

 

 

 

 

 

(mounting slug method)

 

 

 

 

(mounting slug method)

 

 

(drill & tap method)

 

 

 

 

a

 

 

 

 

 

a

b

 

 

 

a

 

 

 

 

b

 

 

c

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

d

 

 

 

 

 

d

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

e

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

c

d

 

 

 

 

 

 

b

 

 

 

 

 

f

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

c

 

3814

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Track

 

 

 

 

 

 

 

 

 

 

 

 

 

Track

 

 

 

 

 

mounting slug type

 

 

 

drill/tap type

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12 mm

 

 

 

 

 

 

 

 

9 mm

 

 

 

 

 

 

 

 

 

 

 

 

(15/32")

 

 

 

 

 

 

 

(3/8")

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3815

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

13 mm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(1/2")

 

 

 

 

 

 

 

 

 

 

 

 

 

(1/2")

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Cars

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2707

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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.

Loctite is a trademark of Henkel AG & Company KGaA

Track and Accessories

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Part No.

Description

 

 

 

 

 

 

 

 

 

 

 

 

 

Includes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Mounting slug method

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3818, 3819

Track Mounting 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®

 

 

 

 

 

 

 

 

3820

(d) 21 x HFS1009 flathead screws 4 x 20 mm.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3821, 3822

Screwpin Endstop Kit

(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;

3823

(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®.

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 (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®

2707

Track (Micro CB)

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.

 

 

 

 

 

 

 

 

System AA (CB)

 

 

 

3
Harken BATTCAR Installation Manual

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

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)

Drill & tap (additional)

 

5.

Phillips screwdriver

13. Spring clamp

6

 

 

 

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

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

 

 

 

 

 

300 ft2 28 m2

250 ft2 23 m2

3813

3816

3814, 3815

Sail Modifications

See page 12 - 13.

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

Number of 2.05 m (6'8 7/8")

track sections

 

 

 

6.350 m to 8.382 m

 

20'10" to 27'6"

 

 

 

8.407 m to 10.439 m

5

27'7" to 34'3"

 

 

 

10.465 m to 12.471 m

6

34'4" to 40'11"

 

 

 

12.497 m to 14.529 m

7

41'0" to 47'8"

 

 

Tools/Sizing/Sail Modifications/Track Length

 

 

2

 

 

1

 

3

8

 

 

 

 

 

 

 

 

 

 

7

11

 

 

 

 

 

 

9

 

12

13

 

 

10

 

 

 

 

 

 

 

 

 

17

 

 

 

1

 

 

 

 

 

8"

 

 

 

203 mm

 

 

 

2

 

 

 

System AA (CB)

4

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

47'  4"

14.427 m

6'  5"

1.956 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

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").

3/8" (10 mm)

6

System AA (CB)

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

Will not 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.

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
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