BATTCAR INSTALLATION MANUAL System A CB and Slider
Contents
1. 3 Becket spacer on sail for 1777 3812 3828 or 3831 intermediate cars Determine Track Length A Measure track length from point 1 to point 2 See diagram at left Use this T measurement in two charts to follow 1 Upper end 203 mm 8 above black band Track is longer than sail luff length to allow stretch as sail ages Track must not block halyard exit 2 Lower end Bottom of track will be approximately 10 mm 3 8 above gooseneck fitting When installed 3824 3825 3826 endstop kit 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 at right 3808 3809 3810 Endstop kit Cut a 203 mm 9 piece from finished end of one of the 2 05 m 6 8 7 8 3807 tracks You will 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 Number of Track Track length example Sections Track Length 2 05 m 68 7 8 n 2 05 m 6 871 i Track Sections Bottom 203 mm 8 v endstop track and variable m 5 NEL 1 1 length top track included 10516 m to 12522 m 2 05 6878 measurements below 34 6 to 41 1 T See example below 12 548 m to 14 580 m NL T PA 1 41 2 to 4710 it 2 05 m 6 87 s 14 605 m to 16 6372. Operating Precautions When lowering sail do not let halyard go Ease cars down by keeping a wrap on winch IMPORTANT On unstayed masts avoid over rotation of sail On boats with unstayed masts vang must be used to prevent over rotation of upper part of sail Over rotation can damage batten receptacles o 17 System A CB slider CB Sliders Systems Sailmakers Instructions a CB CB 3830 Slider F 3803 A 3802 CB 3812 1777 3828 3831 Slider 1777 3828 D Dimensions measured from aft face of mast Boltrope setback D Pin Stud No Description in mm in mm in mm in mm in mm mm System A CB 3811 Headboard assembl 82 8 213 12 8 35 21142785 57 73 4 102 Jis 5 3812 Intermediate car 21 4 57 18 8 35 3 4 19 316 5 3829 10 mm stud 21 73 18 8 35 21 4 57 311 16 94 316 5 10 3830 Battcar receptacle 21 13 13 8 35 21 73 57 146 316 5 3831 Universal 21 73 12 8 35 Ya 19 316 5 3881 Battcar 12 mm stud 21 13 13 35 23 4 69 37 8 99 1 4 6 12 3882 Long batten car 12mm stud 41 8 105 13 8 35 23 4 69 37 8 99 6 12 3883 Reef car 41 8 105 13 8 35 54 19 6 System A Slider 3827 Headboard car assembly 6 153 176 27 2 54 311 16 94 ne 5 1777 Intermediate car low load 2 51 1 28 Ya 19 316 5 3828 Intermediate car 13 4 44 11 16 27 2 17 316 5 3802 Battcar 10 mm st
3. 136 m 59 8 18 186 m 59 10 18 237 m 60 0 18 288 m 60 2 18 339 m 60 4 18 390 m 60 6 18 440 m 60 8 18 491 m 60 10 18 542 61 0 18 593 m 61 2 18 644 m 61 4 18 694 m Top Track Length 15 6 41 mm 21 6 52 mm 3 76 mm 9 127 d 178 mm 9 229 mm ii 279 mm 330 Ve 381 mm 1 432 mm IT 483 mm 119 533 mm Waal 584 mm gu 635 mm 283 686 mm 20 737 mm Qu 787 mm 209 838 mm 28 889 mm S 940 mm 3 3 991 mm 3 5 1 041 m 1 092 m 849 1 143 9 i 1 194 m 4 1 1 245 m 4 3 1 295 m 4 5 1 346 m 4 7 1 397 m 4 9 1 448 m 4 11 1 499 m S 1 549 1 600 5 5 1 651 S 1 702 m 529 1 753 3 In 1 803 m 61 1 854 6 3 1 905 65 1 956 6 7 2 007 m 6 878 2 054 Preassembly CB System Slug Mount 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 two 5 5 mm 13 64 holes in cut end of track Center at 8 mm 5 16 and 27 mm 11 16 Short top track lengths 41 mm 15 6 Use existing hole Do not drill second hole 52 mm 2 1 16 Use existing hole drill hole 5 18 8 mm from cut end ih System A CB slider Cut Top Track to Length 27mm 1118 CB Slider Systems Slug Mount Check Fit of Mounting Slugs Car 67 mm 2 5 8 connector slug must fit feeder opening File opening to make longer Use halyard with retrieval line to hoist 67 m
4. CB slider CB System Slug Mount Install Track 4 Slide slugs into place with putty knife Loosely install 5 mm 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 5 Loosen top screw Slide top track up and position next 2 05 m 6 8 3 4 track Mast up Tighten bottom screw to hold track 6 Slide 15 mounting slugs and then the connector slug into mast groove Mast up Tape in place One drop blue Loctite adhesive into each hole Loctite is a registered trademark of Henkel AG amp Company KGaA System A CB slider CB System Slug Mount 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 fifteen 5 mm x 20 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 untill track slides Tighten new bottom screw securely CAUTION Do not let tracks drop Severe injury to hands A fingers can result 9 Repeat until full length tracks installed 10 Raise tracks so 203 mm 8 bottom 3808 3809 3810 Endstop Kit track fits Leave bottom 203 mm 97 track 11 Install screwpin endstop kit pA unuk Garean Stale feeder gap load bottom track slugs bef
5. 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 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 if you don t follow instructions The message will tell you how to reduce the WARNING This symbol alerts you to potential hazards that may kill or hurt you and others chance of injury you do not follow instructions The message will tell you how to reduce the CAUTION This symbol alerts you to potential hazards that may hurt you and others if chance of injury WARNING Strictly follow all instructions to avoid potential hazards that may kill or hurt you and others www h
6. Westhaven Aukland 1010 New Zealand Telephone 64 9 303 3744 Fax 64 9 307 7987 Web harken co nz Email harken harken co nz Harken Polska SP ZOO ul Rydygiera 8 budynek 3A lokal 101 pietro 01 793 Warszawa Poland Tel 48 22 561 93 93 Fax 48 22 839 22 75 Web harken pl Email polska harken pl Harken Sweden AB Main Office and Harken Brandstore V stmannagatan 81B SE 113 26 Stockholm Sweden Telephone 46 0303 61875 Fax 46 0303 61876 Mailing address Harken Sweden AB Box 64 SE 440 30 Marstrand Web harken se Email harken harken se Harken UK Ltd Bearing House Ampress Lane Lymington Hampshire S041 8LW England Telephone 44 01590 6891 22 Fax 44 01590 610274 Web harken co uk Email enquiries harken co uk Please visit http www harken com locator aspx to locate Harken dealers and distributors Printed in USA 4248 10 14
7. m 8 47 11 to 547 203 m 8 54 8 to 614 5 System A CB slider CB Slider Systems Top Track Length Slug Mount Top track length chart use for 3807 slug mount track Round track length to nearest 25 mm 17 Note Chart is based on using 8 203 mm end track at bottom 27 9 27 10 27 11 28 1 28 3 28 5 28 7 28 9 28 11 29 1 29 3 29 5 29 7 29 9 29 11 30 1 30 3 30 5 30 7 30 9 30 11 31 1 31 3 31 5 31 7 31 9 31 11 32 1 32 3 32 5 32 7 32 9 32 11 33 1 33 3 33 5 33 7 33 9 33 11 34 1 34 3 34 5 8 458 m 8 484 m 8 509 m 8 560 m 8 611 m 8 661 m 8 712 m 8 763 m 8 814 m 8 865 m 8 915 m 8 966 m 9 017 m 9 068 m 9 119 m 9 169 m 9 220 m 9 271 9 322 9 373 9 423 9 474 9 525 9 576 9 627 9 677 9 728 9 779 9 830 9 881 m 9 931 9 982 10 033 10 084 10 135 10 185 m 10 236 m 10 287 m 10 338 m 10 389 m 10 439 m 10 490 m 4rz 1258 ari 14605m 413 12573m 48 0 14630m 4t 6 12649m 483 14707m 418 12700 485 14757m 44 140 12751m 487 14808 420 12802 489 14859 422 12 852 4811 14910m 424 12900m 491 14961m 426 12954 493 15 011 428 130058 495 X 15062m 4210 130560m 497 15 113 430 13106 499 15164m 432 13 157 4911 15215m 434 13208m
8. 0 5 mm screws separately Do not use 3807 open backed track It requires mounting slugs See page 8 for drill tap sizes and mounting instructions Loctite is a registered trademark of Henkel AG amp Company KGaA System A CB slider CB Slider Systems Sizing Sail Modifications 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 5 5 mm 3 64 Drill amp Tap additional 5 Phillips screwdriver 13 Spring clamp 6 Hammer 14 Spring loaded center punch not shown 7 Hacksaw 15 Drill bit 4 2 mm 5 2 not shown 8 Center punch 16 Tap 5 x 80 mm 10 32 not shown 9 File 17 Transfer punch 5 2 mm or 205 Mast Up Installation Stepladder secured to the boat Work Height 2 13 m 7 above boom Sizing Make sure that you have the correct size Battcar system for your boat Car part numbers Car Maximum sail area Headboard Battcars Intermediate type Monohull Multihull 3811 3829 3830 3812 3831 CB 600 ft 56m 500ft 46m 1 A 3827 3802 3803 3828 Slider 600f 56m 500ft 46m 203 mm 1777 Slider 350f 33m 300ft 28m 8 Sail Modifications See page 12 1 Mainsail headboard A Drill new halyard location B Drill attachment to accept clevis pin for 3811 3827 headboard car coupler 2 Batten receptacle on sail to accept 10 mm threaded stud Note Harken does not supply receptacle
9. 501 15265m 430 13259 503 15 316 438 13310 505 15 367m 4310 13360m 507 15 418 440 1341 m 509 15469 442 13 462 5011 15519m 444 13513 5T 15570m 446 13564 513 15621m 448 13614m 515 15672m 4410 13 665 597 15 723 45 02 13 716 519 15 773 452 13 767 5111 15 824m 45 42 13 818 521 X 15875m 45 60 13868 523 15926 38 1 11862m 458 13919m 525 15977m 391 11913m 4510 13970m 527 16027 460 14021m 529 16078 462 14072m 5211 16 129m 397 12065m 464 14122 531 16 180 399 12 116m 466 14173 533 16231 468 14224 535 16281 46 10 14275m 53 7 16332m 4702 14320m 539 16383 4T2 14376 5311 16434m 474200 14 427m 541 16485m 4T 6 14478m 543 16535 47 8 14520m 545 16586m 4710 14580m 547 16637m Total Track Length as defined on page 3 System A CB slider 54 8 16 662 m 54 9 16 688 m 55 0 16 764 m 55 2 16 815 m 55 4 16 866 m 55 6 16 916 m 55 8 16 967 m 55 10 17 018 m 56 0 17 069 m 56 2 17 120 m 56 4 17 170 m 56 6 17 221 m 56 8 17 272 m 56 10 17 323 m 57 0 17 374 m 57 2 17 424m 57 4 17 475 m 57 6 17 526 m 978 17 577 57 10 17 628 58 0 17 678 58 2 17 729 58 4 17 780 m 58 6 17 831 m 58 8 17 882 m 58 10 17 932 m 59 0 17 983 m 59 2 18 034 m 59 4 18 085 m 59 6 18
10. BATTCAR INSTALLATION MANUAL System A CB and Slider Installation Manual Intended for specialized personnel or expert users 4248 10 14 Introduction Safety precautions 2 Preassembly Slug Mount Drill amp 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 slug mount only 7 Installation Slug Mount Install track 8 10 Install screwpin endstop kit 10 Preassembly Drill amp Tap Parts 4 11 Track length 11 Remove old track 11 Installation Drill amp Tap Drill tap and fasten 11 Operation Slug Mount Drill amp Tap Load cars on track 12 Load cars on track with sail attached 13 Lost balls 13 Load cars on track with sail attached slider 14 Load sail on cars CB slider 14 15 Maintenance Slug Mount Drill 8 Tap Removing sail 16 Car maintenance cleaning inspect 16 Lazy Jacks 16 Operating precautions 16 Sailmaker s Instructions Slug Mount Drill amp Tap Dimensions 17 Installing headboard car assembly 17 Headboard plates 17 Battcars with batten receptacles 18 19 Distance between attachment points reef points 20 Attaching sail to intermediate cars 21 Troubleshooting Installation Operation 22 Addresses 24 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
11. CB Slider Systems Attaching Sail to Intermediate Cars Sailmaker s Instructions Sail setback from luff tape to intermediate car clevis pin will vary depending upon intermediate and batten car Setback Intermediate Cars Batten Cars 3802 3803 3829 CB Cars 3830 CB car Slider cars w 10 mm stud w batten recpt Setback Luff tape to pin 1777 26 mm 17 30 mm 13 1 44 mm 13 4 1777 3812 3828 3812 23 mm 7 8 37 mm 17 5 3828 27 mm 11 s 30 mm 13 1 44 mm 13 7 Plastic spacers come with 1777 3812 and 3828 intermediate cars Seize spacer to webbing by stitching just behind plastic spacer Seize webbing to sail by stitching up against sail System A CB slider 22 CB Slider Systems Installation Troubleshooting Cut end of top or bottom track is at joint Make sure the anodized end is toward the full length track Tracks do not butt up against each other SEE racks will come together when you loosen the Track weight pulling tracks apart 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 CB cars do not fit on track Balls are missing bid cars load balls and slide cars back Sail headboard does not fit inside coupler Ring was not pressed far enough Take sail to sailmaker CB Slider Systems Opera
12. Shim Use enclosed rubber shim so thin flat battens or small diameter round battens fit correctly inside receptacle To insert shim take apart batten receptacle with batten inside Place rubber shim on one side of the batten Assemble Note screw and nuts are not captive System A CB slider Sailmaker Instructions CB Slider Battcars with Batten Receptacles 3830 CB 3803 Slider Sailmaker Instructions Assembly 16 mm 5 8 Place batten receptacles on same side of sail Make sure maximum diameter of batten front of coverplate presses on swivel pin retainer that secures swivel pin Tighten screws and nuts 42 88 mm 1 11 16 6 mm 1 4 maximum thickness of batten System A CB slider 20 CB Slider Systems 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 may be slightly greater Contact Harken to discuss sail reshaping to eliminate luff flutter Note Adding battens may reduce stack height by eliminating luff 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 21 System A CB slider Diagram A Diagram B
13. and install screws using blue Loctite adhesive Tip Use low speed drill with tap for cutting threads IMPORTANT Use blue Loctite adhesive instead of oil for tapping lubricant 3 Align track at joints Use 2711 splice links and round rods or dowels on outside of track to align during installation Hold in place with spring or C clamps until track is secured Load all cars before installing bottom track and endstop Loctite is a registered trademark of Henkel AG amp Company KGaA System A CB slider CB System Load Cars on Track DE 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 cars Hold car so cap screw head faces up Align car on guide section of loader track and gently roll onto upper tracks If car sticks realign and roll onto track Tip To load headboard car assembly angle headboard coupler roll car onto track If necessary remove headboard assembly HARKEN m 2 Load intermediate car if used Alternate with batten cars until all cars are loaded Mast up Use halyard to hold cars up 3 Install screwpin stop 3808 3809 3810 Endstop kit Remove bottom 203 mm 8 track and install cars Tip Use halyard to hold tracks up System A CB slider CB System Load Cars on Track with Sail Attached Cars with sail attached can be loaded by carefully aligning car w
14. arken com manuals for general warnings and instructions System A CB slider CB Slider Systems Parts Headboard Car Assemblies Intermediate Cars 3812 3828 1777 3883 Batten Cars 3830 3881 1 CN 3802 3882 3829 3831 Max headboard Max batten Maximum Part Length Width Weight thickness Width working load No Description in mm in mm 07 g in mm in mm in mm Batten Ib kg CB Cars Typical Boat Length Monohulls 11 3 15 2 m 37 50 ft Multihulls 9 1 12 2 m 30 40 ft 3811 Headboard car assembl 83 8 213 21 4 57 18 518 3 16 14 1600 725 3812 Intermediate car 21 4 57 21 4 57 4 109 3829 Battcar 10 mm stud 21 73 21 4 57 6 157 600 272 3830 Battcar 40 mm receptacle 21 8 73 2 4 57 9 253 15 41 5 3 16 Flat round 600 272 3881 Battcar 12 mm stud 21 73 21 4 57 6 4 182 xad 600 272 3831 Universal Battcar 21 73 21 4 57 4 3 122 600 272 3882 Batten car 12 mm stud 413 105 21 4 57 8 2 232 875 397 3883 Reef car 41 8 105 21 57 6 1 174 875 397 Slider Cars Typical Boat Length Monohulls 11 3 15 2 m 37 50 ft Multihulls 9 1 12 2 m 30 40 ft 3827 Headboard car assembl 6 153 11 4 35 10 269 3 16 14 1600 725 1777 Low load intermediate 2 51 11 4 32 1 1 32 200 91 3828 Interme
15. diate car 13 4 44 13 35 1 6 45 350 159 3802 Battcar 10 mm stud 13 4 44 13 8 35 2 8 80 350 159 3803 Battcar 40 mm receptacle 13 4 44 13 8 35 6 4 181 19 41 Sg 16 Hat round 350 159 System A CB slider CB Slider Systems Parts Track mounting kit 3804 3805 3806 gt Screwpin endstop kits Endstop kits 3824 3825 3826 3808 3809 3810 h Track slug type Track drill and tap Spare car screws 12 5 mm 4 Pm 5 G 3807 4 22 1 22 mm I Track and Accessories Part No Description Includes Mounting Slug Method 3804 3805 Track mounting kit a 15 mounting slugs 19 mm 3 4 b 1 connector slug 67 mm 2 s 2 tubes blue Loctite adhesive 3806 9 d 17 HFS1015 flathead screws 5 x 20 mm 3824 3825 amp otewoin endsteb kt e 1 end track with screwpin stop f 1 top stop slug 32 mm 11 4 g 1 top endstop 263A h 1 mounting slug 19 mm 3 4 3826 i 2 HFS320 flathead screws 5 x 25 mm j 2 HFS1015 flathead screws 5 x 20 mm 1 tube blue Loctite adhesive 38089809 Endstop kit 0 2 endstops 263A i 4 HFS320 flathead screws 5 x 25 mm f 2 stop slugs 32 mm 17 3807 Track Section length 2 05 m 6 87 s Number of track sections will vary according to luff length of your mainsail Drill amp Tap Method 2720 Track Use for masts without grooves or when slugs will not fit Purchase stainless steel 1
16. il Slider System If your system has slider Battcars without ball bearings leave slides attached and slide cars off beginning at the bottom Car Maintenance Cleaning 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 deter gent spray water into ball bearings and circulate Clean tracks with detergent and water Use OneDrop Ball Conditioner CB System Once dry use only a single drop of McLube OneDrop ball bearing conditioner Do not use spray lubricants because ball bearings may skid not roll Apply one to two drops of McLube OneDrop to ball contact surfaces of track Roll car back and forth through OneDrop several times to distribute onto bearings Wipe remaining OneDrop off track OneDrop is preferred but you can also use one to two drops of a light machine oil Too much attracts dirt McLube is a registered trademark of McGee Industries Inc Inspect Inspect Battcars for loose locknuts Replace Inspect batten receptacles for loose screws CB Slider Systems Lazy Jacks Use shockcord to hold Lazy Jacks open so Battcars and battens will not catch on them when hoisting sail This will also help stop Lazy Jacks from slapping on sail Attach one end to lower spreader tips and the other to Lazy Jacks Make Shockcord sure shockcord is long enough so boom can swing out all the way without damaging spreaders 5
17. ith track and supporting sail to keep weight off cars Line up car on guide portion of loader Press car toward mast and carefully roll car onto track Begin with upper cars and work down Tip Have another person help hold sail while you load cars CB System Consult chart for ball type Torlon or Delrin ball bearings 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 Car Length Bearings Number Purchase Ball No Car Type in mm Color Material er Car PartNo _ Balls Set in mm 3811 Headboard cars 2 83 s 213 Brown Torlon 60 177 21 1 4 6 3812 Intermediate car 21 4 57 Brown Torlon 32 177 21 1 4 6 3829 Batten car w threaded stud 21 8 73 Brown Torlon 40 177 21 1 4 6 3830 Battcar w 40 mm receptacle 21 8 73 Brown Torlon 40 177 21 1 4 6 3831 Universal car 21 8 73 Brown Torlon 40 177 21 1 4 6 3881 Batten car w 12 mm threaded stud 21 8 73 Brown Torlon 40 177 21 1 4 6 3882 Batten car w 12 mm threaded stud 4 105 Brown Torlon 60 177 21 1 4 6 3883 Reef car 41 105 Brown Torlon 60 177 21 1 4 6 Delrin is a registered trademark of E du Pont de Nemours and Company or its affiliates Torlon is a registered trademark of Solvay Advanced Polymers System A CB slider 14 Slider System Load Cars on Track with Sail Attached Slider cars can be loaded onto tracks with or without sail attached Line up car on guide portion of loader Pres
18. m 2 5 8 connector slug up mast to check for burrs in groove Mast prebend May require straightening before installation Storm Trysail Track Cars must clear storm trysail track Tracks often converge above spreaders Aft face of mast must be flat or convex Check fit Test track Put mounting slug in groove track section on mast Tighten with screw Track must be drawn tightly to mast CB cars 57 mm 211 ii Mounting screw must be long enough mast groove 35 mm 198 If necessary purchase longer screws Clear of trysail track Warning Screws need minimum of 5 threads turns engaged to hold track to mast Turn screw 360 five times after threads engage slug A System A CB slider 8 CB System Slug Mount Install Track 1 Slip top track slugs into mast groove Use 32 mm 1 1 4 mounting slug for top stop Short top track lengths Top slug 41 mm 15 1 67 mm 25 52 mm 21 67 19 mm 3 4 Mast up Tape 32 mm 1 1 4 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 5 mm x 25 mm endstop screws through endstop track and into endstop slug Short top track lengths 41 mm 15 1 Use one screw in stop 52 mm 21 16 Use both screws Mast up Remove tape Tighten screw to hold track Loctite is a registered trademark of Henkel AG amp Company KGaA 9 System A
19. ore installing track Note If bottom full length track blocks 11 System A CB slider CB Sliders Systems Drill Tap Install Track Track and Accessories Part No Description Includes Purchase from Harken Use for masts without grooves or when slugs will not fit Purchase 2720 stainless steel 8 4 mm screws separately Do not use 3817 open backed track It requires mounting slugs See page 11 for drill tap sizes and mounting instructions 2707 Track Micro CB 2724 Splice links One needed for each track joint amp 263 Endstop set p d Purchase Separately 2724 10 5 mm Flathead screws Purchase 10 fasteners meter of track 263 Drill 4 2 mm 5 32 Tap 10 32 5 x 80 mm Determining Track Length Bottom track must be short enough to remove easily Use 457 mm to 609 mm 18 to 24 length Do not use 3807 track for drilling and tapping Remove Old Track IMPORTANT Before removing old track scribe pencil line down either side Drill Tap and Fasten After old track is removed attach string to mast to line up track during installation 1 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 in center of track hole using a narrow shaft spring loaded machinist s punch with plastic centering tube or a transfer punch Track hole size is 2 05 or 5 2 mm 2 Drill track hole holding drill perpendicular to mast face Tap threads
20. s are dry apply one to two drops of McLube OneDrop conditioner to ball contact surfaces of track Roll car back and forth through OneDrop several times to distribute onto bearings Wipe remaining OneDrop off track OneDrop is preferred but you can also use one to two drops of a light machine oil Too much oil attracts dirt Warranty For additional safety maintenance and warranty information www harken com manuals or the Harken catalog Loctite is a registered trademark of Henkel AG amp Company KGaA McLube is a registered trademark of McGee Industries Inc OneDrop is a trademark of McLube a Division of McGee Industries 23 System A CB slider Corporate Headquarters N15W24983 Bluemound Rd Pewaukee WI 53072 USA Telephone 262 691 3320 Fax 262 701 5780 Web www harken com Email harken harken com Harken Australia Pty Ltd 1B Green Street Brookvale N S W 2100 Australia Telephone 61 2 8978 8666 Fax 61 2 8978 8667 Web harken com au Email info harken com au Harken France ZA Port des Minimes BP 3064 17032 La Rochelle Cedex 1 France Telephone 33 05 46 44 51 20 Fax 33 05 46 44 25 70 Web harken fr Email info harken fr Harken Italy S p A Via Marco Biagi 14 22070 Limido Comasco Italy Telephone 39 031 3523511 Fax 39 031 3520031 Web harken it e Email info harken it Harken New Zealand Ltd 158 Beaumont Street Unit 11 Orams Marine Centre
21. s car toward 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 3883 Reef Car Load Sail on Cars 1 Beginning with lower cars use 4 mm hex key and 8 mm wrench or nut driver to attach sail to cars Tighten lock nut until bottom tip of fastener is flush with nut For 3883 reef car line up plastic becket spacer and insert clevis pin 3883 reef car System A CB slider CB Slider Systems Load Sail on Cars 2 Screw threaded stud to sail batten receptacle Thread completely in and then back off two turns Receptacle must be allowed to rotate on stud 3 Load toggle using 4 mm hex key and 8 mm wrench or nut driver Tighten lock nut Do not over tighten Make sure toggle can pivot 3a For 3881 and 3882 battcars line up toggle and insert clevis pin 4 Attach head of sail to headboard car with clevis pin and cotter pin 4a For 3881 and 3882 battcars press quick release button and pushup on bottom of pin Remove clevis pin System A CB slider CB Slider Systems Removing Sail Removing Sail CB System From cars Remove clevis pin from head of sail Use a 4 mm hex wrench and a 8 mm wrench or nut driver on other cars Cars and sail Keep cars lined up with track when sliding off Inspect cars 20 balls per side Replace 5 mm locknut after two removals Removing Sa
22. tion Troubleshooting Use detergent and fresh water to flush dirt out of cars move cars up down to circulate follow with Dirt in cars high pressure water clean track grooves Condition Cars bind balls using McLube One Drop See below Stud threaded too tightly into receptacle Back off threaded stud two turns T Remove cars load balls and slide cars back on Balls missing from car track Mounting screws will not tighten Incorrect mounting slug used Get new 6 mm lock nut 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 Use topping lift or rod Vang and shock cord topul 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 Vertical post or pin on batten receptacle bending ded loads are being transferred to batten recep 2 and outhaul loads to mast Reef tack fitting will not reach reef hook Reef point too close to sail attachment Move intermediate car sail attachment 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 Do not use spray lubricants because ball bearings may skid not roll Once cars and track
23. ud 13 4 44 11 16 27 218 54 316 5 10 3803 Battcar receptacle 13 4 44 11 16 27 21 8 54 5 130 316 5 CB Slider Systems Installing Headboard Car Assembly Headboard coupler attaches to standard headboards some headboard modification required Maximum thickness of headboard plates and sail 14 mm 9 16 G Center of coupler attachment hole to front edge of boltrope ECBITTT ESA 9 5 hs Coupler attachment hole Coupler Attachment Hole Drill 11 mm 7 16 coupler attachment hole so center is 101 mm 4 from top of headboard Consult chart to determine G based on Battcar used Leave at least 9 mm 3 8 between front of headboard plate and front edge of coupler attachment hole System A CB slider 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 63 5 mm 2 1 2 aft of existing hole CB Slider Battcars with Batten Receptacles 3830 CB 3803 Slider Option 1 Round battens End batten pocket 254 mm 10 from receptacle Flat battens End batten pocket 254 mm 10 from receptacle Option 2 Round battens Pucker batten pocket draw edges together before inserting batten Flat battens Fit batten into receptacle If necessary pucker batten pocket and draw edges together before inserting May require optional shim Optional
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