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Harken 1777, Installation Manual

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Harken 1777 Installation Manual Download Page 20

 

System A (CB/slider) 

18

Headboard coupler attaches to standard headboards - some headboard modification required.

Maximum thickness of headboard plates and sail: 14 mm (9/16")

Halyard

attachment

hole

63.5 mm

(2 1/2")

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.

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.

CB/Slider Systems 

Installing Headboard Car Assembly

CB/Sliders Systems 

Sailmakers Instructions

Dimensions (measured from aft face of mast)

100 mm 

4"

G

Min 9.5 mm 

(

3

/

8

")

Coupler 

attachment 

hole

G

Center of coupler 

attachment hole to 

front edge of

 

boltrope

3802

40 mm (1

9

/

16

")

3830

30 mm (1

3

/

16

")

3829

44 mm (1

3

/

4

")

3803

43 mm (1

11

/

16

")

CB 

3829 

Slider 

3802

D

C

B

A

E

F

, CB 

3812, 1777, 

3828, 3831 

Slider 

1777, 3828

B

A

E

D

CB 

3830 

Slider 

3803

D

C

B

A

E

CB 

3811 

Slider 

3827

D

B

A

E

C

Part 

No.

Description

A

B

C 

Boltrope setback

D

E 

Pin Ø

F 

Stud Ø

in

mm

in

mm

in

mm

in

mm

in

mm

mm

System A CB

3811

Headboard car assembly

8

3

/

8

213

1

3

/

8

35

2

1

/

4

/2

7

/

8

*

57/73*

4

102

3

/

16

5

—

3812

Intermediate car

2

1

/

4

57

1

3

/

8

35

—

—

3

/

4

19

3

/

16

5

—

3829

Battcar/10 mm stud

2

7

/

8

73

1

3

/

8

35

2

1

/

4

57

3

11

/

16

94

3

/

16

5

10

3830

Battcar/receptacle

2

7

/

8

73

1

3

/

8

35

2

7

/

8

73

5

3

/

4

146

3

/

16

5

—

3831

Universal Battcar

2

7

/

8

73

1

3

/

8

35

—

—

3

/

4

19

3

/

16

5

—

3881

Battcar/12 mm stud

2

7

/

8

73

1

3

/

8

35

2

3

/

4

69

3

7

/

8

99

1

/

4

6

12

3882

Long batten car/12mm stud

4

1

/

8

105

1

3

/

8

35

2

3

/

4

69

3

7

/

8

99

1

/

4

6

12

3883

Reef car

4

1

/

8

105

1

3

/

8

35

—

—

3

/

4

19

1

/

4

6

—

System A Slider

3827

Headboard car assembly

6

153

1

1

/

16

27

2

1

/

8

 

54

3

11

/

16

94

3

/

16

5

—

1777

Intermediate car/low-load

2

51

1

1

/

8

28

—

—

3

/

4

19

3

/

16

5

—

3828

Intermediate car

1

3

/

4

44

1

1

/

16

27

—

—

21

/

32

17

3

/

16

5

—

3802

Battcar/10 mm stud

1

3

/

4

44

1

1

/

16

27

2

1

/

8

 

54

—

—

3

/

16

5

10

3803

Battcar/receptacle

1

3

/

4

44

1

1

/

16

27

2

1

/

8

 

54

5

1

/

8

130

3

/

16

5

—

Summary of Contents for 1777

Page 1: ...2 3831 Universal Battcar 27 8 73 21 4 57 4 3 122 600 272 3882 Batten car 12 mm stud 41 8 105 21 4 57 8 2 232 875 397 3883 Reef car 41 8 105 21 4 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 assembly 6 153 11 4 35 10 269 9 16 14 1600 725 1777 Low load intermediate car 2 51 11 4 32 1 1 32 200 91 3828 Intermediate ...

Page 2: ...dstops 263A i 4 HFS320 flathead screws 5 x 25 mm f 2 stop slugs 32 mm 11 4 3807 Track Section length 2 05 m 6 87 8 Number of track sections will vary according to luff length of your mainsail Drill Tap Method 2720 Track Use for masts without grooves or when slugs will not fit Purchase stainless steel 10 5 mm screws separately Do not use 3807 open backed track It requires mounting slugs See page 8 ...

Page 3: ...ation 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 Operation Slug Mount Drill 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 Dri...

Page 4: ...perty 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 manua...

Page 5: ...2 3831 Universal Battcar 27 8 73 21 4 57 4 3 122 600 272 3882 Batten car 12 mm stud 41 8 105 21 4 57 8 2 232 875 397 3883 Reef car 41 8 105 21 4 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 assembly 6 153 11 4 35 10 269 9 16 14 1600 725 1777 Low load intermediate car 2 51 11 4 32 1 1 32 200 91 3828 Intermediate ...

Page 6: ...dstops 263A i 4 HFS320 flathead screws 5 x 25 mm f 2 stop slugs 32 mm 11 4 3807 Track Section length 2 05 m 6 87 8 Number of track sections will vary according to luff length of your mainsail Drill Tap Method 2720 Track Use for masts without grooves or when slugs will not fit Purchase stainless steel 10 5 mm screws separately Do not use 3807 open backed track It requires mounting slugs See page 8 ...

Page 7: ...t can be lower on mast See page 7 step 11 Drill lower hole for stop See page 5 step 3 Number of Track Sections Bottom 203 mm 8 endstop track and variable length top track included in measurements below See example below Track Length Number of 2 05 m 6 8 7 8 Track Sections 8 458 m to 10 490 m 27 9 to 34 5 5 10 516 m to 12 522 m 34 6 to 41 1 6 12 548 m to 14 580 m 41 2 to 47 10 7 14 605 m to 16 637 ...

Page 8: ... 411 m 50 9 15 469 m 57 6 17 526 m 2 11 889 mm 30 9 9 373 m 37 5 11 405 m 44 2 13 462 m 50 11 15 519 m 57 8 17 577 m 3 1 940 mm 30 11 9 423 m 37 7 11 455 m 44 4 13 513 m 51 1 15 570 m 57 10 17 628 m 3 3 991 mm 31 1 9 474 m 37 9 11 506 m 44 6 13 564 m 51 3 15 621 m 58 0 17 678 m 3 5 1 041 m 31 3 9 525 m 37 11 11 557 m 44 8 13 614 m 51 5 15 672 m 58 2 17 729 m 3 7 1 092 m 31 5 9 576 m 38 1 11 608 m ...

Page 9: ... 05 m 6 8 3 4 track 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 Preassembly CB System Slug Mount Cut Top Track to Length 8 mm 5 16 27 mm 11 16 Short top track lengths 41 mm 1 5 16 Use existing hole Do not drill second hole 52 mm 2 1 16 Use existing hole drill hole 5 16 8 mm from cut end ...

Page 10: ...rebend 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 11 or more 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 lon...

Page 11: ...ystem Slug Mount Install Track Short top track lengths Top slug 41 mm 15 16 67 mm 25 8 52 mm 21 16 19 mm 3 4 Mast up Tape 32 mm 1 1 4 slug even with top of upper track Tape other slugs in place Short top track lengths 41 mm 15 16 Use one screw in stop 52 mm 21 16 Use both screws 3 Thread 5 mm x 25 mm endstop screws through endstop track and into endstop slug Loctite is a registered trademark of He...

Page 12: ...ide 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 Company KGaA ...

Page 13: ...ew that holds tracks Slide track up If screws bind in mast groove opening loosen them untill track slides Tighten new bottom screw securely 9 Repeat until full length tracks installed 10 Raise tracks so 203 mm 8 bottom track fits 11 Install screwpin endstop kit Note If bottom full length track blocks feeder gap load bottom track slugs before installing track CAUTION Do not let tracks drop Severe i...

Page 14: ...e Tip Use low speed drill with tap for cutting threads IMPORTANT Use blue Loctite adhesive instead of oil for tapping lubricant CB Sliders Systems Drill Tap Install Track Part No Description Includes Purchase from Harken 2707 Track Micro CB Use for masts without grooves or when slugs will not fit Purchase stainless steel 8 4 mm screws separately Do not use 3817 open backed track It requires mounti...

Page 15: ...yard to hold cars up 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 3 Install screwpin stop CB System Load Cars on Track 3808 3809 3810 Endstop kit Remove bo...

Page 16: ... Type Car Length Bearings Number per Car Purchase Part No Balls Set Ball Ø in mm Color Material in mm 3811 Headboard cars 2 83 8 213 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 27 8 73 Brown Torlon 40 177 21 1 4 6 3830 Battcar w 40 mm receptacle 27 8 73 Brown Torlon 40 177 21 1 4 6 3831 Universal car 27 8 73 Brown Torlon 4...

Page 17: ...reef car line up plastic becket spacer and insert clevis pin 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 Press 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 headb...

Page 18: ...t driver Tighten lock nut Do not over tighten Make sure toggle can pivot 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 4a For 3881 and 3882 battcars press quick release button and pushup on bottom of pin Remove clevis pin 3a For 3881 and 3882 battcars line up toggle and insert clevis pin ...

Page 19: ...r two removals CB Slider Systems Removing Sail 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 McLub...

Page 20: ...0 30 mm 13 16 3829 44 mm 13 4 3803 43 mm 111 16 CB 3829 Slider 3802 D C B A E F CB 3812 1777 3828 3831 Slider 1777 3828 B A E D CB 3830 Slider 3803 D C B A E CB 3811 Slider 3827 D B A E C Part No Description A B C Boltrope setback D E Pin Ø F Stud Ø in mm in mm in mm in mm in mm mm System A CB 3811 Headboard car assembly 83 8 213 13 8 35 21 4 27 8 57 73 4 102 3 16 5 3812 Intermediate car 21 4 57 1...

Page 21: ...ceptacle with batten inside Place rubber shim on one side of the batten Assemble Note screw and nuts are not captive 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 pock...

Page 22: ...e sure front of coverplate presses on swivel pin retainer that secures swivel pin Tighten screws and nuts CB Slider Battcars with Batten Receptacles 3830 CB 3803 Slider Sailmaker Instructions 6 mm 1 4 maximum thickness of batten 16 mm 5 8 maximum diameter of batten 42 88 mm 1 11 16 ...

Page 23: ...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 Diagram B Di...

Page 24: ... Instructions 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 Intermediate Cars Batten Cars 3802 3803 Slider cars 3829 CB Cars w 10 mm stud 3830 CB car w batten recpt Setback Luff tape to pin 1777 26 mm 1 30 mm 13 16 44 mm 13 4 3812 23 mm 7 8 37 mm 17 16 3828 27 mm 11 1...

Page 25: ...ck catching Use file to round off corners of track 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 ...

Page 26: ...aumont Street Unit 11 Orams Marine Centre 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 I piętro 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 Västmannagatan 81B SE...

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