Harken HC9045 User Manual
BATTCAR SWITCH SYSTEM
INSTALLATION MANUAL
26 mm, 32 mm
Installation Manual – Intended for specialized personnel or expert users
Introduction
Safety precautions 2
Preassembly
Tools 2
Parts 3-4
Sizing 5
Track length/switch height considerations 5
Track length 6
Mounting track and switch 7
Mounting track to mast 7
Assembly
Install track (general instructions) 7
Mounting switch 8
Mounting storage track 9
Mounting gate track 9
Mounting standard/high-load track 10
Mounting top track 10
Commissioning
Loading cars on track 11
Loading headboard 12
Removing toggle from cars 13
Operation
Raising sail 13
Sailmaker’s Instructions
Dimensions 14
Installing headboard car assembly 14
Distance between attachment points 15
Setting reef points 15
Trysail Switch System
Preassembly 16
Installing track 16
Loading cars 16
Sailmakers’s instructions 16
Replacement parts 17 - 18
Troubleshooting/inspection/maintenance/warranty 19
4677 12/13
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
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 may 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
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
you do not follow instructions. The message will tell you how to reduce the
chance of injury.
Tools
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.
4
1
6
2
8
7
3
9
10
11
1.Tape measure 8. Tape
2. Power drill 9. File
3. Drill bits 10. Hex key
4. Hammer 11. McLube
5. Plastic hammer 12. Tap for mast mounting holes (not shown)
6. Hacksaw
7. Transfer punch Threadlocking adhesive for mast screws
2 26 mm/32 mm Battcar Switch System 07/14/11
™
Sailkote
™
Preassembly Parts
HC9045
HC9046
Headboard car
(assembly)
Intermediate car
Reef car 26 mm
Tack car
HC7493
HC7322
HC8125
HC8099
Trysail car
Reef car 32 mm
C9342
C9494
HC7325
HC8076
Batten car with
threaded stud
3876
HC7324
HC8098
Web-on
standard
HC7316
C7814
Main Components
Part No. Description System Comments
HC9045
Headboard car
HC7493
Intermediate car Consult sailmaker for quantity required.
HC7324
Batten car 12mm Threaded stud. Purchase batten receptacle separately.
HC7325
Reef car Use to secure tack when reefing.
HC8125
Tack car Use with halyard lock to tension luff.
C9494
Trysail car Use with trysail switch.
HC9046
Headboard car
HC7322
Intermediate car
HC8098
Batten car 12mm Threaded stud. Purchase batten receptacle separately.
HC7316
Batten car 14mm Threaded stud. Purchase batten receptacle separately.
HC8076
Reef car Use to secure tack when reefing.
HC8099
Tack car Use with halyard lock to tension luff.
C9342
Trysail car Use with trysail switch.
Headboard Plates
3876
Standard web-on headboard See sailmaker instructions.
3877
Square top web-on headboard See sailmaker instructions.
11/24/10 26 mm/32 mm Battcar Switch System 3
Must use 3876 or 3877 headboard.
26 mm
Must use 3876 or 3877 headboard.
32 mm
26 mm
32 mm
3877
Web-on
square top
Preassembly Parts
C
B
Storage track
HC8147
Storage track
HC10060
HC8148
HC8149
HC8150
Gate track
HC8221
HC8226
Endstop
Trysail switch
1522A
548A
Splice links
HC8222
HC8227
A
5
/8"
16 mm
11/32"
11/32"
11/32"
26mm
26mm
26 mm
5
/32" (4 mm)
HC8147 HC8148
HC7466 HC8221
11/32"
26 mm
5
5
16 mm
13
/16"
20 mm
/8"
11/4"
32 mm
/32" (4 mm)
1
/4"
6 mm
HC10060
311/16"
93.3 mm
D
Track switch
HC8149 HC8150
HC7391 HC8226
T-Track, Splice Links and Enstops
Part
No. Description
26 mm
HC7466 3 m T-Track 1181/83000 11/
HC8879 2 m T-Track/high-load 78
HC8222 Splice link — — 1
1522A Endstop 2
32 mm
HC7391 3m T-Track 1181/83000 11/
HC8880 2m T-Track/high-load 78
HC8227 Splice link — — — — — — 0.2 5 — — —
548A Endstop 2
*Includes spacer tube for cutting adapters. See page 7.
Length Width Height Weight Fasteners
in mm in mm in mm oz g in mm mm
3
/42000 11/
5
/
32
55 117/
3
/42000 11/
27
/
32
72 21/
32
32
1
/
32
32
4
4
32
5
26
/816 61.1 17361/
5
26
/816 40.3 11411/
26 — — 0.1 3 — — —
39 — — — — — — —
13
32
/1620 96.2 27345/
13
32
/1620 63.1 17905/
52 — — — — — — —
C9341 C9342
C9492 C9493
4
4
16
16
Fastener
spacing
6 75
6 50
8 75
8 50
HC8220 26 mm
HC7382 32 mm
Switch, Storage and Gate Track
Length
Part
No. Description
(A)
in mm in mm in mm in mm oz g in mm mm
26 mm
HC8220 Switch 251/4641 4 102 4 1025/
HC8147 500 mm Storage track 19
HC8148 725 mm Storage track 28
HC10060 725 mm Double storage track 28
HC8221 Gate track 11
11
/16500 11/
17
/32725 11/
17
/32725 311/1693.3 — —
13
/16300 11/
32 mm
HC7382 Switch 281/2724 5 127 5 12713/
HC8149 800 mm Storage track 31
HC8150 1025 mm Storage track 40
HC8226 Gate track 11
Trysail Switch C9340, C9341, C9492, C9493 Trysail Tracks – See page 16
4 26 mm/32 mm Battcar Switch System 11/24/10
1
/2800 11/
11
/321025 11/
13
/16300 11/
Width
(B)
32
26 — —
32
26 — —
32
26 — —
4
32 — —
4
32 — —
4
32 — —
Switch Width
(C)
Height
(D) Weight Fasteners
8
16 43.1 1225
5
/
8
16 10.2 291
5
/
8
16 14.8 419
5
/
8
16 57.2 1623
5
/
8
16 6.1 174
16
20 72.8 2068
13
/
16
20 25.6 728
13
/
16
20 32.8 933
13
/
16
20 9.6 273
Fastener
spacing
1
/
4
1
/
4
1
/
4
1
/
4
1
/
4
5
/
16
5
/
16
5
/
16
5
/
16
6 —
6 50
6 50
6 50
6 75
8 —
8 50
8 50
8 75
Preassembly Sizing
Sizing
Make sure you have the correct size battcar system for your boat.
System
26 mm
32 mm
Minimum Maximum
50 ft (15.2 m) 80 ft (24 m) HC9045 HC7324 HC7493 HC7325 HC8125
80 ft (24 m) 130 ft (40 m) HC9046 HC8098, HC7316 HC7322 HC8076 HC8099
Fits Boats
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 pass each other when
top of car is at “A” distance above
bottom of switch. See chart at right.
Part No.
Headboard Car
26 mm
32 mm
Unit
Part No.
Battcar
A
in mm
3.94 100
6.44 163
Part No.
Intermediate Car
Part No.
Reef Car
Part No.
Tack Car
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
12"
305 mm
3852
03/30/09 26 mm/32 mm Battcar Switch System 5
Preassembly Track Length
Layout system using charts to plan track location and lengths.
A
B
C
C1
Variable-Length Top Track (26/32 mm Systems)
Length Hole Spacing
mm in mm
75
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
mm in mm
3000 118.11 75
Length Quantity
High-Load Track (26/32 mm Systems)
Length Hole Spacing
mm in mm
2000 78.74 50
Place in reefed headboard areas.
Length
Trysail Switch—26mm System Hole Spacing
Length —
mm in mm
368 14.50 Variable
Trysail Switch—32mm System Hole Spacing
Length —
mm in mm
406 16.00 Variable
Total track length __________
- SUM __________
Top track length A
_________
X =
+
X =
Quantity
+
=1
Quantity
Gate Track—26/32 mm Systems
Length Hole Spacing
D
E
F
6 26 mm/32 mm Battcar Switch System 11/24/10
mm in mm
300 11.81 75
Removable track - Allows cars to be left attached to sail and removed
from top of switch.
Switch—26mm System
Length —
mm in —
641 25.24 —
Switch—32mm System
Length —
mm in —
724 28.50 —
Storage Track—26 mm System
Length Hole Spacing
mm in mm
500 19.69 50
725 28.54 50
Storage Track—32 mm System
Length Hole Spacing
mm in mm
800 31.50 50
1025 40.35 50
Quantity
Quantity
Quantity
SUM
=1
=1
=
1
calculate “Top track length.”
+
+
+
Enter “SUM” above to
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