Harken HC7906 User Manual

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.