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SERVICE MANUAL

Service routine, system-size identification and the replacement balls, beckets, endcaps, ball loaders and CB wire clips for Harken Battcar Standard Systems AA, A, B and C.

DocumentHarken Battcar Standard Systems Quick Service
FormatPDF · 2 pages · 0.2 MB
LanguageEnglish
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ServiceIdentify Your SystemBall & Becket ChartEndcaps, Loaders & ClipsHC7537 RetrofitProducts
Harken Battcar Standard Systems — Quick Service

Service at Regular Intervals

  • Service after storage, when cars have too much friction, or if balls seem to slide instead of roll.
  • Flush with fresh water and detergent, move the cars back and forth to circulate the balls, then high-pressure water.
  • Clean the track grooves, then a single drop of McLube OneDrop Ball Bearing Conditioner in each ball race.
  • You need: earth-friendly detergent, McLube OneDrop, water hose.

Inspect Carefully For

  • Cracked, corroded or elongated batten toggles: replace immediately.
  • Loose car fasteners: check all locknuts, cotter pins and batten receptacle screws.
  • Loose track screws or misaligned track: run a car up and down with the retrieval line.
  • Missing bearings: see the chart below.
  • Bent wire clip (CB only): replace from the wire clip chart. Replacement CB cars will not roll on older track; CB cars need the groove for the ball retaining wire.

Identify Your System

  • To find the system size only, measure the top of the track and use the table below.
  • To identify a car, measure the car body width (not the stud toggle or batten receptacle) to the nearest few mm or 1/16".
  • System A, B or C cars with black endcaps on the short sides (2 screws each) are the earlier non-captive bearing (non-CB) design.
  • Then use the Car Length column in the identification chart to pick the exact car.
System Slider car Ball bearing car Track
AA 1" / 25 mm 1 9/16" / 40 mm 1/2" / 13 mm
A 1 3/8" / 35 mm (low-load 1 1/4" / 32 mm) 2 1/4" / 57 mm 7/8" / 22 mm
B 1 11/16" / 42 mm 2 3/4" / 70 mm 1 1/16" / 27 mm
C – 3 3/8" / 85 mm 1 1/4" / 32 mm

Car Identification & Ball / Becket Replacement

System Car part no. Description Car length Ball material Balls per car Balls per set Ball Ø Ball part no. Becket slot Becket pin Ø Becket part no.
AA 3813 CB headboard 5 3/16" / 132 mm Torlon 40 20 3/16" / 5 mm 2708 – – –
AA 3814 Slider intermediate 1 3/4" / 44 mm – – – – – 3/4" / 19 mm 0.197" / 5 mm H-35322A
AA 3815 CB intermediate 2 3/16" / 56 mm Delrin 40 20 3/16" / 5 mm 2708 3/4" / 19 mm 0.197" / 5 mm H-35322A
AA 3816 CB Battcar 2 3/16" / 56 mm Torlon 40 20 3/16" / 5 mm 2708 – – –
A 3811 CB headboard 8 3/8" / 213 mm Torlon 60 21 1/4" / 6 mm 177 – – –
A 3812 CB intermediate 2 1/4" / 57 mm Torlon 32 21 1/4" / 6 mm 177 3/4" / 19 mm 0.197" / 5 mm H-35322A
A 3828 Slider intermediate 1 3/4" / 44 mm – – – – – 3/4" / 19 mm 0.197" / 5 mm H-35322A
A 3829 / 3830 CB Battcar 2 7/8" / 73 mm Delrin/Torlon* 40 21 1/4" / 6 mm 176/177* – – –
A 3831 CB Battcar 2 7/8" / 73 mm Delrin/Torlon* 40 21 1/4" / 6 mm 176/177* 3/4" / 19 mm 0.197" / 5 mm H-35322A
A 1792 / 1807 Non-CB headboard 3 5/8" / 92 mm Torlon 52 21 1/4" / 6 mm 177 – – –
A 1777 Slider intermediate 2" / 51 mm – – – – – 3/4" / 19 mm 0.197" / 5 mm H-35322A
A 1894 Non-CB intermediate 2 1/8" / 54 mm Delrin/Torlon* 30 21 1/4" / 6 mm 176/177* 3/4" / 19 mm 0.188" / 4.76 mm H-SB113
A 1976 / 1944 / 1825 / 1901 Non-CB Battcar 3" / 76 mm Delrin/Torlon* 40 21 1/4" / 6 mm 176/177* – – –
A 1977 Non-CB Battcar 3" / 76 mm Delrin/Torlon* 40 21 1/4" / 6 mm 176/177* 3/4" / 19 mm 0.188" / 4.76 mm H-SB26
B 3852 CB headboard 10 1/2" / 267 mm Torlon 60 25 5/16" / 8 mm 1526 – – –
B 3863 CB intermediate 2 9/16" / 68 mm Delrin/Torlon* 28 25 5/16" / 8 mm 1583/1526* 3/4" / 19 mm 0.188" / 4.76 mm H-SB26
B 3836 Slider intermediate 2 3/16" / 56 mm – – – – – 3/4" / 19 mm 0.188" / 4.76 mm H-SB26
B 3856 / 3857 / 3879 CB Battcar 4 5/16" / 109 mm Delrin/Torlon* 45 25 5/16" / 8 mm 1583/1526* – – –
B 3859 CB Battcar 4 5/16" / 109 mm Delrin/Torlon* 48 25 5/16" / 8 mm 1583/1526* 1" / 26 mm 0.394" / 10 mm H-39069A
B 3860 CB reef car 5 3/16" / 132 mm Delrin/Torlon* 60 25 5/16" / 8 mm 1583/1526* 1" / 26 mm 0.394" / 10 mm H-39069A
B 1973 Non-CB headboard 4 3/8" / 111 mm Torlon 48 25 5/16" / 8 mm 1526 – – –
B 1978 / 1946 / 1794 / 1826 / 1902 Non-CB Battcar 3 13/16" / 97 mm Delrin/Torlon* 40 25 5/16" / 8 mm 1583/1526* – – –
B 1979 Non-CB Battcar 3 13/16" / 97 mm Delrin/Torlon* 40 25 5/16" / 8 mm 1583/1526* – – –
B 1895 Non-CB intermediate 2 3/4" / 70 mm Delrin/Torlon* 30 25 5/16" / 8 mm 1583/1526* 7/8" / 22 mm 0.25" / 6.35 mm H-SB28
B 1980 Non-CB Battcar 3 3/16" / 97 mm Delrin/Torlon* 40 25 5/16" / 8 mm 1583/1626* (as printed) 7/8" / 22 mm 0.25" / 6.35 mm H-SB29
C 3867 CB headboard 18 5/8" / 473 mm Torlon 90 25 3/8" / 10 mm 547 – – –
C 3871 CB intermediate 3 3/4" / 96 mm Torlon 34 25 3/8" / 10 mm 547 1" / 26 mm 0.394" / 10 mm H-39069A
C 3868 / 3869 / 3870 CB Battcar 5 3/8" / 136 mm Torlon 50 25 3/8" / 10 mm 547 – – –
C 3872 CB Battcar 5 3/8" / 136 mm Torlon 50 25 3/8" / 10 mm 547 1 3/8" / 35 mm 0.472" / 12 mm H-42227
C 3873 CB reef car 9 1/8" / 231 mm Torlon 90 25 3/8" / 10 mm 547 1 3/8" / 35 mm 0.472" / 12 mm H-42227
C 1782 Non-CB headboard 5 1/2" / 140 mm Torlon 50 25 3/8" / 10 mm 547 – – –
C 1785 Non-CB intermediate 4" / 102 mm Torlon 36 25 3/8" / 10 mm 547 1 1/16" / 27 mm 0.313" / 7.94 mm H-MR25
C 1784 / 1795 / 1827 / 1828 / 1829 / 1903 Non-CB Battcar 4 3/4" / 121 mm Torlon 42 25 3/8" / 10 mm 547 – – –

*Torlon used on all high-load "HL" cars.

Dealer Replaceable Parts

  • All track components; car components including bearings, beckets, endcaps and CB wire clips; Harken Battcar receptacles.
  • Some Harken-supplied Battslide components; clevis pins (similar off-the-shelf pins are usually compatible).

Endcap Sets (cars earlier than CB)

Part No. System Material
HSB78 A Plastic View part →
HMR3 B Plastic View part →
HC1653 B Aluminum Ask us to source it →
HBB48 C Plastic View part →
HC289 C Aluminum Ask us to source it →

Ball Loaders (cars earlier than CB)

Part No. System
HSB116 A View part →
HMR2 B View part →
HBB1 C View part →

CB Wire Clips (order 2)

Part No. Track width System Car length Clip length (installed)
H-33629A 13 mm AA 2 3/16" / 56 mm 2.15" / 55 mm Ask us to source it →
H-39062A 22 mm A 2 1/4" / 57 mm 2.27" / 58 mm Ask us to source it →
H-36239A 22 mm A 2 1/4" / 57 mm 2.24" / 57 mm Ask us to source it →
H-30291A 22 mm A 2 7/8" / 73 mm 2.87" / 73 mm Ask us to source it →
H-35582A 27 mm B 2 9/16" / 68 mm* 2.72" / 69 mm Ask us to source it →
H-33989A 27 mm B 4 1/4" / 108 mm 4.23" / 107 mm Ask us to source it →
H-33990A 27 mm B 5 3/16" / 132 mm 5.17" / 131 mm Ask us to source it →
H-35643 32 mm C 3 3/4" / 96 mm 3.70" / 94 mm Ask us to source it →
H-35629A 32 mm C 5 3/8" / 136 mm 5.31" / 135 mm Ask us to source it →
H-37506B 32 mm C 9 1/8" / 231 mm 9.05" / 230 mm Ask us to source it →

*System B 68 mm car: look for a dimple in the centre. If there is no dimple, replace the car.

HC7537 Retrofit for A/B Battslide 10 mm Elbow Joint

  • Schaefer Battslide elbow fittings are no longer available and have no repair parts.
  • HC7537 is a toggle fitting with a 10 mm stud to fix existing systems.
  • Either buy a 10 mm nosepiece for the receptacle from Schaefer, or a new receptacle that takes a 10 mm stud (Bainbridge Sailman, Rutgerson, Antal or North Sails Parco fitting).
Part No. Description
HC7537 Toggle fitting with 10 mm stud Ask us to source it →

Need a part that isn't listed? Ask us to source it and quote the part number from the PDF.

Products in this Manual