BATTCAR SWITCH SYSTEM
INSTALLATION MANUAL
18 mm
Installation Manual – Intended for specialized personnel or expert users
Introduction
Safety precautions 2
Preassembly
Tools 2
Parts 3 - 4
Sizing/sail modification/switch height 5
Top track length 6
Track length 6
Assembly—Slug-Mount Track
Cut top track to length 7
Check fit of mounting slugs and car 7
Install track 8 - 9
Install switch 10 - 11
Assembly—Drill and Tap Track
Removing old track 12
Mount track to carbon mast 12
General instructions 12
Install switch 13
Install track 14 - 15
Install top stop 15
Commissioning
Loading headboard assembly 16
Loading cars 16
Attaching sail 16
Lazy Jacks 17
Operation
Raising sail 17
Sailmakers Instructions
Dimensions 18
Installing headboard car assembly 18
Distance between attachment points 19
Setting reef points 19
Replacement Parts 20 - 21
Troubleshooting/Warranty 22
4679 11/14
t
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
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 users, 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
1
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 (
Drill -
4.2 mm (
5. Phillips screwdriver (slug mount) 10-32 or 5 mm tap (drill/tap) – not shown
6. Hammer Transfer punch 5 mm (
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
2
3
7
9
8
7
/32") (slug mount) 11. McLube® Sailkote™ dry lubricant
5
/32") (drill/tap)
4
10
11
3
/16") (drill/tap) – not shown
5
6
Preassembly Parts
HEADBOARD CAR
(ASSEMBLY)
HC7906
HC7906HL
BATTEN CARS
WITHOUT RECEPTACLE
HC8537
HC7904HL
HC8537HL
INTERMEDIATE
CARS
HC7905
HC7905HL
Cars
Part No. Description System Comments
HC7906
HC7905
HC8537
HC7906HL
HC7905HL
HC8537HL
HC7904HL
*If receptacle is removed, do not mix base intermediate car with batten receptacle cars. See page 16.
Headboard car assembly
Intermediate car Consult sailmaker for quantity required.
Batten car 10 mm threaded stud. Purchase batten receptacle separately.
Headboard car assembly
Intermediate car Consult sailmaker for quantity required. Uses Delrin
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.
Low-load
High-load
Use regular headboard.
Use regular headboard. Uses low friction slider insert.
SPARE CAR SCREWS
Important! Do not overtighten
screw and nut. Car will bind
and may warp permanently.
®
slider insert.*
Delrin is a registered trademark of E. I. du Pont de Nemours and Company or its affiliates.
3
Preassembly Parts
Switch (slug mount) Switch (drill and tap)
Track mounting kit (slug mount)
HC9106, HC9107, HC9108
HC9702, HC9703, HC9704
Slug mount track
a
c
Switch mounting kit (slug mount)
HC8918
a b
HC8919, HC8921
Switch/Track (Slug Mount)
HC8800
18 mm
11
/16"
HC8811
4 mm (
5
/32")
b
15 mm
19
/32"
d
HC8800
HC8811
Drill and tap track
d
c
12.7 mm
1
/2"
18 mm
11
/16"
HC7827
HC7827
HC9597
4 mm (
5
/32")
HC8798
HC8230
HC8799
HC10417
Part No. Description Comments
HC8798
HC8799
HC8918, HC8919
HC8921
HC8800, HC8811
HC9106, HC9107
HC9108
HC9702, HC9703
HC9704
Switch (short) Length: 605 mm (23
Switch (long) Length: 857 mm (333/4"); 1 x switch; 2 x screw-pin endstops; 1 x flathead screw HFS320 (5 x 25 mm); 1 x upper stop H-42662
Switch mounting kit
Track
Track mounting kit
Extra slugs for HC8811
(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 (25/8"); (c) 2 x blue Loctite; (d) 21 x HFS1015 flathead screws
(5 x 20 mm).
(a) 10 x mounting slugs 19 mm (3/4"); (b) 1 x splice slug 67 mm (25/8"); (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.
13
/16"); 1 x switch; 2 x screw-pin endstops; 1 x flathead screw HFS320 (5 x 25 mm); 1 x upper stop H-42662
Switch/Track (Drill and Tap)—Use for masts without grooves or when slugs will not fit
Part No. Description Comments
HC8230
HC10417
HC7827
HC9597
Loctite is a registered trademark of Henkel AG & Company KGaA.
4
Splice link Joins HC7827 track sections; purchase two (2) for each section of track
Switch Length: 857 mm (33
Length: 3000 mm (1181/8"); hole spacing: 100 mm; purchase stainless steel #10 (5 mm) screws separately (quantity 13.333
Drill/tap track
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
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.
3
/4"); Switch may be shortened to 605 mm (2313/16"); 1 x switch; 2 x screw pin endstops; 1 x upper stop H-42662
Preassembly Sizing/Sail Modifications
Sizing
Note width and shape of switch and build
a platform on mast to mount.
Sizing
Make sure you have the correct size Battcar system for your boat.
System
18 mm
18 mm HL
Maximum sail area
Monohull Multihull
2
(450 ft2) 30 m2 (325 ft2)
41 m
2
(600 ft2) 46 m2 (500 ft2)
56 m
Track Length and Switch
Height Considerations
Switch 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
HC8798
HC8218
HC8799
HC8219
mm in
286 11
540 21
1
/
4
1
/
4
Part No.
Headboard car
HC7906 HC8537 HC7905
HC7906HL
Part No.
Batten car
HC8537HL,
HC7904HL
Intermediate car
Part No.
HC7905HL
Allow 63 mm (21/2") below track to remove car.
INCORRECT
Feeder
Gap
A
Cars can pass each other if not higher than “A”.
Switch
Locate switch so feeder gap does not
interfere with mounting slugs.
A
3852
305 mm
12"
Make sure track is longer than sail luff to
allow for stretch as sail ages. Track must
not block halyard exit.
5
Preassembly Track Length
Layout system using charts to plan track location and lengths.
A
B
C
Top track—variable-length
Length Hole Spacing
mm in mm
Standard track—slug-mount
Length Hole Spacing
mm in mm
2051 80
Standard track—drill and tap
Length Hole Spacing
3000 118
High-load track—slug-mount
Length Hole Spacing
mm in mm
2051 80
Place in reefed headboard areas on larger boats.
High-load track—drill and tap
2000 78
13
/
16
1
/
8
13
/
16
3
/
4
Total Track Length __________
75
Length Quantity
100
75
Length Quantity
50
50
Top Track Length A __________
- SUM __________
X =
1
+
X =
+
D
Switch—slug-mount
Length
mm in
605 2313/
857 333/
Switch—drill and tap
Length
mm in
605 2313/
857 333/
Short drill and tap switch is created by shortening switch.
16
4
16
4
Length Quantity
—
—
—
—
—
—
—
—
X =
+
=1
Quantity
SUM
Enter SUM above to
calculate Top Track Length.
2
6
Assembly—Slug-Mount Cut Top Track to Length
Cut variable length top track.
Check Fit of Mounting Slugs and Car
Check fit
Deburr cut.
Slightly round track corners that will
slide against mast.
CORRECT
Slug
Will Tighten
INCORRECT
Slug
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 track underside.
Mounting screw must be long enough for
mast groove. If necessary, purchase longer
screws.
10 mm (
3
/8")
Drill 5.5 mm (7/32") hole in cut end
of track for endstop.
CORRECT INCORRECT
10 or
more
Slug
Slug
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.
67 mm (25/8") splice slug must fit feeder
opening. File opening to make longer.
Use halyard with retrieval line to run
67 mm (25/8") splice slug up mast to
check for burrs in groove.
Mast prebend: Might require straightening
before installation.
Clear of Trysail Track?
Cars must clear storm trysail track.
Tracks often converge above spreaders.
Aft face of mast must be flat
or convex.
42 mm (121/32")
7
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
50 mm hole spacing.
Slip top track slugs into mast groove. Use
32 mm (3/4") mounting slug for top stop.
Mast-up: Tape top stop slug even with top
of upper track. Tape other slugs in place.
Loctite is a registered trademark of Henkel AG & Company KGaA.
One drop blue Loctite® adhesive into each
splice slug hole.
100 mm
omit every other
screw and slug.
Thread 5 mm x 25 mm endstop screw
through endstop, track, and into slug.
Mast-up: Remove tape. Tighten screw
to hold track.
8
Slide slugs into place with putty knife.
Loosely install 5 mm x 20 mm screws.
Tip: Use putty knife to see if screws
are loose enough to slide in groove.
Remember: Tracks may stick when
reaching a spliced area on mast.
50 mm
reef position.
High-load track with
50 mm hole spacing.
100 mm
omit every other
screw and slug.
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.
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.
CAUTION! Do not let tracks
drop. Severe injury to hands
and/or fingers can result.
Repeat until full-length tracks installed.
Loosen top screw. Slide top track up and
position next 2.05 m (6'87/8") track.
Mast-up: Tighten bottom screw to
hold track.
Loctite is a registered trademark of Henkel AG & Company KGaA.
Slide 19 mounting slugs and splice slug
into mast groove.
Mast-up: Tape in place.
One drop blue Loctite® adhesive into
each hole.
Hold switch in place and make sure there
is 64 mm (21/2") below for loading cars.
9
Assembly—Slug-Mount Install Track
2
1
Switch
bottom
Note location of bottom of switch and
storage tracks on mast. Refer to chart
below and put marks on mast at two (2)
or three (3) locations as shown. Make
sure slug is not located at feeder gap.
See page 6.
Wide
section
Back of
switch
Flat slug: Load slug into mast so plastic
locator screw is at bottom.
Slug will fasten in “wide section” of slot.
Back of
switch
Narrow
section
Round slug: Load slug into mast so plastic
locator screw is at top.
Slug will fasten in “narrow section” of slot.
Part
No.
HC8798
HC8799
Switch length
603 mm
(
23
857 mm (33
1 2 3
mm in mm in mm in
3
/
4
)
79 31/8219 85/8— —
3
108 43/4335 133/16475 1811/
/
4
)
16
Load slugs.
10
Tighten screw so slug stays in place at
location from chart above.
Check fit (round slug shown).
Assembly—Slug-Mount Install Switch
Install switch over slugs so plastic locator
screw is through center hole.
Install connector screw using blue Loctite®
adhesive on screw. If necessary loosen
plastic locator screws.
Install screw in open slug hole using blue
Loctite adhesive.
Round slug will go below/flat slug above.
Loctite is a registered trademark of Henkel AG & Company KGaA.
Remove plastic locator screw and replace with
mounting screw. Use blue Loctite adhesive.
11
Assembly—Drill and Tap Mount General Instructions
Part No. Comments
HC7827
—
HC8230
HC8218
HC8219
Track
1
Length: 3000 mm (118
Do not use HC8800 or HC8811 for drill and tap.
#10 (5 mm) flathead screws (not included); 131/3 fasteners/meter of track.
Splice links. Order one per section of track.
Length: 605 mm (23
Switch: 605 mm (23
Includes two screw-pin endstops and one upper stop.
/8") Determine track length. See page 6.
Track Fasteners
Switch
13
/16")
13
/16") and storage track: 252 mm (915/16").
Drill
Tap
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.
Drill and Tap Sizes
mm in
4.2 mm
5 x .80 mm 10-32
HC7827
12.7 mm
(1/2")
5
/32
18 mm
(11/16")
4 mm (
HC7827
5
/32")
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.
Specific instructions follow.
Loctite is a registered trademark of Henkel AG & Company KGaA.
12
Assembly—Drill and Tap Mount Install Switch
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.
13
Assembly—Drill and Tap Mount Install Track
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.
14
Assembly—Drill and Tap Mount Install Track
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
Use H-42662 as top stop.
15
Commissioning Slug-Mount / Drill and Tap Mount
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.
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
WARNING! Overspray from
McLube will cause slippery
must be on left. If loading on right, plain
foot must be on right.
decks which can result in
loss of footing. Cover decks
or spray cars off boat.
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.
Hole in hole
Hole in Hole
Hole in batten/
headboard car
Intermediate car
with Delrin® slider.
No hole in
intermediate car
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 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
HC8537HL
HC7906HL
HC7905YHL
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. I. du Pont de Nemours and Company or its affiliates.
16
12 mm batten car Low friction Yes
10 mm batten car Low friction Yes
Headboard cars Low friction Yes
Intermediate car Delrin No
If screw extends below
nut, it is overtightened.
Commissioning Lazy Jacks
H
A
R
K
E
N
H
A
R
K
E
N
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 car 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.
IMPORTANT! Watch for
binding at switch. Stop
hoisting 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.
17
Sailmakers Instructions Slug-Mount / Drill and Tap Mount
C
B
HC7906
HC7906HL
D
C
B
B
E
A
A
D
E
A
F
HC7905
HC7905HL
HC7904HL
HC8537HL
HC8537
E
D
Dimensions (measured from aft face of mast)
Part No. Description in mm in mm in mm in mm mm mm
A B C boltrope setback D E pin Ø F stud Ø
HC7906
HC7905
HC8537
HC7906HL
HC7905HL
HC7904HL
HC8537HL
Headboard car 7
Intermediate car 2
Batten car (10 mm stud) 2
Headboard car 7
Intermediate car 2
Batten car (12 mm stud) 2
Batten car (10 mm stud) 2
13
/
16
1
/
2
1
/
2
13
/
16
1
/
2
1
/
2
1
/
2
A B C boltrope setback D E pin Ø F stud Ø
Part No. Description in mm in mm in mm in mm mm mm
HC7906
HC7905
HC8537
HC7906HL
HC7905HL
HC7904HL
HC8537HL
Headboard car 7
Intermediate car 2
Batten car (10 mm stud) 2
Headboard car 7
Intermediate car 2
Batten car (12 mm stud) 2
Batten car (10 mm stud) 2
13
/
16
1
/
2
1
/
2
13
/
16
1
/
2
1
/
2
1
/
2
Mounted on slug mount track
198 11/
63 11/
63 11/
198 11/
63 11/
63 1
63 1
4
4
4
4
4
1
/
4
1
/
4
Mounted on drill tap track
198 11/
63 11/
63 11/
198 11/
63 11/
63 1
63 1
8
8
8
8
8
1
/
8
1
/
8
31 29/
31 29/
31 29/
31 29/
31 29/
31 2
31 2
29 215/
29 215/
29 215/
29 215/
29 215/
29 2
29 2
16
16
16
16
16
9
/
16
9
/
16
32
32
32
32
32
15
/
32
15
/
32
65 43/
65 3/
65 39/
65 43/
65 3/
65 3
65 3
62 41/
62 3/
62 37/
62 41/
62 3/
62 3
62 3
16
4
16
16
4
3
/
4
9
/
16
16
4
16
16
4
5
/
8
7
/
16
106 6 —
19 6 —
90 6 10
106 6 —
19 6 —
95 6 12
90 6 10
103 6 —
19 6 —
88 6 10
103 6 —
19 6 —
92 6 12
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").
100mm
(4")
51 mm (2")
Min 9.5 mm
3
(
/8")
Coupler attachment hole
Drill 11 mm (
is 101 mm (4") from top of headboard and 51 mm (2")
from front edge of boltrope.
Leave at least 9 mm (
plate and front edge of coupler attachment hole.
18
7
/
16
") coupler attachment hole so center
3
/
8
") between front of headboard
Coupler
attachment hole
Halyard attachment hole
Use aft hole if headboard has two (2).
If not, drill second hole to accept halyard shackle pin.
Locate hole approximately 64 mm (2
64 mm
1
(2
/2")
Halyard
attachment
hole
1
/
2
") aft of existing hole.
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.
CORRECT
DIAGRAM A
INCORRECT
Loaded cars must
not ride in this area
while sailing.
DIAGRAM B
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.
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.
19
Replacement Parts
6
HC7906
5
2
HC8537
2
4
3
HC7905
4
2
3
4
3
1
1
Part No. Qty Description
1
2
3
4
5
6
H-40882 2 Car
H-36184B 1 Headboard receptacle
HFS1059 2 Screw SHCS M6 x 40 mm*
HFS852 2 Nut M6 locking
H-24211A 1 Clevis pin
HFS181 1 Cotter pin
*SHCS = Socket head cap screw.
HC7906
Part No. Qty Description
1
2
3
4
1
2
3
4
H-40882 1 Car
MP-0708 1 Delrin
HFS1059 1 Screw SHCS M6 x 40 mm*
HFS852 1 Nut M6 locking
Part No. Qty Description
H-40882 1 Car
H-36490A 1 Threaded stud
HFS1059 1 Screw SHCS M6 x 40 mm*
HFS852 1 Nut M6 locking
*SHCS = Socket head cap screw.
HC7905
HC8537
1
®
roller
Delrin is a registered trademark of E. I. du Pont de Nemours and Company or its affiliates.
20
Replacement Parts
7
8
2
HC7904HL
HC7906HL
4
6
HC7906HL
Part No. Qty Description
1
H-59240 (w/MP-171 pegs) 2 Car with guide pegs
2
3
4
5
6
7
8
H-36184B 1 Headboard receptacle
HFS1059 2
HFS852 2 Nut M6 locking
H-45064 4 Igus bushing
4913 4 Harken label
HFS181 1 Cotter pin
H-24211A 1
1
Screw SHCS
M6 x 40 mm*
3
/8 x 1.1"
Clevis pin
5
2
HC8537HL
3
4
HC7905HL
2
5
2
3
5
4
6
1
6
1
3
5
4
6
1
3
HC7904HL
Part No. Qty Description
1
H-59240 (w/MP-171 pegs) 1 Car with guide pegs
2
3
4
5
6
H-37120A 1 Threaded stud
HFS1059 1
HFS852 1 Nut M6 locking
H-45064 2 Igus bushing
4913 2 Harken label
Screw SHCS
M6 x 40 mm*
*SHCS = Socket head cap screw.
HC7905HL
Part No. Qty Description
1
H-45530 (w/MP-171 pegs) 1 Car w/guide pegs
2
3
4
5
6
*SHCS = Socket head cap screw.
Delrin is a registered trademark of E. I. du Pont de Nemours and Company or its affiliates.
MP-0708 1 Delrin
HFS1059 1
HFS852 1 Nut M6 locking
H-45064 2 Igus bushing
4913 2 Harken label
Screw SHCS
M6 x 40 mm*
®
roller
*SHCS = Socket head cap screw.
Part No. Qty Description
1
H-59240 (w/MP-171 pegs) 1 Car with guide pegs
2
3
4
5
6
*SHCS = Socket head cap screw.
H-36490A 1 Threaded stud
HFS1059 1
HFS852 1 Nut M6 locking
H-45064 2 Igus bushing
4913 2 Harken label
HC8537HL
Screw SHCS
M6 x 4 mm*
21
Problem Probable Cause
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.
Track weight pulling tracks apart.
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.
Solution
Tracks will come together when you loosen the
bottom screw and push the tracks up the mast.
Slugs catching on mast 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.
Loosen screws slightly. If necessary have someone
at splice area to wiggle the slug past the splice.
Troubleshooting
Problem Probable Cause Solution
Slider damaged or missing. Check and/or replace slider.
Spray a small amount of McLube
in underbody track slot of all cars. If possible spray cars
Too much friction.
Cars bind.
Stud threaded too tightly into receptacle. Back off threaded stud two turns.
Cap screws and nuts are overtightened on plastic cars. Loosen nut until screw end is even with plastic in nut.
off boat. If this is not possible, use a drop cloth to keep
overspray off deck. McLube will cause slippery decks
which can result in loss of footing (page 16).
®
Sailkote™ lubricant
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.
Cars jam when raising sail. Headboard or cars are catching on Lazy Jacks.
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.
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. I. du Pont de Nemours and Company or its affiliates. Loctite is a registered trademark of Henkel AG & Company KGaA.
McLube is a registered trademark of McGee Industries, Inc. SailKote is a trademark of McLube, a division of McGee Industries.
Use topping lift or rod vang and shockcord to pull
Lazy Jacks out to shrouds.
Transfer reef downhaul and outhaul loads to mast
or boom gooseneck.
Maintenance
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
Sail Control
Ultimate
FURLING
Q
&
A
HOW CAN I REDUCE HEEL
AND GET BETTER CONTROL
WITH A REEFED SAIL?
Harken MKIV roller reefing
and furling units solve the
inefficient shape of
reefed sails with
independent head
and tack swivels.
The independent
swivels allow the
middle to furl first,
flattening the sail
and reducing heel.
WITH HARKEN MKIV
JIB REEFING AND FURLING
Easy Shorthanded Cruising
Instead of changing sails, simply furl
or unfurl to suit the conditions.
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.
Bob Grieser Photo
Small outer drums fit on narrow bows
TOP 25 FURLING Q&A:
www.harken.com/usa
Our Tech Service Team is ready to answer your furling questions. Call 262-691-3320 or email harken@harken.com
9 rows of ball bearings cut friction
and evenly distribute the load
Large inner spool diameter
increases pulling power
TECH TIP #4
You can have total sail shape and
reefing control from your cockpit
by adding ball bearing genoa lead
cars to your low-friction Harken
furling system.
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
ul. Rydygiera 8, budynek 3A, lokal 101, I pi
Mailing address: Harken Sweden AB, Box 64, SE -440 30 Marstrand
Bearing House, Ampress Lane, Lymington, Hampshire S041 8LW, England
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 • 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 • Fax: (64) 9-307-7987
Web: harken.co.nz • Email: harken@harken.co.nz
Harken Polska SP ZOO
ętro, 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-113 26 Stockholm Sweden
Telephone: (46) 0303 61875 • Fax: (46) 0303 61876
Web: harken.se • Email: harken@harken.se
Harken UK, Ltd.
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
Printed in USA 4679 12/14
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