Battcar Installation Manual System B CB and Slider Cars
Contents
1. A we Jil CB 3840 3841 Slider 3834 3835 Dimensions measured from aft face of mast Part A B No Description in mm in mm in mm System B CB 3838 Headboard car assembly 10 2 267 17 16 36 219 16 T1 3839 Intermediate car 29 16 68 17 1 36 3840 Battcar 10 mm stud 45 16 109 17 15 36 213 16 71 3841 Battcar 12 mm stud 41 5 114 17 16 36 213 16 T1 3842 Universal Battcar 41 4 108 17 16 36 3843 Reef car 53 16 132 17 16 36 System B Slider 3833 Headboard car assembly Th 190 11 4 32 21 4 57 3834 Battcar 10 mm stud 23 18 56 11 4 32 21 4 57 3835 Battcar 12 mm stud 23 18 56 11 4 32 21 4 57 3836 Intermediate car 23 16 56 11 4 32 CB Slider Systems Headboard coupler attaches to standard headboards some headboard modifi cation required Maximum thickness of headboard plates and sail 14 mm CB 11 2 38 Slider 11546 49 mm Coupler Attachment Hole Coupler Attachment Hole Drill 5 16 mm coupler attachment hole so center is 4 108 mm from top of headboard and centered from front edge of boltrope CB Slider Leave at least 98 9 mm between front of headboard plate and front edge of coupler attachment hole 19 5 35 mm 178 22 mm System B CB Slider BN 1 3039 3842 2 3843 D Slider 3036 E F D Pin Stud 0 in mm in mm mm 47 1 110 1 4 6 Ya 19 6 51 6 129 1 4 6 10 51 16 129 1 4 6 12. 4 Slide slugs into place with putty knife Loosely install 6 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 6 2 One drop blue Loctite into each connector slug hole 5 Loosen top screw Slide top track up and position next 691 2 06 m track Mast up Tighten bottom screw to hold track System B CB Slider Install Track 3 Thread a 6 x 20 mm screw through endstop track and into endstop slug Short top track lengths 11 2 38 mm Use one screw in stop 23 8 60 mm Use both screws Mast up Remove tape Tighten 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 4252 1 05 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 20 mm screws 4252 1 05 8 Slide tracks up enough to fit next track 9 Repeat until full length tracks installed Mast up Hold upper tracks Loosen screw that holds tracks Slide track up If screws bind mast groove opening loosen them untill track slides Tighten new bottom screw securely WARNING Do not let tracks drop Severe injury can result NOTE If bo
3. 3838 Headboard Cars 2 53s 132 Brown Torlon 60 1526 25 She 3839 Intermediate Car 26 68 Brown Torlon 28 1526 25 he 3040 w 10 mm Threaded Stud 4 4 108 Brown Torlon 40 1526 25 3840 w 12 mm Threaded Stud 4 4 108 Brown Torlon 40 1526 25 3042 Universal Car 4 108 Brown Torlon 40 1526 25 Zn 3043 Reef Car 56 132 Brown Torlon 60 1526 25 he Slider System 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 4252 1 05 System B CB Slider Slider System 1 Beginning with lower cars use 5 mm hex wrench and 10 mm wrench or nut driver to attach sail to cars Tighten locknut until bottom tip of fastener is flush with nut Do not over tighten Make sure toggle can pivot CB System Load Sail on Cars 4 Attach head of sail to headboard car with clevis pin and cotter pin 2 Screw threaded stud to terminal 3 Load toggle using 5 mm hex wrench and 10 mm wrench or nut driver Tighten locknut Do not over tighten Load Sail on Cars Attach sail to system beginning with lowest car Line up toggle and insert clevis pin If itis a no wind day hoist mainsail as you attach sail to cars System B CB Sli
4. instead of oil for tapping lubricant System B CB Slider Install Track by Drilling and Tapping 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 4252 1 05 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 2 Load intermediate car if 3 Install screw stop 3850 3851 Endstop Kit cap screw head faces up Align used Alternate with batten Remove bottom 9 241 mm car on guide section of loader until all cars are loaded track and install cars track and gently roll onto upper tracks If cars stick realign and Mast up Use halyard to TIP Use halyard to hold roll onto track hold cars tracks 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 Number Car Type in mm Color Material per Car Part No Balls Set in mm
5. step 11 Drill lower hole for stop See page 5 step 3 4252 12 05 System B CB Slider CB Slider Systems Round track length to nearest 1 25 mm NOTE Chart is based on using a 99 7 238 mm or 91 241 mm lower end track 4t 6 417 41 8 41 10 42 42 42 42 42 42 10 43 43 43 43 43 43 10 44 44 44 44 44 44 10 45 45 0916 135 9 I I 47 10 48 0 48 2 12 649 m 12 675 m 12 700 m 12 751 m 12 802 m 12 852 m 12 903 m 12 954 m 13 005 m 13 056 m 13 106 m 13 157 m 13 208 m 13 259 m 13 310 m 13 360 m 13 411 m 13 462 m 13 513 m 13 564 m 13 614 m 13 665 m 13 716 m 13 767 m 13 818 m 13 868 m 13 919 m 13 970 14 021 14 072 m 14 122 m 14 173 14 224 m 14 275 14 326 14 376 14 427 14 478 14 529 14 580 14 630 14 681 48 48 48 48 48 ceiuior EN j 49 11 4101 00 4 90 11 91 11 C1 N 92 11 oJNII S2 24 24 94 11 Total Track Length as defined 3 61 9 61 10 61 11 14 707 14 732 14 757 m 14 808 m 14 859 m 14 910 m 14 961 m 15 011 m 15 062 m 15 113 m 15 164 m 15 215 m 15 265 m 15 316 m 15 367 m 15 418 m 15 469 m 15 519 m 15 570
6. Balls missing from car Remove cars load balls and slide cars back on track CB cars bind Use detergent and fresh water to flush dirt out of Dirt in cars cars move cars up down do circulate follow with high pressure water clean track grooves 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 T l Use topping lift or rod vang and shock cord to pull Cars jam when raising sail Headboard or cars are catching on lazy jacks lazy jacks out to shrouds 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 l Transfer reef downhaul and outhaul loads to mast 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 Loctite is a registered trademark of Henkel AG amp Company KGaA 14 System B CB Slider 4252 1 05 HARKEN N15W24983 Bluemound Rd Pewaukee Wisconsin 53072 USA Telephone 262 691 3320 Fax 262 701 5780 Web www harken com e Email harkenQharken com Printed in USA 4252 1143
7. that will slide lt SU against mast 1 46 30 mm Short top track lengths 11 2 38 mm Use existing hole Do not drill second hole 23 3 60 mm Use existing hole drill hole 8 mm from cut end CB Slider Systems Check Fit of Mounting Slugs amp Car 1 CB Cars 23 4 70 mm Slider Cars 111 16 42 mm Will Tighten Will Not Tighten Test track Put mounting slug in groove track section on mast Tighten with screw Mounting screw must be long enough for mast groove If necessary purchase longer screws 3 76 mm connector slug must fit feeder opening File opening to make longer Clear of Trysail Track Use halyard with retrieval line to run Cars must clear storm trysail track Tracks 3 76 mm connector slug up mast Warning Screws need minimun often converge above spreaders to check for burrs in groove 5 threads turns engaged to hold track to mast Aft face of mast must be flat or convex Mast prebend May require straightening before installation Turn screw 360 five times after threads engage slug 42521 05 System B CB Slider 5 CB Slider Systems Slip top track slugs into mast groove Use 36 mm mounting slug for top stop Short top track lengths Top slug 1 7 38 mm 3 76 mm 2 s 60 mm 22 mm Install 3 76 mm connector slug at bottom Mast Tape 17 amp 36 mm slug even with top of upper track Tape other slugs in place
8. 2 Ya 19 6 Ya 19 1 4 6 45 119 1 4 6 39 16 91 1 4 6 10 334 96 1 4 6 12 1 4 6 Installing Headboard Car Assembly Halyard 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 5 mm aft of existing hole 4252 12 05 CB Slider Systems Distance Between Setting Reef Points Attachment Points opace reef points halfway between sail attachment points Battens or reef points may need to be moved Battens and intermediate cars placed at sailmaker s discretion Maximum distance between attachment points Viagram A is 41046 1 2 m to 1 35 m NOTE Batten fittings and cars cannot handle reefing outhaul or downhaul loads Transfer loads to a tack fitting Diagram B 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 Sailmaker s Instructions DIAGRAM A CB Slider Systems Sail setback from luff tape to intermediate car clevis pin CB 3039 1 32 mm Slider 3836 1 25 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 Cars If you combine 3836 S
9. 20 244 m 20 295 m 20 345 m 20 396 m 20 447 m 20 498 m 20 549 m 20 599 m 20 650 m 20 701 m 20 752 m 20 803 m 20 853 m 70 8 70 10 TV ow 71 2 71 4 71 6 11 8 71 10 12 72 72 12 RISC 72 10 73 0 13 2 13 4 73 6 13 8 73 10 14 0 14 2 4 4 14 6 14 8 74 10 75 0 ub 20 879 20 904 m 20 930 m 20 980 m 21 031 m 21 082 m 21 133 m 21 184 m 21 234 m 21 285 m 21 336 m 21 387 m 21 438 m 21 488 m 21 539 m 21 590 m 21 641 m 21 692 m 21 742 m 21 793 m 21 844 m 21 895 m 21 946 m 21 996 m 22 047 m 22 098 m 22 149 m 22 200 m 22 250 M 22 301 m 22 392 M 22 403 m 22 454 m 22 504 m 22 555 M 22 606 m 22 65 m 22 08 m 22 758 m 22 809 m 22 860 m 22 911 m Top Track Length Top Track Length 1 7 38mm 23 60mm 3 760 mm 5 127 mm 7 178mm 9 229mm 11 279 mm SO VS SEN MA 15 432mm 1 7 483mm mm 111 584mm mm 2 3 666 mm SN 2211 2 9 838mm 211 889mm 3 1 940mm 3 3 991 mm 3 5 104m 3 7 1 092 m 3 9 1143m 3 11 1194m 4 1 1 245 m 4 3 1 295 m 4 5 1 346 m 4 1397m 4 9 1448m 411 1 499m 5 1 1549m 5 3 600 5 ES 5 f 1702m S S 1 6 1 1 854m Mm 6 5 19561 6 7 2 007 m 6 9 s 2 060 m 4252 1 05 CB Slider Systems Cut Top Track to Length 1 Cut special length top track from 691 2 Deburr cut 3 Drill two 1 6 5 mm holes in cut 2 06 m track 5 Slightly round track corners
10. H mma nn gr i HARKEN Baticar installation Manual System B CB and Slider Cars 6mm Glevis Pin CB Slider Systems Parts List Thank you for puchasing Harken s B Intermediate Cars Universal Battcar Reef Car Battcar system Please read manual before assembling system Headboard Cars Assembly 1 3839 3836 Slider Batten Cars without Receptacle 3842 CB 3843 CB You will need these tools Tape Measure 3840 3841 CB Phillips Screwdriver 3833 3834 3835 Slider Power screwdriver Slider Drill Drill Bit 17 64 6 5 mm Hex wrench 5 mm Nut Driver 10 mm or Open Box Wrench Genterpunch Hammer Track Mounting Kit Screwpin Endstop Kits Putty knife Hacksaw File Tape 3845 3846 3847 3848 Mast Up Installation Stepladder 0 4 secured to the boat f Work Height 7 2 13 m above boom Track Mounting Slug Type h x Endstop Kits 3850 3851 ET NE 14 mm 3844 iV Weis Ps Track Drill and Tap Type CB Slider System Parts Cane SS ome ee No Part No Description 8838 38338 Headboard cars Cars 38398 3836 Intermediate cars n battens are close enough intermediate cars are not needed 3840 383 Battencr 10 mm Threaded stud Purchase batten receptacle separately 8381 383 Battencr 12 mm Threaded stud Purchase batten receptacle separately 83842 UnivesaBatcar Purchase batten receptacle and th
11. der 4252 1 05 CB System Removing Sail Press quick release button and push up on bottom of pin Remove clevis pin CB System Battcar 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 CB Slider Systems 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 b Slider System If your system has slider battcars without ball bear ings leave slides attached and slide cars off beginning at the bottom CB System 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 Battcar fittings for loose locknuts Replace Inspect batten receptacles for loose screws 4252 1 05 System B CB Slider Removing Sail Car Maintenance CB Sliders Systems Sailmakers Instructions
12. f pin for 23833 or 3838 headboard 3011 3040 3841 3839 car coupler Slider System 2 Batten receptacle on sail to accept 10 mm threaded stud Note Harken does not 900 ft 700 ft 3833 3834 3835 3836 supply receptacle 3 Becket spacer on sail for 3839 CB or 3836 slider intermediate cars CB Slider Systems Track Length Number of Track Sections Botton endstop track and variable length top track included Number of Track 6 9 2 06m Length Track Sections 41 6 to 482 7 12 649 m to 14 681 m 48 3 to 54111 8 14 707 m to 16 739 m 55 0 to 619 9 16 764 m to 18 796 m 619 to 68 5 10 18 821 m to 20 853 m 68 6 10752 14 20 879 m to 22 911 m Determine Track Length Measure track length from point 1 to point 2 See diagram at left Use this measurement in two charts to follow 1 Upper End 8 203 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 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 9 4 238 mm piece from finished end of one of the 6 9 2 06 m 3844 tracks You will remove this track when loading cars So it can be lower on mast See page 7
13. lider Intermediate cars with CB cars use the 1 35 mm CB setback shown above DIAGRAM B Attaching Sail to Intermediate Cars See at Left Em 3839 3836 4252 12 05 System B CB Slider 13 CB Slider Systems Installation Troubleshooting Make sure the anodized end is towards the Cut end of top or bottom track is at joint full length track Tracks do not butt up against each other Tracks will come together when you loosen the bottom screw and push the tracks up the 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 l Loosen screws slightly If necessary have someone Slugs catching on mast splice at splice area to wiggle the slug past the splice Track weight pulling tracks apart 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 Track and cars are not the same size Contact your dealer or Harken CB cars do not fit on track Balls are missing Remove cars load balls and slide cars back on track Sail headboard does not fit inside coupler Ring was not pressed far enough Take sail to sailmaker CB Slider Systems Operation Troubleshooting
14. m 15 621m 15 672 m 15 723 15 773 m 15 824 m 15 875 m 15 926 m 15 977 m 16 027 m 16 078 m 16 129 m 16 180 m 16 231 m 16 281 m 16 332 m 16 383 m 16 434 m 16 485 m 16 535 m 16 586 m 16 637 m 16 688 m 16 739 m 95 99 95 95 99 25 96 96 96 96 96 96 97 of 97 97 97 97 98 98 98 98 0 1 16 789 2 16 815 4 6 8 10 10 16 764 m 16 866 m 16 916 m 16 967 m 10 17 018 m 17 069 m 17120 m 17170 17 221m 17 272 17 323 17 374 17 424 17 475 17 526 17 577 m 17 628 m 17 678 m 17 729 m 17 780 m 17 831 m 17 882 m 17 932 m 17 983 m 18 034 m 18 085 m 18 136 m 18 186 m 18 237 m 18 288 m 18 339 m 18 390 m 18 440 m 18 491 m 18 542 m 18 593 m 18 644 m 18 694 m 18 745 m 18 796 m 62 62 62 62 62 62 11 63 63 63 63 63 63 11 64 64 64 64 64 64 11 65 65 65 65 65 65 11 66 66 66 66 66 66 11 67 67 67 67 67 67 1t 68 f 68 3 68 5 System B CB Slider o ool 1 18 821 18 847 18 872 18 923 18 974 19 025 19 075 19 126 19 177 m 19 228 m 19 2 9 m 19 329 m 19 380 m 19 431 m 19 482 m 19 533 m 19 583 m 19 634 m 19 685 m 19 736 m 19 787 m 19 83 m 19 888 m 19 939 m 19 990 m 20 041 m 20 091 m 20 142 m 20 193 m
15. readed stud separately 8435 sd Reef Tackcar Requires special track with closer hole spacing Track and Accessories 3845 3046 Track Mounting a 19 mounting slugs s 22 mm b 1 connector slug 3 76 mm Kit 2 Tubes Blue Loctite d 21 HFS321 Flathead screws 6 x 20 mm 3847 Screwpin e 1 end track with screwpin stop f 1 top stop slug 17167 36 1 top endstop 1522A h 1 mounting slug 1 8 3848 Endstop Kit 22 mm i 2 HFS321 flathead screws 6 x 20 mm 2 HFS1037 flathead screws 6 x 30 mm 1 tube blue Loctite 3850 3851 Endstop Kit g 2 endstops 1522A i 4 HFS1037 flathead screws 6 x 30 mm f 2 stop slugs 17 16 36 mm 3844 Track slug type Section length 6 9 s 2 06 m Number of track sections depends on luff length of your mainsail Track drill and Use for masts without grooves or when slugs will not fit Purchase stainless steel 1 4 mm screws separately tap Do not use 3844 track It requires mounting 51105 See page 8 for drill tap sizes and mounting instructions 9 System B CB Slider 4252 12 05 CB Slider Systems Sizing Sail Modifications Sizing Sail Modifications Make sure that you have the correct size battcar system for your boat See page 12 Maximum Sail Area Part No Part No Part No 1 Mainsail Headboard Monohull Multihull Headboard Battcars Intermediate Cars A Drill new halyard location B Drill Attachment to accept clevis 900 ft 700
16. ttom full length track blocks feeder gap load bottom track slugs before installing track 10 Raise tracks so 91 241 mm bottom 3850 3851 Endstop Kit leave feeder track fits bottom 99 7 238 mm track off untill cars are installed 11 Install bottom feeder track with stop System B CB Slider CB Sliders Systems Required Parts 1616 Track Determine Track Length Bottom track must be short enough to remove easily Use 18 to 24 457 mm to 609 mm length Do not use 3844 track for drilling and tapping 14 6 mm Flathead Screws not included 10 fasteners meter of track 1619 Splices 3850 3851 Endstop Set Drill and Tap sizes U S Imperial Metric Drill 13 64 5 mm Tap 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 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 PORTER CABLE 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
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