BATTCAR SWITCH SYSTEM INSTALLATION MANUAL 26
Contents
1. d tg 1 p Tr F M W 29 4 2 mE ES Make sure track is longer than sail luff to allow for stretch as sail ages Track must not block halyard exit Using gate track above switch allows bottom storage track to extend down to gooseneck a w 03 30 09 26 mm 32 mm Battcar Switch System HC7325 HC8076 HC8125 HC8099 Preassembly Track Length Layout system using charts to plan track location and lengths Variable Length Top Track 26 32 mm Systems Total track length Length Hole Spacing SUM 9 Top track length If possible use a storage track with holes drilled for endstops positioned at the upper end for top endstop Standard Track 26 32 mm Systems Length Hole Spacing qmm X in X mm 9 3000 118 11 15 Quantity High Load Track 26 32 mm Systems Length Hole Spacing J mm X in J amp 8qmm J 2000 78 74 50 Place in reefed headboard areas Length Quantity Trysail Switch 26mm System Hole Spacing Length 1 368 14 50 Variable Quantity Trysail Switch 32mm System Hole Spacing Length mm 406 16 00 Variable Gate Track 26 32 mm Systems I Length Hole Spacinc 1 mm X in mm 300 11 81 15 Quantity Removable track Allows cars to be left attached to sail and removed from top of switch Switch 26mm System Length T mm 641 25 24 1 Switch 32mm System mm i 724 22. 32 mm HC7382 HC8149 HC8150 1025 mm Storage track HC8226 Trysail Switch C9340 C9341 C9492 69493 Trysail Tracks See page 16 11 24 10 4 Switch 725 mm Storage track Switch 800 mm Storage track Switch Width 9 Weight Description i i i i g 251 4 641 4 102 4 102 5 16 43 1 1225 19146 500 11 32 26 5 16 10 2 291 28 32 725 11 32 26 5 16 14 8 419 2817 3 725 311 16 93 3 5 16 57 2 1623 111 300 11 32 26 5 16 6 1 174 281 724 5 127 5 127 13 16 20 72 8 2068 311 800 11 4 32 13 16 20 25 6 728 40 1025 11 4 32 13 16 20 32 8 933 111 300 11 4 32 13 16 20 9 6 273 Gate track 26 mm 32 mm Battcar Switch System 5 16 5 16 5 16 5 16 6 6 6 6 6 FCO 50 50 50 75 50 50 75 Preassembly Sizing Make sure you have the correct size battcar system for your boat Part No Reef Car Sizing Part No Tack Car eme Fits Boats Part No Part No Part No Minimum Maximum Headboard Car Battcar Intermediate Car 26 mm 50 ft 15 2 m 80 ft 24 m HC9045 HC7324 HC7493 32 mm 80 ft 24 m 130 ft 40 m HC9046 HC8098 HC7316 HC7322 Track length and switch S height considerations Switch height is determined by the number of cars required for system and the length of the storage track Note Cars will pass each other when top of car is at A distance above bottom of switch See chart at right k LE n J 4
3. BATTCAR SWITCH SYSTEM INSTALLATION MANUAL 26 mm 32 mm Installation Manual Intended for specialized personnel or expert users Introduction Safety precautions Preassembly Tools Parts Sizing Track length switch height considerations Track length Mounting track and switch Mounting track to mast Assembly Install track general instructions Mounting switch Mounting storage track Mounting gate track Mounting standard high load track Mounting top track Commissioning Loading cars on track Loading headboard Removing toggle from cars Operation Raising sail Sailmaker s Instructions Dimensions Installing headboard car assembly Distance between attachment points Setting reef points Trysail Switch System Preassembly Installing track Loading cars Sailmakers s instructions Replacement parts Troubleshooting inspection maintenance warranty 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 4677 12 13 N 9 ec 12 13 13 14 14 15 15 16 16 16 16 17 18 19 Introduction This manual gives technical information on installation and service This information is destined exclusively for specialized personnel or expert users Installation disassembling and reassembling by personnel who are not experts ma
4. 37250 H 36101A Socket head cap screw 1 HCP1730 lgus9 bushing 4 3 H 32605A H 36138A Bushing becket roller 1 H 36138A Bushing becket roller 2 4 HFS920 HFS1586 Lock nut 1 HFS191 Flat washer 8 mm 1 o H 43305 Contact Harken Car assembly sliders guide pins 1 HFS920 Lock nut 1 SES H 3 089A H 37242A Guide pin onl 2 H 37242A Guide pin onl 2 18 26 mm 32 mm Battcar Switch System 12 03 13 Troubleshooting Problem Probable Cause Solution Slider damaged or missing Gheck and or replace slider Use detergent and fresh water to flush dirt out of Dirt in cars cars move cars up down do circulate follow with Cars bind high pressure water clean track grooves Stud threaded too tightly into receptacle Back off threaded stud two turns Car loaded with guide pins on wrong side Check direction car is loaded Operation Can t raise sail cars stop at switch Car loaded upside down Pins in car on wrong side Remove car flip it around and reload Nut on battcar is not holding Lock nut has been used too many times Get new 6 mm lock nut Batten receptacle does not rotate Nuts are too tight Loosen nuts slightly Y 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 Transfer reef downhaul and outhaul loads to mast Vertical post
5. 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 689122 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 07653121439 Printed in USA 4677 12 13
6. Bp FRO FOO PPS J J mH TMA PPO 8 more are listed in bill They are used to hold non replaceable insert bearing in place Quantity 1 BB PRO PPS PPO TH PPO JM mM PPO PPO TB 17 Replacement Parts HC7324 HC8098 HC7316 C7814 PartNo PartNo PartNo PartNo Description Quantity H 3 359A 47961 47960 39218 Toggle stud assembly w bushing 1 HCP1724 MS 1028 HCP704 1819 Igus bushing onl HFS1146 H 36101A H 36101A 48140 Socket head cap screw H 37226A 37226 Delrin washer HCP1739 HCP1730 HCP1730 HCP1819 Igus bushing HFS920 HFS920 920 937 Lock nut H 43303 Contact Harken Car assembly sliders guide pins H 31089A H 37242A H 37242A H 41991 Guide pin onl NO JM PRO IN HC8125 HC8099 Part No Part No Description Quantity H 40900 40891 Socket head cap screw 1 HCP1739 1730 Igus bushing 2 H 40902 36138 Bushing becket roller 2 HFS920 HFS920 Lock nut 1 HC7325 Part No Description Quantity HFS1146 Socket head cap screw 1 HCP1739 Igus bushing H 40902 Bushing becket roller HFS920 Lock nut H 43304 Car assembly sliders guide pins H 31089A Guide pin onl RO 7 IN HC8076 Part No Description Quantity H 40891 Socket head cap screw M10X107 1 HC7493 HC7322 Part No Part No Description Quantity 1 HCP1739 HCP1730 Igus bushing 2 HFS130 Flat washer 10 mm 1 2
7. footing Cover decks or spray cars off boat Note Mustard colored pegs on foot of car guide it to correct side Car will go to side of track where there are no pegs Tip Plain foot to right car goes to right Plain foot to left car goes to left 03 21 12 26 mm 32 mm Battcar Switch System 11 Commissioning Headboard cars have spherical bearings and are designed to run through switch Both cars must run through same side of switch Make sure cars are loaded with pegs on same side 26 mm 32 mm Battcar Switch System Loading Headboard 03 30 09 Commissioning Removing Toggle From Cars When removing parts make sure you retain plastic bushings between vertical pin and hole in car tangs Operation When raising lowering or reefing sail make Sure Sail is not loaded and cars pass through switch easily Watch sail and cars carefully and stop hoisting immediately if any binding is detected Possible sources of binding Cars bind at switch Reef line binds on fingers Reef line binds between car and switch Headboard or battens bind on lazy jacks Battens have draped off boom leveraging car Correct the binding problem or luff sail before resuming hoist If forced the fingers that extend into switch may be damaged requiring expensive switch and car replacement Lazy jacks may also be damaged IMPORTANT When using an electric halyard winch be especially vigilant when raising sail Luff sail W
8. or pin on batten receptacle bending Reef loads are being transferred to batten receptacle or boom gooseneck Reef tack fitting will not reach reef hook Reef point too close to sail attachment Move intermediate car sail attachment Delrin is a registered trademark of E du Pont de Nemours and Company or its affiliates Iguse is a legally registered trademark of Igus GmbH and or Igus Inc Loctite is a registered trademark of Henkel AG amp Company KGaA Inspection Inspect parts periodically and especially before long passages Check for loose nuts cotter pins or track screws Check toggles or batten threaded studs for wear If parts are under load during long passages it is important to inspect them carefully while in use WARNING Parts degrade over time and may become weak Failure to inspect and correct may result in system jamming or breaking under load Harken equipment is designed for minimal maintenance but some maintenance is required for optimum and safest possible operation and to comply with the Harken limited warranty In general the most important aspect of maintenance is to keep your equipment clean by frequently flushing with fresh water In corrosive atmospheres stainless parts may show discoloration around holes rivets and screws This is not serious and may be removed with a fine abrasive With the exception of winches do not use grease unless specifically recommended in the instruction sheet Flush blo
9. track using this single screw and align Side to side correctly Use tape to hold in place Use longer car to test alignment Move up several holes and use transfer punch to mark a second hole Remove track and drill and tap hole Fasten track using two screws Mark all remaining holes using punch Remove track and drill and tap all holes Before installing track make sure upper end has splice piece inserted Use threadlocking adhesive to secure screw see instructions that begin on page 8 11 21 11 26 mm 32 mm Battcar Switch System 7 Assembly Mounting Switch Insert three splice links into switch track Using a plastic hammer tap them in place Carefully align track and tape in place Use a transfer punch to mark a single hole Remove and drill and tap Fasten with single screw no adhesive Re align and mark a second hole using transfer punch Screw to mast using two screws no adhesive Mark remaining holes using transfer punch Remove and drill and tap remaining holes Mount switch to mast using threadlocking adhesive on screws as required 8 26 mm 32 mm Battcar Switch System 07 21 11 Assembly Mounting Storage Tracks Make sure storage track ends with holes for endstop are at bottom If shortening is required cut track from upper end maintaining holes for endstop Fix bottom loader tracks by placing track over splice and tapping into place using plastic hammer Align track and tape in place Use t
10. 8 50 Storage Track 26 mm System T Length Hole Spacing mm in X mm 500 19 69 25 50 7 28 54 50 1 Storage Track 32 mm System Quantity Length Hole Spacing mm nm mm SUM 800 31 90 50 Enter SUM above to 50 1025 40 35 calculate Top track length 26 mm 32 mm Battcar Switch System 11 24 10 Preassembly Mounting Track and Switch Note width and shape of switch and build a platform on mast for mounting If using two storage tracks make sure switch and storage tracks are on the gt Ml same flat surface Curved mast surfaces will not allow correct alignment HC10060 Double storage track for the 26 mm comes with a tube to cut spacers to adapt to curved mast surfaces Note when mounting to curved surfaces wedges will be necessary under the switch HC10060 Double storage track for 26 mm Preassembly Mounting Track to Mast Consult with mastbuilder Use suitable reinforcing plates when fastening track to carbon spars Assembly General Instructions When mounting tracks work meticulously using a straight edge reference line along mast Do not let tracks vary from this line Tape track in place and centerpunch hole at bottom using a transfer punch Tip for mounting to aluminum mast Use low speed drill with tap for cutting threads IMPORTANT Use blue Loctite instead of oil to lubricate tap Remove track and drill and tap single hole Fasten
11. atch for any binding or jamming at the switch and stop hoist immediately if any occurs If winch operator does not have a good view of switch cars station a crewmember with a good view and communication to operator If there is a jam damage to switch and cars will occur very quickly resulting in expensive repairs unless hoisting is stopped IMPORTANT Make sure reef outhaul loads are not applied to cars when in switch Damage to switch and cars will occur resulting in expensive repairs Important Watch for binding at switch Stop hoisting immediately 07 21 10 26 mm 32 mm Battcar Switch System 13 Sailmakers Instructions Dimensions Headboard car assembly Headboard not included Intermediate car 26 mm reef car Description 26 mm HC9045 Headboard car assembly 10 s 270 17 16 37 3 92 HC7493 Intermediate car 23 60 17 16 37 177 32 47 3 16 21 HC7324 Batten car 215 16 75 17 16 37 127 32 47 229 3 73 41 46 103 12 7325 Reef 317 32 90 17 16 37 177 32 47 1 25 HC8125 Tack car 317 32 90 17 16 37 177 32 47 1 25 32 mm HC9046 Headboard car assembly 11 280 11 47 33 16 100 HC7322 Intermediate car 25 16 75 11 47 23 60 1 25 HC8098 Batten car 12mm stud 317 32 90 11 47 37 16 87 419 117 12 HC7316 Batt
12. cks thoroughly with fresh water Periodically disassemble the blocks and clean with detergent and fresh water IMPORTANT Exposure to some teak cleaners and other caustic solutions can result in discoloration of part and is not covered under the Harken warranty Warranty For additional safety maintenance and warranty information see www harken com manuals or the Harken catalog 03 22 12 26 mm 32 mm Battcar Switch System 19 HARKEN 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 CO Italy Telephone 39 031 3523511 Fax 39 031 3520031 Web harken it e Email info harken it Harken New Zealand Lid 158 Beaumont Street Westhaven Box 90689 Victoria St West Auckland 1142 New Zealand Telephone 64 9 303 3744 Fax 64 9 307 7987 Web harken co nz Email harken harken co nz Harken Polska SP Z00 ul Rydygiera 8 budynek 3A lokal 101 pietro 01 793 Warszawa Poland Tel 48 22
13. e reinforcing plates when fastening track to carbon spars Loading Cars Load cars with guide pins on the same side as the trysail storage track If storage track is on the starboard side make sure pins are on starboard side when loading onto track Sailmaker instructions Trysail storage track Place cars so that there are none in the special compound bend track section or switch Cars placed in this area under load will damage fingers of switch 16 26 mm 32 mm Battcar Switch System Guide pins C9342 amp C9494 No load in this area of trysail track 07 20 11 Replacement Parts Part No HC9045 MS 292 MS 284 MS 285 AL 2037 H 3 545A HFS203 HFS1146 H 46463 HFS920 H 43304 H 31089A Part No HC9046NP MS 291 MS 288 MS 287 AL 2047 MS 265 H 37545A HFS203 H 36101A HCP1730 HFS191 HFS920 Contact Harken H 37242A amp OI amp GW 03 21 12 26 mm 32 mm Battcar Switch System HC9045 26 mm System Description Coupler assembl Smalley ring Cup Spherical becket Coupler onl Clevis pin Cotter pin M8 x 52 SHCS Igus bushing lock nut Car assembly with sliders and pins Guide pin HC9046 32 mm System Description Coupler assembl Smalley ring Cup Spherical becket Coupler onl Igus bushing Clevis pin Cotter pin M10 x 68 SHCS Igus bushing Flatwasher Thin lock nut Car bod Guide pin Quantity 1
14. en car 14mm stud 317 32 90 11 47 3 16 87 421 32 118 14 HC8076 Reef car 41 32 115 17 s 47 23 8 60 1 25 HC8099 Tack car 41 32 115 11 47 23 8 60 1 25 Sailmakers Instructions Use 13 4 45 mm webbing Holes in 3876 3877 headboard accept 416 16 mm cheek Web on Web on blocks for leech line Use 4 mm standard i square top x 10 mm fasteners If more reinforcement is necessary web through lightening holes in m m in mm 14 26 mm 32 mm Battcar Switch System 03 30 09 Sailmakers Instructions Distance Between Attachment Points DIAGRAM A Battens and intermediate cars placed at sailmaker s discretion Maximum distance between attachment points is 4 to 4 6 1 2 m to 1 35 m Distance may be slightly greater Contact Harken to discuss sail reshaping to eliminate luff flutter Note Adding battens may reduce stack height by eliminating cars While sailing loaded cars must not ride in this area 08 19 10 Slug Drill Tap Mount DIAGRAM B Setting Reef Points space reef points halfway between sail attachment points Battens or reef points may need to be moved See Diagram A above Note Batten fittings and cars cannot handle reefing outhaul or downhaul loads Transfer loads to a tack fitting See Diagram B above IMPORTANT When setting up reef make sure cars are not loaded when they are in the swi
15. er punch Threadlocking adhesive for mast screws 2 26 mm 32 mm Battcar Switch System 07 14 11 Preassembly Parts Headboard car assembly HC9045 HC9046 Main Components Part No HC9045 HC7493 HC7324 HC7325 HC8125 C9494 HC9046 HC7322 HC8098 HC7316 HC8076 HC8099 C9342 Description Headboard car Intermediate car Batten car Reef car Tack car Trysail car Headboard car Intermediate car Batten car Batten car Reef car Tack car Trysail car Headboard Plates 3876 3877 11 24 10 Standard web on headboard Square top web on headboard Intermediate car Tack car HC7493 HC7322 HC8125 HC8099 Trysail car Reef car 26 mm 1 C9342 C9494 HC7325 HC8076 Batten car with threaded stud 3876 HC7324 Web on HC8098 standard HC7316 07814 Comments Must use 3876 or 3877 headboard System Consult sailmaker for quantity required 12mm Threaded stud Purchase batten receptacle separately Use to secure tack when reefing Use with halyard lock to tension luff Use with trysail switch Must use 3876 or 3877 headboard 12mm Threaded stud Purchase batten receptacle separately 3877 Web on square top 14mm Threaded stud Purchase batten receptacle separately Use to secure tack when reefing Use with halyard lock to tension luff Use with trysail switch See sailmaker instructions See sailmaker instructions 26 mm 32 mm Battca
16. r Switch System Preassembly Storage track HC10060 Storage track A Gate track HC8147 HC8148 HC8149 HC8150 108221 Trysail switch 8226 Endstop 1522A 548A Splice links 11 32 p HC8222 2 HC8227 5 2 4 mm HC8147 HC8148 HC7466 HC8221 11 32 5 26 mm ENSE 5 2 4 mm i HC10060 311 16 93 3 mm gt Tur i 32 mm Ly 1 4 6 mm 13 46 ki 20 mm HC8149 8150 Y HC7391 HC8226 C9341 09342 C9492 9493 T Track Splice Links and Enstops 26 mm HC7466 HC8879 HC8222 1522A 32 mm HC7391 HC8880 HC8227 948A Length Width Description in mm in mm 3 m T Track 118 3000 11 32 26 2 m T Track high load 78 2000 11 32 26 Splice link 11 32 26 Endstop 23 32 55 117 32 39 3m T Track 118 3000 114 32 2m T Track high load 78 2000 11 4 32 Splice link Endstop 29 72 21 32 52 Height 18 46 13 16 Weight 02 g Fasteners 61 1 1736 1 4 6 403 1141 1 4 6 0 1 3 96 2 2734 5 16 8 63 1 1790 5 16 8 0 2 9 Y Track switch Fastener spacing mm 75 50 19 50 C B o Parts w HC8220 26 mm HC7382 32 mm Includes spacer tube for cutting adapters See page 7 Switch Storage and Gate Track Fastener spacing mm Fasteners i mm 26 mm HC8220 HC8147 500 mm Storage track HC8148 HC10060 125 mm Double storage track HC8221 Gate track
17. ransfer punch to mark hole Remove track drill and tap Fasten track using single screw Center punch another hole drill tap and fasten track Center punch remaining holes drill tap and install using threadlocking adhesive Assembly Mounting Gate Tracks With gate track off mast use plastic hammer to tap splice link into upper end of track Carefully align track Use transfer punch to mark holes Drill tap and mount as directed above IMPORTANT Do not use threadlocking adhesive on screws because gate track is removed for loading cars 07 21 11 26 mm 32 mm Battcar Switch System 9 Assembly Mounting Standard High Load Tracks With track off mast tap upper splice link into track using procedures outlined above Follow general instructions page with regard to drilling and taping a single hole etc Always make sure to keep tracks aligned Assembly Mounting Top Track If possible use a storage track with holes drilled for endstops positioned at the upper end for top endstop 10 26 mm 32 mm Battcar Switch System 03 30 09 Commissioning Load Cars on Track Remove gate track Install cars from above switch Lubricate cars onshore before loading Before bringing headboard assembly or cars onboard boat spray underbody track slot see arrows above with a light coating of McLube Sailkote WARNING Overspray from McLube will cause slippery decks which may result in loss of
18. tch area If reef outhaul loads are applied to switch the switch and cars will be damaged resulting in expensive repairs Instruct operators to not raise or lower sails with high loads on the cars while in the switch area Harken is not responsible for damage to the switch area due to reef loads or raising or lowering a sail when the sail is loaded 26 mm 32 mm Battcar Switch System 15 Trysail Switch System Maximum Part Length Width Weight Fasteners working load No Description in mm in mm 02 0 mm Ib kg 26 mm C9493 X Port trysail switch t 141 368 425 3 121 21 762 6 C9492 Starboard trysail switch 141 368 425 3 121 27 762 6 C9494 Car body 23 60 11 32 26 5 143 1001 454 32 mm C9341 Port trysail switch t 16 406 57 149 43 1222 8 C9340 Starboard trysail switch 16 406 57 8 149 43 1222 8 C9342 Car body 215 16 75 31 32 77 11 309 595 270 Available in black or clear anodized Allow 8 weeks lead time Trysail car Preassembly Trysail switch Use standard track and bend to transition between side tracks and switch The cars s should not be under load in this section Installer is responsible for determining 09341 thebend of the track compound bend isrequired to transition from the side of themast to the aft face IMPORTANT Special care must be taken so that the trysail or standard cars do not hit the adjoining track Installing Track Consult with mast builder Use suitabl
19. y 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 WARNING This symbol alerts you to potential hazards that may kill or hurt you and others A if you don t follow instructions The message will tell you how to reduce the chance of injury CAUTION This symbol alerts you to potential hazards that may hurt you and others if A you do not follow instructions The message will tell you how to reduce the chance of injury WARNING Strictly follow all instructions to avoid potential hazards that may kill or hurt you and others See www harken com manuals for general warnings and instructions Tools 1 Tape measure 8 Tape 2 Power drill 9 File 3 Drill bits 10 Hex ke 4 Hammer 11 McLube Sailkote 5 Plastic hammer 12 Tap for mast mounting holes not shown 6 Hacksaw 7 Transf
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