Harken HC9045 Battcar Switch System User Manual

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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
BATTCAR SWITCH SYSTEM
INSTALLATION MANUAL
26 mm, 32 mm
Installation Manual – Intended for specialized personnel or expert users
4677 12/13
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
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Summary of Contents

Page 1 - 26 mm, 32 mm

Please read these instructions carefully before installing, servicing, or operating the equipment. This manual may be modified without notice. See: ww

Page 2

10 26 mm/32 mm Battcar Switch System 03/30/09Assembly Mounting Standard/High-Load TracksAssembly Mounting Top TrackWith track off mast, tap upper

Page 3 - Preassembly Parts

03/21/12 26 mm/32 mm Battcar Switch System 11Commissioning Load Cars on TrackRemove gate track.Install cars from above switch.Lubricate cars onshor

Page 4

12 26 mm/32 mm Battcar Switch System 03/30/09Commissioning Loading HeadboardHeadboard cars have spherical bearings and are designed to run through

Page 5 - 12"

07/21/10 26 mm/32 mm Battcar Switch System 13Commissioning Removing Toggle From CarsWhen removing parts, make sure you retain plastic bushings betw

Page 6 - Top track length A

14 26 mm/32 mm Battcar Switch System 03/30/09Part No. DescriptionA B C D E FG Stud Øin mm in mm in mm in mm in mm in mm mm26 mm HC9045 Headboard car

Page 7 - HC10060 Double storage

Distance Between Attachment PointsBattens and intermediate cars placed at sailmaker's discretion. Maximum distance between attachment points is 4

Page 8

16 26 mm/32 mm Battcar Switch System 07/20/11Trysail Switch SystemPart No. DescriptionLength Width Weight FastenersMaximum working loadin mm in mm o

Page 9

03/21/12 26 mm/32 mm Battcar Switch System 17HC9046—32 mm SystemPart No. Description Quantity1HC9046NP Coupler assembly 1aMS-291 Smalley ring 2bMS-2

Page 10

18 26 mm/32 mm Battcar Switch System 12/03/13 HC8125 HC8099Part No. Part No. Description Quantity1H-40900 H-40891 Socket head cap screw 12H

Page 11

03/22/12 26 mm/32 mm Battcar Switch System 19WARNING: Parts degrade over time and may become weak. Failure to inspect and correct may result in syst

Page 12

2 26 mm/32 mm Battcar Switch System 07/14/11Tools21489361.Tape measure 8. Tape2. Power drill 9. File3. Drill bits 10. Hex key4. Hammer 11. McLub

Page 13 - Watch for binding at

Corporate HeadquartersN15W24983 Bluemound Rd, Pewaukee, WI 53072 USATelephone: (262) 691-3320 • Fax: (262) 701-5780Web: www.harken.com • Email: harke

Page 14 - Headboard car

11/24/10 26 mm/32 mm Battcar Switch System 3Part No. Description System CommentsHC9045Headboard car26 mmMust use 3876 or 3877 headboard.HC7493Interm

Page 15 - INCORRECT

4 26 mm/32 mm Battcar Switch System 11/24/10Switch, Storage and Gate TrackPart No. DescriptionLength (A)Width (B)Switch Width(C)Height (D) Weight

Page 16 - Sailmaker instructions

03/30/09 26 mm/32 mm Battcar Switch System 5Preassembly SizingSizingMake sure you have the correct size battcar system for your boat.Track length an

Page 17 - Replacement Parts

6 26 mm/32 mm Battcar Switch System 11/24/10Preassembly Track LengthLayout system using charts to plan track location and lengths.FStorage Track—26

Page 18

11/21/11 26 mm/32 mm Battcar Switch System 7Preassembly Mounting Track to MastAssembly General InstructionsNote width and shape of switch and bui

Page 19

8 26 mm/32 mm Battcar Switch System 07/21/11Assembly Mounting SwitchInsert three splice links into switch track.Using a plastic hammer, tap them in

Page 20 - Printed in USA 4677 12/13

07/21/11 26 mm/32 mm Battcar Switch System 9Assembly Mounting Storage TracksMake sure storage track ends with holes for endstop are at bottom. If

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