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
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
Wedge Wedge
switch and storage tracks are on the
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 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 transfer
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 7,
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 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 Loading Headboard
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.
12 26 mm/32 mm Battcar Switch System 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 Raising Sail
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
Important
Watch for binding at
switch. Stop hoisting
immediately.
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 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.
07/21/10 26 mm/32 mm Battcar Switch System 13
Sailmakers Instructions Dimensions
C
B
B
D
A
A
D
A
C
E
F
G
Batten car
32 mm Reef car
Headboard car
assembly
(Headboard not
included)
A
B
C
D
C
B
D
Intermediate car
26 mm reef car
Part
No. Description
A B C D E F
in mm in mm in mm in mm in mm in mm mm
Stud Ø
26 mm
G
HC9045 Headboard car assembly 105/8270 17/
HC7493 Intermediate car 2
HC7324 Batten car 2
HC7325 Reef car 3
HC8125 Tack car 3
3
/
8
60 17/
15
/
16
75 17/
17
/
32
90 17/
17
/
32
90 17/
16
37 35/
16
16
16
16
37 127/
37 127/
37 127/
37 127/
32
32
32
32
47
47 — — 229/
/
16
21 — — — — —
32
73 41/
16
103 12
8
92 — — — — —
13
47 1 25 — — — — —
47 1 25 — — — — —
32 mm
HC9046 Headboard car assembly 11 280 17/
HC7322 Intermediate car 2
HC8098 Batten car/12mm stud 3
HC7316 Batten car/14mm stud 3
HC8076 Reef car 4
HC8099 Tack car 4
15
/
17
/
17
/
17
/
17
/
16
32
32
32
32
75 17/
90 17/
90 17/
115 17/
115 17/
8
47 315/
8
47 23/
8
47 — — — — 37/
8
47 — — — — 37/
8
47 23/
8
47 23/
8
60 1 25 — — — — —
8
60 1 25 — — — — —
8
60 1 25 — — — — —
16
100 — — — — —
16
16
87 419/
87 421/
32
32
117 12
118 14
Sailmakers Instructions Installing Headboard Car Assembly
Use 13/4" (45 mm) webbing. Holes in
headboard accept 416 16 mm cheek
blocks for leech line. Use 4 mm
x 10 mm fasteners.
If more reinforcement is necessary,
web through lightening holes.
System
26 mm
32 mm
3876 3877
in mm in mm
A
57/16 138 53/4 146
B
29/32 58 29/32 58
A
53/4 146 61/16 154
B
219/32 66 219/32 66
A
B
3876
Web-on
standard
A
3877
Web-on
square top
B
14 26 mm/32 mm Battcar Switch System 03/30/09
Sailmakers Instructions Slug-/Drill/Tap Mount
Distance Between Attachment Points
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
luff cars.
DIAGRAM A
CORRECT
INCORRECT
While sailing
loaded cars
must not ride
in this area.
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 switch 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.
08/19/10 26 mm/32 mm Battcar Switch System 15
Trysail Switch System
Part
No. Description
26 mm
C9493 Port trysail switch*‡ 141/
C9492 Starboard trysail switch*‡ 14
C9494 Car body*‡ 2
32 mm
C9341 Port trysail switch*‡ 16 406 57/
C9340 Starboard trysail switch*‡ 16 406 5
C9342 Car body*‡ 2
*Available in black or clear anodized ‡Allow 8 weeks lead time
Length Width Weight Fasteners
in mm in mm oz g mm lb kg
2
1
/
2
3
/
8
15
/
16
368 425/
368 425/
Preassembly
Use standard track and bend to transition
between side tracks and switch. The cars
should not be under load in this section.
Installer is responsible for determining
thebend of the track. A 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.
60 11/
75 31/
32
32
32
8
7
/
8
32
C9493
C9492
C9341
C9340
Maximum
working load
121 27 762 6 — —
121 27 762 6 — —
26 5 143 — 1001 454
149 43 1222 8 — —
149 43 1222 8 — —
77 11 309 — 595 270
Trysail car
Trysail switch
Guide pins
C9342
C9494
Installing Track
Consult with mast builder. Use suitable
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
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.
Trysail storage
track
Main
track
No load in this area of trysail track
16 26 mm/32 mm Battcar Switch System 07/20/11
Replacement Parts
1
a
b
c
b
4
7
HC9045—26 mm System
Part No. Description Quantity
1
HC9045 Coupler assembly 1
a
MS-292 Smalley ring 2
b
3
2
d
5
6
*8 more are listed in bill. They are used to hold
non-replaceable insert bearing in place.
MS-284 Cup 4
c
MS-285 Spherical becket 2
d
AL-2037 Coupler only 1
2
H-37545A Clevis pin 1
3
HFS203 Cotter pin 1
4
HFS1146 M8 x 52 SHCS 2
5
H-46463 Igus
6
HFS920 M8 lock nut 2
7
H-43304
8
H-31089A Guide pin 4
®
bushing 8
Car assembly with
sliders and pins
2
8
HC9046—32 mm System
Part No. Description Quantity
1
HC9046NP Coupler assembly 1
a
MS-291 Smalley ring 2
b
MS-288 Cup 4
c
1
3
a
b
c
b
d
2
e
4
5
6
7
MS-287 Spherical becket 2
d
AL-2047 Coupler only 1
e
MS-265 Igus
2
H-37545A Clevis pin 1
3
HFS203 Cotter pin 1
4
H-36101A M10 x 68 SHCS 2
5
HCP1730 Igus
6
HFS191 Flatwasher 2
7
HFS920 Thin lock nut 2
8
Contact Harken Car body 2
9
H-37242A Guide pin 4
®
bushing 2
®
bushing 4
8
9
03/21/12 26 mm/32 mm Battcar Switch System 17
Replacement Parts
HC7324 HC8098 HC7316 C7814
Part No. Part No. Part No. Part No. Description Quantity
1
H-37359A H-47961 H-47960 H-39218A Toggle/stud assembly w/bushing 1
1a
1
HCP1724 MS-1028 HCP704 HCP1819 Igus
2
HFS1146 H-36101A H-36101A H-48140 Socket head cap screw 1
3
4
5
6
6a
— H-37226A H-37226A — Delrin
HCP1739 HCP1730 HCP1730 HCP1819 Igus
HFS920 HFS920 HFS920 HFS937 Lock nut 1
H-43303 Contact Harken Car assembly/sliders/guide pins 1
H-31089A H-37242A H-37242A H-41991 Guide pin only 2
®
bushing only 2
®
washer 2
®
bushing 2
2
1a
3
7
6a
HC7325
Part No. Description Quantity
1
HFS1146 Socket head cap screw 1
2
HCP1739 Igus
3
H-40902 Bushing/becket roller 2
4
HFS920 Lock nut 1
5
H-43304 Car assembly/sliders/guide pins 1
6
H-31089A Guide pin only 2
®
bushing 2
3
2
3
1
4
5
3
4
5
HC8125 HC8099
Part No. Part No. Description Quantity
1
H-40900 H-40891 Socket head cap screw 1
2
HCP1739 HCP1730 Igus
3
H-40902 H-36138A Bushing/becket roller 2
4
HFS920 HFS920 Lock nut 1
3
2
1
4
5
®
bushing 2
6
2
3
3
2
4
1
4
6
7
1
5
8
6
HC8076
5
HC7493 HC7322
Part No. Part No. Description Quantity
1
HCP1739 HCP1730 Igus
2
H-37250A H-36101A Socket head cap screw 1
3
H-32605A H-36138A Bushing/becket roller 1
4
HFS920 HFS1586 Lock nut 1
5
H-43305 Contact Harken Car assembly/sliders/guide pins 1
5a
H-37089A H-37242A Guide pin only 2
18 26 mm/32 mm Battcar Switch System 12/03/13
®
bushing 2
Part No. Description Quantity
1
H-40891 Socket head cap screw M10X107 1
2
HFS130 Flat washer 10 mm 1
3
HCP1730 Igus
4
H-36138A Bushing/becket roller 2
5
HFS191 Flat washer 8 mm 1
6
HFS920 Lock nut 1
7
H-37242A Guide pin only 2
®
bushing 4
Troubleshooting
Operation
Problem Probable Cause Solution
Slider damaged or missing. Check and/or replace slider.
Dirt in cars.
Cars bind.
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.
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.
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.
®
is a legally registered trademark of Igus® GmbH and/or Igus® Inc.
Igus
®
is a registered trademark of Henkel AG & Company KGaA.
Loctite
Use detergent and fresh water to flush dirt out of
cars; move cars up/down do circulate; follow with
high pressure water; clean track grooves.
Use topping lift or rod vang and shock cord to pull
lazy jacks out to shrouds.
Transfer reef downhaul and outhaul loads to mast
or boom gooseneck.
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.
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.
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
N15W24983 Bluemound Rd, Pewaukee, WI 53072 USA
Web: www.harken.com • Email: harken@harken.com
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
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
Via Marco Biagi, 14, 22070 Limido Comasco (CO) Italy
Telephone: (39) 031.3523511 • Fax: (39) 031.3520031
158 Beaumont Street, Westhaven, P.O. Box 90689, Victoria St. West, Auckland 1142, New Zealand
Telephone: (64) 9-303-3744 • Fax: (64) 9-307-7987
ul. Rydygiera 8, budynek 3A, lokal 101, I pi
Main Office and Harken Brandstore: Västmannagatan 81B
Telephone: (46) 0303 61875 • Fax: (46) 0303 61876
Mailing address: Harken Sweden AB, Box 64, SE -440 30 Marstrand
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
Corporate Headquarters
Telephone: (262) 691-3320 • Fax: (262) 701-5780
Harken Australia Pty, Ltd.
Harken France
Web: harken.fr • Email: info@harken.fr
Harken Italy S.p.A.
Web: harken.it • Email: info@harken.it
Harken New Zealand, Ltd.
Web: harken.co.nz • Email: harken@harken.co.nz
Harken Polska SP ZOO
Tel: +48 22 561 93 93 • Fax: +48 22 839 22 75
Web: harken.pl • Email: polska@harken.pl
Harken Sweden AB
SE-113 26 Stockholm Sweden
Web: harken.se • Email: harken@harken.se
Harken UK, Ltd.
ętro, 01-793 Warszawa, Poland
Please visit: http://www.harken.com/locator.aspx
to locate Harken dealers and distributors
Printed in USA 4677 12/13
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