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Harken 3813, Installation Manual

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Harken 3813 Installation Manual Download Page 1

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

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

Summary of Contents for 3813

Page 1: ...it 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 t...

Page 2: ...erty 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 manual...

Page 3: ... 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 Track and Accessories 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 enoug...

Page 4: ...asure to lower end of track Preassembly CB System Slug Mount Drill Tap Tools Sizing Sail Modifications Track Length 8 203 mm 1 2 4 System AA CB 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 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 1...

Page 5: ...38 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 14...

Page 6: ...ide against mast 1 Cut special length top track from 2 05 m 6 8 3 4 track 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 Preassembly CB System Slug Mount Cut Top Track to Length 6 System AA CB ...

Page 7: ...ion 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 Check Fit 40 mm 1 9 16 11 or more 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 necessar...

Page 8: ...at bottom Mast up Tape 32 mm 1 1 4 slug even with top of upper track Tape other slugs in place 2 Squeeze one drop blue Loctite into each connector slug hole 3 Thread 4 mm x 25 mm endstop screw through endstop track and into endstop slug Mast up Remove tape Tighten screw to hold track Installation CB System Slug Mount Install Track 8 System AA CB Loctite is a trademark of Henkel AG Company KGaA ...

Page 9: ... 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 7 8 track Mast up Tighten bottom screw to hold track 6 Slide 19 mounting slugs and then the connector slug into mast groove Mast up Tape in place One drop blue Loctite into each hole Loctite is a trademark of Henkel AG Company KGaA ...

Page 10: ...ws 8 Slide tracks up enough to fit next track Mast up Hold upper tracks Loosen screw that holds tracks Slide track up Tighten new bottom screw securely 9 Repeat until full length tracks installed 10 Raise tracks so 152 mm 6 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 d...

Page 11: ...in 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 2711 Splice links One nee...

Page 12: ...tite 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 Installation CB System Drill Tap Install Track Loctite is a trademark of Henkel ...

Page 13: ...ks 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 Installation CB System Slug Mount Drill Tap Load Cars on Track Part No Car Type Car Length Bearings Number per Car Part No Balls Set Ball Ø in mm Color Material in mm 3813 Headboard Cars 5 3 16 132 Brown Torlon 40...

Page 14: ...l type Torlon or Delrin 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 Operation CB System Slug Mount Drill Tap Load Cars on Track 14 System AA CB Torlon is a registered trademark of Solvay Advanced Polymers Delrin is a registered trademark of E I du Pont de Nemours and Company or its affiliates ...

Page 15: ...h and 8 mm wrench or nut driver to attach sail to cars Tighten locknut until bottom tip of fastener is flush with nut 4 Attach head of sail to headboard car with clevis pin and cotter pin 2 Screw threaded stud to terminal 3 Load toggle using 4 mm hex wrench and 8 mm wrench or nut driver Tighten locknut Do not over tighten ...

Page 16: ...ews Removing Sail 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 HA RKEN H A R K E N Lazy Jacks Use shock cord to hold lazy jacks open so battcars and battens will not catch on them when hoisting sail ...

Page 17: ...ttachment Hole Drill 11 mm 7 16 coupler attachment hole so center is 101 mm 4 from top of headboard and 25 mm 1 from front edge of boltrope Leave at least 9 mm between front of headboard plate and front edge of coupler attachment hole Dimensions 3815 A E D B C B B Sailmaker s Instructions CB System Slug Mount Drill Tap Dimensions Installing Headboard Coupler Car Part No A B C D E Locknut Size mm F...

Page 18: ...d Diagram A Note Batten fittings and cars cannot handle reefing outhaul or downhaul loads Transfer loads to tack fitting Diagram B Diagram B Diagram A Attach Sail to Intermediate Cars Sail setback from luff tape to intermediate car clevis pin 3814 20 mm 13 16 3815 20 mm 13 16 Plastic spacers come with 3814 and 3815 intermediate cars Seize spacer to webbing by stitching just behind plastic spacer S...

Page 19: ... slightly Cars jam when raising sail Headboard or cars are catching on lazy jacks Use topping lift or rod vang and shock cord to pull 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 Reef loads are being transferred to batten receptacle Transfer reef downh...

Page 20: ...and Ltd 158 Beaumont 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 Västman...

Page 21: ... 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 Track and Accessories 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 enoug...

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