BATTCAR SWITCH SYSTEM INSTALLATION MANUAL 18
Contents
1. Use H 42662 as top stop Install Track 15 Commissioning 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 adhesive WARNING Overspray from McLube will cause slippery decks which can result in loss of footing Cover decks or spray cars off boat Loading headboard assembly Note location of guide pegs on the feet of cars Guide pegs must be on same side Also cars must be loaded so pegs are on inside of switch Plain foot will be on outside If loading on left plain foot must be on left If loading on right plain foot must be on right Tip To load headboard car assembly angle headboard Roll car onto tracks If necessary remove headboard assembly IMPORTANT When all cars are aluminum do not mix intermediate cars with other cars See below Batten headboard car with low friction slider H Hole in hole Hole in batten headboard car Intermediate car with Delrin slider No hole in intermediate car If cars are off track and sail attaching hardware removed do not mix intermediate base cars with batten or headboard base cars All cars have center hole in aluminum car Low friction sliders have a hole in the plastic visible from below and from hole in aluminum car Part No Description Slider Material Hole in Plastic Slider HC7904HL 12 mm b2. 2051 8013 6 100 Standard track drill and tap Length Hole Spacing 3000 1181 75 X Length Quantity High load track slug mount Length Hole Spacing mim Jj 2051 9013 16 50 Place in reefed headboard areas on larger boats f High load track drill and tap Length Quantity Switch slug mount Length 605 2313 16 857 333 4 Switch drill and tap ofa Length 605 2313 16 857 333 4 Short drill and tap switch is created by shortening switch 1 Quantity SUM Enter SUM above to calculate Top Track Length Assembly Slug Mount Cut Top Track to Length Cut variable length top track Check Fit of Mounting Slugs and Car xj AX oa d k s e j iss 1 j 3 raii 7 f T TOME T j PA L D Mel I ifs d 1 P L i 1 7 e 3 y a i i b 1 L 67 mm 2 s splice slug must fit feeder opening File opening to make longer Use halyard with retrieval line to run 67 mm 2 s splice slug up mast to check for burrs in groove Mast prebend Might require straightening before installation Drill 5 5 mm 32 hole in cut end of track for endstop Deburr cut Slightly round track corners that will slide against mast CORRECT INCORRECT CORRECT INCORRECT Will Tighten Will Not Tighten Test track Put mounting slug in groove track section on mast Tighten with screw Make sure track will tighten to mast before Slug contacts trac
3. BATICAR SWITCH SYSTEIM INSTALLATION MANUAL 18 mm Installation Manual Intended for specialized personnel or expert users Introduction Safety precautions Preassembly Tools Parts sizing sail modification switch height Top track length Track length Assembly Slug Mount Track Cut top track to length Check fit of mounting slugs and car Install track Install switch Assembly Drill and Tap Track Removing old track Mount track to carbon mast General instructions Install switch Install track Install top stop Commissioning Loading headboard assembly Loading cars Attaching sail Lazy Jacks B Operation OT VAM aa ICI I je EAM Raising sail Sailmakers Instructions Dimensions Installing headboard car assembly Distance between attachment points Setting reef points Replacement Parts Troubleshooting 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 4679 11 14 10 11 12 12 12 13 14 15 15 16 16 16 17 18 18 19 19 20 21 22 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 may cause serious damage to property injury to use
4. Via Marco Biagi 14 22070 Limido Comasco CO Italy Telephone 39 031 3523511 Fax 39 031 3520031 Web harken it Email info harken it Harken New Zealand Ltd 158 Beaumont Street Unit 11 Orams Marine Centre Westhaven Aukland 1010 New Zealand Telephone 64 9 303 3744 e Fax 64 9 307 7987 Web harken co nz e 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 e Fax 48 22 839 22 75 Web harken pl Email polska harken pl Harken Sweden AB Main Office and Harken Brandstore Vastmannagatan 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 Lid Bearing House Ampress Lane Lymington Hampshire 041 8LW England Telephone 44 01590 6891 22 Fax 44 01590 610274 Web harken co uk Email enquiries harken co uk Please visit http Awww harken com locator aspx to locate Harken dealers and distributors 0119765321558 85 Printed in USA 4679 12 14
5. 16 90 6 10 HC7906HL Headboard car FAIT 198 11 4 31 29 16 65 43 16 106 6 HC7905HL Intermediate car 21 2 63 11 4 31 29 16 65 3 4 19 6 HC7904HL Batten car 12 mm stud 21 2 63 11 4 31 29 16 65 33 4 95 6 12 HC8537HL Batten car 10 mm stud 21 2 63 11 4 31 29 16 65 39 16 90 6 10 Mounted on drill tap track A B C boltrope setback D E pin F stud 0 Part No Description in mm in mm in mm in mm mm mm HC7906 Headboard car TANIT 198 11 3 29 215 32 62 4i he 103 6 HC7905 Intermediate car 21 2 63 11 3 29 215 32 62 3 4 19 6 HC8537 Batten car 10 mm stud 21 2 63 11 3 29 215 32 62 3 16 88 6 10 HC7906HL Headboard car T he 198 11 3 29 215 32 62 4i he 103 6 HC7905HL Intermediate car 21 2 63 11 3 29 215 32 62 3 4 19 6 HC7904HL Batten car 12 mm stud 21 2 63 11 5 29 215 32 62 35 8 92 6 12 HC8537HL Batten car 10 mm stud 21 2 63 11 2 29 215 32 62 37 16 88 6 10 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 Halyard attachment hole Coupler attachment hole Coupler attachment hole Halyard attachment hole Drill 11 mm 16 coupler attachment hole so center Use aft hole if headboard has two 2 is 101 mm 4 from top of headboard and 51 mm 2 from front 2 of boltrope 2 If not drill second hole to accept halyard shackle pin Locate hole approximately 64 mm 2 2 aft of existing hole
6. HFS852 1 Nut M6 locking 5 H 45064 2 Igus bushing 5 H 45064 2 Igus bushing 6 4913 2 Harken label 6 4913 2 Harken label SHCS Socket head cap screw SHCS Socket head cap screw Delrin is a registered trademark of E du Pont de Nemours and Company or its affiliates 21 Problem Probable Cause Solution Cut end of top or bottom track at joint Make sure the anodized end is toward the full length track Tracks do not butt up against each other roon Tracks will come together when you loosen the pe pone 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 Loosen screws slightly If necessary have someone at splice area to wiggle the slug past the splice Corners of cut track catching Use file to round off corners of track Track will not slide up mast Mast has too much prebend Ease backstay and or straighten mast Paint or other material clogging mast groove Clean out groove Sail headboard does not fit inside coupler Ring was not pressed far enough Take sail to sailmaker Troubleshooting Slugs catching on mast splice Problem Probable Cause Solution Slider damaged or missing Check and or replace slider Spray a small amount of McLube Sailkote lubricant in underbody track slot of all cars If possible spray c
7. Leave at least 9 mm 3 8 between front of headboard plate and front edge of coupler attachment hole 18 Sailmaker s Instructions Slug Mount Drill and Tap Mount Distance Between Attachment Points Battens and intermediate cars placed at sailmaker s discretion Maximum distance between attachment points is 1 2 m 1 35 m 4 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 DIAGRAM B Loaded cars must not ride in this area Setting reef points ee 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 Important When setting up reef make sure cars are not loaded when they are in the switch area If reef outhaul loads are applied to switch switch and cars will be damaged resulting in expensive repairs Instruct operators not to raise or lower sails with high loads on cars while in the switch area Harken is not responsible for damage to the switch area due to reef loads or for raising or lowering a sail when the sail is loaded Replacement Parts HC8537 HC7906 HC7905 1 HC7906 HC7905 Part No Qty Description Part No Qty Description 1 H 40882 2 Car 1 H 40882 1 Car 2 H 36184B 1 H
8. mast at two 2 or three 3 locations as shown Make sure slug is not located at feeder gap See page 6 Slug will fasten in wide section of slot 1 2 3 Part No Switch length mm in mm in mm in HC8798 603 mm 2334 79 3 s 219 855 HC8799 857 mm 3334 108 434 335 1331s 475 18 16 Load slugs Tighten screw so slug stays in place at location from chart above Back of switch Narrow section pa _ MN I Round slug Load slug into mast so plastic locator screw is at top Slug will fasten in narrow section of slot Check fit round slug shown Assembly Slug Mount Install Switch D E Install switch over slugs so plastic locator Install connector screw using blue Loctite Install screw in open slug hole using blue screw is through center hole adhesive on screw If necessary loosen Loctite adhesive plastic locator screws Round slug will go below flat slug above Remove plastic locator screw and replace with mounting screw Use blue Loctite adhesive Loctite is a registered trademark of Henkel AG amp Company KGaA 11 Assembly Drill and Tap Mount General Instructions PartNo o Coms Drill and Tap Sizes Track mm in Drill 4 2 5 HC7827 Length 3000 mm 118 s Determine track length See page 6 mm 32 Do not use HC8800 or HC8811 for drill and tap Tap 5 x 80 mm 10 32 Track Fasteners 10 5 mm flathead screws not included 13 3 fasteners mete
9. 15 flathead screws 9 X 20 mm a 10 x mounting slugs 19 mm 3 4 b 1 x splice slug 67 mm 25 7 c 1 x blue Loctite d 10 x HFS1015 flathead screws 5 x 20 mm For sail headboard location at full hoist and when sail is reefed HC8800 HC8811 Track HC9106 HC9107 um Hco10g Track mounting kit HC9702 HC9703 HC9704 Extra slugs for HC881 1 Switch Track Drill and Tap Use for masts without grooves or when slugs will not fit Part No Description Comments HC8230 oplice link Joins HC7827 track sections purchase two 2 for each section of track HC10417 Switch Length 857 mm 3393 4 Switch may be shortened to 605 mm 2393 16 1 x switch 2 x screw pin endstops 1 x upper stop H 42662 Length 3000 mm 1181 2 hole spacing 100 mm purchase stainless steel 10 5 mm screws separately quantity 13 333 HC7827 Drill tap track fasteners meter of track Do not use open backed HC8800 or HC8811 track requires mounting slugs See page 12 for drill tap sizes and mounting instructions Length 2000 mm 783 4 hole spacing 50 mm purchase stainless steel 10 5 mm screws separately quantity 13 333 HC9597 Drill tap track fasteners meter of track Do not use open backed HC8800 or HC8811 track requires mounting slugs See page 12 for drill tap sizes and mounting instructions Loctite is a registered trademark of Henkel AG amp Company KGaA 4 Preassembly Sizing Sail Modifications Sizing Note width and shape
10. ar and switch Headboard binds on Lazy Jacks 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 Watch for any binding or jamming at the switch Stop hoist immediately if any occurs If winch operator does not have a good view of switch cars station a crew member with a good view and communication to operator Crew member must be able to communicate problems to the winch operator immediately 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 Sailmakers Instructions Slug Mount Drill and Tap Mount HC7906 HC7906HL HC7905 HC7905HL HC7904HL HC8537HL HC8537 Dimensions measured from aft face of mast Mounted on slug mount track A B C boltrope setback D Eping Fstud Part No Description in mm in mm in mm in mm mm mm HC7906 Headboard car T he 198 11 4 31 29 16 65 43 16 106 6 HC7905 Intermediate car 21 2 63 11 4 31 29 16 65 3 4 19 6 HC8537 Batten car 10 mm stud 21 2 63 11 4 31 29 16 65 3
11. ars Too much friction off boat If this is not possible use a drop cloth to keep Cars bind overspray off deck McLube will cause ey decks which can result in loss of footing page 16 Stud threaded too BEES into receptacle Back off threaded stud two turns Cap screws and nuts are overightened on plastic cars screws and nuts are overtightened on plastic cars Loosen nut until screw end is even with plastic in nut 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 Locknut has been used too many times Get new 6 mm locknut Batten receptacle does not rotate Nuts are too tight Loosen nuts slightly Use topping lift or rod vang and shockcord 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 or pin on batten receptacle bending Reef loads are being transferred to batten receptacle 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 Loctite is a registered trademark of Henkel AG amp Company KGaA McLube is a registered trad
12. atten car Low friction Yes HC8537HL 10 mm batten car Low friction Yes HC7906HL Headboard cars Low friction Yes HC7905YHL Intermediate car Delrin No McLube is a registered trademark of McGee Industries Inc SailKote is a trademark of McLube a division of McGee Industries Delrin is a registered trademark of E du Pont de Nemours and Company or its affiliates 16 Slug Mount Drill and Tap Mount Loading cars Pegs on foot of car guide it to correct side Pegs must be on inside Tip Load cars on right track plain foot on right left track plain foot on left Attaching sail Important Tighten until screw is even with plastic insert in nut Do not overtighten Car will bind and can warp permanently If screw extends below nut it is overtightened Commissioning Lazy Jacks Use shockcord to hold Lazy Jacks open so Battcars and battens will not catch on them This will also help stop slapping of Lazy Jacks on sail Attach one end to lower spreader tips and other to Lazy Jacks Make sure shockcord is long enough so boom can swing all the way out without damaging spreaders Operation Raising Sail When raising lowering or reefing sail make sure sail is not loaded and cars pass easily through switch Watch sail and cars carefully 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 c
13. eadboard receptacle 2 MP 0708 1 Delrin roller 3 HFS1059 2 Screw SHCS M6 x 40 mm 3 HFS1059 1 Screw SHCS M6 x 40 mm 4 HFS852 2 Nut M6 locking 4 HFS852 1 Nut M6 locking 5 H 24211A 1 Clevis pin 6 HFS181 1 Cotter pin HC8537 SHCS Socket head cap screw Part No ty Description 1 H 40882 1 Car 2 H 36490A 1 Threaded stud 3 HFS1059 1 Screw SHCS M6 x 40 mm 4 HFS852 1 Nut M6 locking SHCS Socket head cap screw Delrin is a registered trademark of E du Pont de Nemours and Company or its affiliates 20 Replacement Parts HC7904HL 2 HC8537HL HC7906HL HC7905HL 5 y HC7906HL Part No Qty Description 1 H 59240 w MP 171 pegs 2 Car with guide pegs HC7904HL 2 H 36184B 1 Headboard receptacle Part No Qty Description 3 HFS1059 2 und 1 H 59240 w MP 171 pegs 1 Car with guide pegs d 2 H 37120A 1 Threaded stud 4 HFS852 2 Nut M6 locking num i Screw SHCS 5 H 45064 4 Igus bushing M6 x 40 mm 6 4913 4 Harken label 4 HFS852 1 Nut M6 locking 1 HFS181 1 Cotter pin 3 g x 1 1 D H 45064 2 Igus bushing 8 H 24211A 1 Clevis pin 6 4913 2 Harken label SHCS Socket head cap screw SHCS Socket head cap screw HC7905HL HC8537HL Part No Qty Description Part No Qty Description 1 H 45530 w MP 171 pegs 1 Car w guide pegs 1 H 59240 w MP 171 pegs 1 Car with guide pegs 2 MP 0708 1 Delrin roller 2 H 36490A 1 Threaded stud Screw SHCS Screw SHCS 3 HFS1059 1 M6 x 40 mm 3 HFS1059 1 M6 x 4 mm 4 HFS852 1 Nut M6 locking 4
14. ed sails with Je independent head 3 and tack swivels CH The independent swivels allow the middle to furlfirst flattening the sail lt and reducing heel Safe and Convenient The ability to reef makes it easy to reduce Speed and gain visibility off the bow all from the safety of your cockpit Small outer drums fit on narrow bows 9 rows of ball bearings cut friction DW and evenly distribute the load TOP 25 FURLING Mite W W V narKen Ht Il n Large inner spool diameter increases pulling power TECH TIP 4 You can have total sail shape and reefing control from your cockpit La by adding ball bearing genoa lead cars to your low friction Harken furling system INNOVATIVE SAILING SOLUTIONS Our Tech Service Team is ready to answer your furling questions Call 262 691 3320 or email harken harken com HARKEN Corporate Headquarters N15W24983 Bluemound Rd Pewaukee WI 53072 USA Telephone 262 691 3320 e Fax 262 701 5780 Web www harken com e Email harken harken com Harken Australia Pty Ltd 1B Green Street Brookvale N S W 2100 Australia Telephone 61 2 8978 8666 e 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
15. emark of McGee Industries Inc SailKote is a trademark of McLube a division of McGee Industries 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 blocks thoroughly with fresh water Periodically disassemble the blocks and clean with detergent and fresh water Lubrication is not required 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 www harken com manuals or the Harken catalog 22 s rA i SII WITH HARKEN MKIV JIB REEFING AND FURLING Easy Shorthanded Cruising Instead of changing sails simply furl or unfurl to suit the conditions ONY Bob Grieser Photo HOW CAN REDUCE HEEL AND GET BETTER CONTROL WITH A REEFED SAIL Harken MKIV roller reefing and furling units solve the inefficient shape of reef
16. gistered trademark of Henkel AG amp Company KGaA 12 Assembly Drill and Tap Mount Insert splice link into switch track Using a plastic hammer tap link into place Carefully align track and tape in place Use a transfer punch to mark a single hole Remove track Drill and tap Fasten with single screw no adhesive Realign track and mark a second hole using transfer punch Screw to mast using two screws no adhesive Mark remaining holes using transfer punch Remove track Drill and tap remaining holes Mount switch to mast using threadlocker Or epoxy on screws as required Install Switch 13 Assembly Drill and Tap Mount HC10417 only If shortening is required use lines scribed on switch track to indicate cut line Make sure you add 254 mm 10 to the upper track length Before mounting track move endstops and tether to new locations Tip Move one at a time so you can see how the line is run through the deadend hole Carefully align track Use transfer punch to mark holes Drill tap and mount as directed above Important Do not use epoxy or threadlocker on screws because gate track is removed for loading cars Install Track Assembly Drill and Tap Mount With track off mast tap upper splice link into track using procedures outlined above Follow general instructions page 15 for drilling and taping a single hole Always make sure tracks are aligned Install Top Stop
17. if screws to hold track are loose enough to slide in groove Remember Tracks may stick when Y reaching a spliced area on mast 100 mm omit every other screw and slug A Assembly Slug Mount Install Track Hold full length track piece up to mast Loosely install top screw Use putty knife to slide additional slugs and splice slug into place Loosely install all nineteen 5 mm x 20 mm screws Slide tracks up enough to fit next track Repeat until full length tracks installed Mast up Hold upper tracks Loosen screw that holds tracks Slide track up If screws bind in mast groove opening loosen them until track slides Tighten new bottom screw securely A CAUTION Do not let tracks drop Severe injury to hands and or fingers can result Loosen top screw Slide top track up and position next 2 05 m 6 87s track Mast up Tighten bottom screw to hold track Loctite is a registered trademark of Henkel AG amp Company KGaA slide 19 mounting slugs and splice slug Hold switch in place and make sure there Into mast groove is 64 mm 2 2 below for loading cars Mast up Tape in place One drop blue Loctite adhesive into each hole Assembly Slug Mount Install Track Wide 9 section Back of switch Note location of bottom of switch and Flat slug Load slug into mast so plastic Storage tracks on mast Refer to chart locator screw is at bottom below and put marks on
18. k underside Warning Some masts might not allow enough screw engagement into slug Screws need a minimum of 10 threads turns engaged to hold track to mast Turn screw 360 at least 10 times after threads engage slug Mounting screw must be long enough for mast groove If necessary purchase longer screws Clear of Trysail Track Cars must clear storm trysail track 42 mm 121 32 Tracks often converge above spreaders Aft face of mast must be flat TUR i or convex Assembly Slug Mount Install Track Note When using HC8811 track put slugs at 50 mm intervals at sail headboard location at full hoist and when sail is reefed Otherwise skip holes So slugs are at 100 mm hole spacing Full hoist High load track with 90 mm hole spacing E i E Slip top track slugs into mast groove Use One drop blue Loctite adhesive into each 32 mm 3 4 mounting slug for top stop splice slug hole Mast up Tape top stop slug even with top of upper track Tape other slugs in place i Loctite is a registered trademark of Henkel AG amp Company KGaA 100 mm omit every other screw and slug 50 mm reef position High load track with E Bn hole spacing Thread 5 mm x 25 mm endstop screw Slide slugs into place with putty knife through endstop track and into slug Loosely install 5 mm x 20 mm screws Mast up Remove tape Tighten screw Tip Use putty knife to see
19. ll 4 2 mm 32 drill tap 9 Phillips screwdriver slug mount 10 32 or 5 mm tap drill tap not shown 6 Hammer Transfer punch 5 mm 3 16 drill tap not shown 7 Hacksaw Mast up installation stepladder secured to the boat Work height 2 13 m 7 above boom McLube is a registered trademark of McGee Industries Inc SailKote is a trademark of McLube a division of McGee Industries 2 Preassembly Parts HC7906 Cars Part No HC7906 HC7905 HC8537 HC7906HL HC7905HL HC8537HL HC7904HL HC8537 edi rer HC7906HL HC7904HL HC8537HL lt a WOOP Nyy S ee NNUAL MY HC7905HL Important Do not overtighten screw and nut Car will bind and may warp permanently Description System Comments Headboard car assembly Use regular headboard Intermediate car Low load Consult sailmaker for quantity required Batten car 10 mm threaded stud Purchase batten receptacle separately Headboard car assembly Use regular headboard Uses low friction slider insert Intermediate car High load Consult sailmaker for quantity required Uses Delrin slider insert Batten car 10 mm threaded stud Purchase batten receptacle separately Uses low friction slider insert Batten car 12 mm threaded stud Purchase batten receptacle separately Uses low friction slider insert If receptacle is removed do not mix base intermediate car with batten receptacle cars See page 16 Delrin is a regis
20. of switch and build a platform on mast to mount Sizing Make sure you have the correct size Battcar system for your boat Maximum sail area Part No Part No system Monohull Multihull Headboard car Batten car 18 mm 41 m 450 ft 30 m 325 ft HC7906 HC8537 18 mm HL 56 m 600 ft 46 m 500 ft HC7906HL HC8537HL HC7904HL Track Length and Switch Height Considerations owitch height is determined by the number of cars required for system and the length of the storage track Note Cars will not pass each other if top of car is higher than A distance See chart below A Switch mm in HC8798 HC8218 296 11 4 HC8799 HC8219 540 21 4 pu i L Til Ld D n ALI Wa Wicca No Mg gn Cars can pass each other if not higher than A 71 ee a E T oo LO So Part No Intermediate car HC7905 HC7905HL 1 i j i k T j um us E nl i E E t j q I i j i I S Locate switch so feeder gap does not interfere with mounting slugs Make sure track is longer than sail luff to allow for stretch as sail ages Track must not block halyard exit Preassembly Track Length Layout system using charts to plan track location and lengths Top track variable length Total Track Length mm SUM Top Track Length A X 1 Length Quantity Standard track slug mount Length Hole Spacing mm in mm
21. r of track pm HC7827 HC8230 Splice links Order one per section of track Switch HC8218 Length 605 mm 231 4 Switch 605 mm 2313 46 and storage track 252 mm 9 5 16 iiL Includes two screw pin endstops and one upper stop un 1 18 Ed Y 4 mm 5 32 12 7 mm A 7 HC7827 Removing Old Track Track on mast Before removing scribe pencil line down either side of track Track off mast Attach string to mast to line up track during installation Mount Track to Carbon Mast Consult with mast builder Use suitable reinforcing plates when fastening track to carbon spars General Instructions When mounting tracks work using a straight edge reference line along mast Do not let tracks vary from this line Tape track in place and center punch hole at bottom using a transfer punch Tip Use low speed drill with tap for cutting threads IMPORTANT Use blue Loctite adhesive instead of oil to lubricate tap Drill and tap single hole Fasten track using this single screw and align side to side correctly Use tape to hold in place Move up several holes and use transfer punch to mark a second hole Remove track Drill and tap hole Fasten track using two screws Mark all remaining holes using punch Remove track Drill and tap all holes Before installing track make sure upper end has splice piece inserted Use threadlocker or epoxy to secure screw opecific instructions follow Loctite is a re
22. rs or injury to 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 at www harken com manuals Purpose Harken Battcars are designed to reduce the size of or to 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 can kill or hurt you and others 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 can hurt you and others if 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 can kill or hurt you and others See www harken com manuals for General Warnings and Instructions Tools e M CON 9 1 Tape measure 8 Center punch 2 Tape slug mount 9 File 3 Power drill screwdriver 10 Putty knife slug mount 4 Drill 5 mm 32 slug mount 11 McLube Sailkote dry lubricant Dri
23. tered trademark of E du Pont de Nemours and Company or its affiliates Preassemhly Parts Switch slug mount Switch drill and tap Track mounting kit slug mount HC9106 HC9107 HC9108 HC9702 HC9703 HC9704 Slug mount track PX gs HC8800 HC8811 18 mm Nhe gt ly 4 mm 5 32 15 mm A 19 3 HC8800 HC8811 Switch mounting kit slug mount HC8918 Drill and tap track HC7827 HC9597 l Je jo 18 mm T u Eu HC8798 B mi e m EA Jf 4 mm 5 2 p Me e e amp LA 12 7 mm A _ i 1 9 e HEROS HC8799 JY Switch Track Slug Mount HC7827 HC10417 Part No Description Comments HC8798 Switch short Length 605 mm 2312 6 1 x switch 2 x screw pin endstops 1 x flathead screw HFS320 5 x 25 mm 1 x upper stop H 42662 HC8799 Switch long Length 857 mm 3393 4 1 x switch 2 x screw pin endstops 1 x flathead screw HFS320 5 x 25 mm 1 x upper stop H 42662 HC8918 HC8919 dris Switch mounting kit a 3 x plastic locator screws HFS1170 5 X 10 mm b 3 x mounting slugs c 1 x blue Loctite adhesive d 6 x flathead screws HFS862 5 x 10 mm Purchase 1 kit for each section of track Length 2051 mm 8013 16 HC8800 hole spacing 100 mm HC8811 Hole Spacing 50 mm Note HC8811 order additional slugs and screws for 50 mm hole spacing a 19 x mounting slugs 19 mm 3 4 b 1 x splice slug 67 mm 25 7 c 2 x blue Loctite d 21 x HFS10
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