Harken 32 mm Big Boat User manual

ONLINE INSTRUCTIONS
Strictly follow all instructions to avoid an accident, damage to your vessel, personal injury
or death. See www.harken.com/manuals for additional safety information.
USA –Tel: [phone] • Web: www.harken.com • Email: [email protected]
Italy –Tel: [phone] • Web: www.harken.it • Email: [email protected]
Features
IMPORTANT: See Inspection and Maintenance at end of manual.
Part
No. Description
Length
A
Width
B
Height
C
Maximum
working load
Breaking
load
in mm in mm in mm lb kg lb kg
T3201B Car/shackle 5
3
/ 8 136 3
11
/ 32 85 2
5
/ 8 73 3000 1361 7000 3175
T3201B.HL HL car/shackle 7
7
/ 16 188 3
11
/ 32 85 2
5
/ 8 73 4500 2041 9000 4081
T3202B Car/stand-up toggle 5
3
/ 16 132 3
11
/ 32 85 3
1
/ 2 89 3000 1361 7000 3175
T3202B.HL HL car/stand-up toggle 7
7
/ 16 188 3
11
/ 32 85 3
1
/ 2 89 4500 2041 9000 4081
T3203B Car/stand-up toggle/ears 5
3
/ 16 132 3
11
/ 32 85 3
1
/ 2 89 3000 1361 7000 3175
T3203B.HL HL car/stand-up toggle/ears 7
7
/ 16 188 3
11
/ 32 85 3
1
/ 2 89 4500 2041 9000 4081
T3204B Car/2 stand-up toggles 9
1
/ 8 231 3
11
/ 32 85 3
1
/ 2 89 5000 2268 10000 4536
T3204B.HL 2 HL cars/2 stand-up toggles 15 381 3
11
/ 32 85 3
1
/ 2 89 9000 4082 18000 8163
T3205B Car/soft attachment 5
3
/ 16 132 3
11
/ 32 85 2 50 3000 1361 7000 3175
T3205B.HL HL car/soft attachment 7
7
/ 16 188 3
11
/ 32 85 2 50 4500 2041 9000 4081
T3221B Car/shackle/2:1 5
3
/ 8 136 3
5
/ 8 98 2
5
/ 8 73 3000 1361 7000 3175
T3221B.HL HL car/shackle/2:1 7
7
/ 16 188 3
5
/ 8 98 2
5
/ 8 73 4500 2041 9000 4081
T3222B Car/stand-up toggle/2:1 5
3
/ 8 136 3
5
/ 8 98 2
5
/ 8 73 3000 1361 7000 3175
T3222B.HL HL car/stand-up toggle/2:1 7
7
/ 16 188 3
5
/ 8 98 2
5
/ 8 73 4500 2041 9000 4081
T3224B Car/2 stand-up toggles/2:1 9
1
/ 8 231 3
5
/ 8 98 3
1
/ 2 89 5000 2268 10000 4536
T3224B.HL 2 HL cars/2 stand-up toggles/2:1 15 381 3
5
/ 8 98 3
1
/ 2 89 9000 4082 18000 8163
A B
C
Specifications
32 mm Big Boat CB Traveler Cars
One-piece car body: Machined from 6061-T6 aluminum for strength and durability.
Hard Lube-anodized: PTFE coated for durability.
Captive ball bearings: Cars easy to load and maintain.
Free running ball bearings in car and control blocks: Easy to adjust car under load.
Newer style CB+ cars: Can convert to old-style non-CB track.
Terms
Control
blocks
Stand-up
toggle
Deadend
bail
Shackle
Center
openings
CB – Captive bearings. Wire retaining clips hold bearings
captive for easy loading onto track and for maintenance.
CB+cars – CB cars that can convert to old-style, non-CB track.
Corner keepers – Used on CB+cars to help retain balls
when cars are off track. Introduced beginning of 2015.
Retaining clips – Formed wires for holding bearings.
CB style track – Track designed with deeper grooves
to accept CB car retaining clips.
CB+car underside
Corner
keeper
Retaining
clip
+stamp
at one end.
Table continues next page

Part
No. Description
Length
A
Width
B
Height
C
Maximum
working load
Breaking
load
in mm in mm in mm lb kg lb kg
T3231B Car/shackle/3:1 5
3
/ 8 136 4 101 2
5
/ 8 73 3000 1361 7000 3175
T3231B.HL HL car/shackle/3:1 7
7
/ 16 188 4 101 2
5
/ 8 73 4500 2041 9000 4081
T3232B Car/stand-up toggle/3:1 5
3
/ 8 136 4 101 3
1
/ 2 89 3000 1361 7000 3175
T3232B.HL HL car/stand-up toggle/3:1 7
7
/ 16 188 4 101 3
1
/ 2 89 4500 2041 9000 4081
T3234B Car/2 stand-up toggles/3:1 9
1
/ 8 231 4 101 3
1
/ 2 89 5000 2268 10000 4536
T3234B.HL 2 HL cars/2 stand-up toggles/3:1 15 381 4 101 3
1
/ 2 89 9000 4082 18000 8163
T3241B Car/shackle/4:1 5
3
/ 8 136 4
3
/ 8 111 3
1
/ 2 89 3000 1361 7000 3175
T3241B.HL HL car/shackle/4:1 7
7
/ 16 188 4
3
/ 8 111 3
1
/ 2 89 4500 2041 9000 4081
T3242B Car/stand-up toggle/4:1 5
3
/ 8 136 4
3
/ 8 111 3
1
/ 2 89 3000 1361 7000 3175
T3242B.HL HL car/stand-up toggle/4:1 7
7
/ 16 188 4
3
/ 8 111 3
1
/ 2 89 4500 2041 9000 4081
T3243B.HL HL car/stand-up toggle/4:1 7
7
/ 16 188 4
3
/ 8 111 3
1
/ 2 89 4500 2041 9000 4081
T3244B Car/2 stand-up toggle/ears/4:1 9
1
/ 8 231 4
3
/ 8 111 3
1
/ 2 89 5000 2268 10000 4536
T3244B.HL 2 HL cars/2 stand-up toggles/4:1 15 381 4
3
/ 8 111 3
1
/ 2 89 9000 4082 18000 8163
Specifications (continued)
Track not shown actual size
Part No. A B C
in mm in mm in mm
Low-profile track
3159, R32.1.5M, R32.2.1M, R32.3M,
R32.3.6M, R32.6M, 3159.8, 3159.12 1
1
/ 4 32
3
/ 4 19 1
5
/ 8 42
High-beam track
3156, R32HB.1.5M, R32HB.1.8M,
R32HB.2.5M, R32HB.3.6M 1
1
/ 4 32 2
1
/ 4 57 1
3
/ 16 30
Track Compatibility
High-
beam
A
B
C
A
B
Groove at waist
for keeper wires
CB cars are shipped for use on CB track with grooves at waist to accept retaining clips, first supplied
by Harken in 2004. See end of manual for older track.
3159, R32 3156, R32HB
C
Curved Track Limitations
Cars will not roll on curved track if radius is under minimum listed below. A shorter car can roll on a
smaller radius. Refer to chart below and make sure radius is equal or greater than radius listed for car.
To determine radius go to www.harken.com. Go to product support, FAQs, traveler track Q&A.
Car
Minimum radius
ft m
3160/3163/3164/3176/3177
T3201B, T3202B, T3203B, T3205B,
T3221B, T3222B, T3231B, T3232B,
T3241B, T3242B
8 2.44
3161/3165/3166
3172/ 3178/3179
T3201B.HL, T3202B.HL, T3203B.HL,
T3205B.HL, T3221B.HL, T3222B.HL,
T3231B.HL, T3232B.HL, T3241B.HL,
T3242B.HL, T3243B.HL
18 5.49
T3204B.HL, T3224B.HL, T3234B.HL,
T3244B.HL 18 5.49
3167
T3204B, T3224B, T3234B, T3244B 24 7.32
Radius*
*Applies to vertical
and horizontal bend
Track for Unsupported Spans
Harken high-beam track is designed for unsupported
spans. The length of span depends on car load. The
higher the car load, the less span track can handle. If
car is sized correctly, car length determines spanning
capability. Longer, high-load (HL) cars require shorter
spans because loads are so much greater. See track
spanning chart in track instructions. www.harken.com
SPAN (inches/meters)
SAIL AREA (feet2/meters2)
Monohulls only
Mid-boom
End-boom
32 mm high-beam
track spanning chart
700
65
650
60
600
56
550
51
500
46
450
42
400
37
350
33
300
28
45
1.14 60 1.52 75 1.9 90 2.27

Stand-up toggle
Soft
attachment post
Stand-up toggles – Harken stand-up toggles fit specific Harken blocks.
To determine mainsheet block compatibility, see 4521
instructions online: www.harken.com/manuals
Soft attachment (T3205B, T3205B.HL) – To attach
loops or straps, remove stop screws and push out
attachment post. Assemble post using blue Loctite®adhesive on screws.
Attaching Mainsheet and Control Blocks
Installing Traveler Car on Track
Position car at end of track and gently roll on. If car does not roll on easily, check to make sure you are
using CB track. Do not remove ball retaining wires. Cars will not roll unless they have retaining clips.
Exception: CB+ cars can convert to non-CB cars. See end of manual. If any balls are lost, refer to
following instructions for quantities and how to load.
2:1 ESP 2:1 Ball bearing
3:1 ESP 3:1 Ball bearing
4:1 ESP 4:1 Ball bearing
6:1 Ball bearing
6:1 ESP
Reeving Cars and End Control Blocks
Attaching Splice to Deadend on Car or Controls
To attach premade splice, pass eye through bail and run tail
through to make a hitch without undoing bail. If line is too large
for this, remove one screw and rotate deadend eyestrap to load
the splice. Reassemble screws using theadlocking solution such
as blue Loctite®adhesive.
Ball Replacement Chart
Position car on edge with retaining clip
in place. Gently push one ball at a time
into car from center of clip. Allow balls to
roll into return race and insert remaining
balls. Do not overfill car!
Loading Ball Bearings into CB Cars
Car Car
length
Balls
per car Balls Order Balls per set Ball Ø
T3201B, T3202B, T3203B, T3205B, T3221B, T3222B,
T3231B, T3232B, T3241B, T3242B
5
3
/ 8 "
(136 mm) 50 Torlon®547 25
3
/ 8 "
(10 mm)
T3201B.HL, T3202B.HL, T3203B.HL, T3205B.HL, T3221B.
HL, T3222B.HL, T3231B.HL, T3232B.HL, T3241B.HL,
T3242B.HL, T3243B.HL
7
7
/ 16 "
(188 mm) 72 Torlon 547 25
3
/ 8 "
(10 mm)
T3204B, T3224B, T3234B, T3244B 9
1
/ 8 "
(231 mm) 90 Torlon 547 25
3
/ 8 "
(10 mm)
T3204B.HL, T3224Bj.HL, T3234B.HL, T3244B.HL 15"
(381 mm) 144* Torlon 547 25
3
/ 8 "
(10 mm)
*Coupled car assembly–each car has 72 balls
Loctite is a registered trademark of Henkel AG & Company KGaA.
Torlon is a registered trademark of Solvay Advanced Polymers.

Removing Ball Bearings from CB Cars
Position car on edge and gently push one
ball at a time from center of retaining clip.
Do not remove retaining clip from car!
Retaining Clip
CB + Big Boat Cars Can Convert To Fit Old-style Non-CB Track.
Important! Requires CB+cars. See complete instructions at www.harken.com/manuals.
See traveler instructions 5070.
CB+cars designed for CB track CB+cars can convert to run
on old-style, non-CB track
Track built after 2003 - No need to convert car Track built through 2003
Groove for
retaining clip
CB track Non-CB track
Converting CB +Cars to Fit Old-Style Non-CB Track
3. Remove retaining clips and corner keepers
over box to catch balls.
1. Use flat-bladed screwdriver to push retaining
clip toward end.
5. Remove two (2) clips from car loader. Slide
car loader in so loading port is on side
of car without balls.
2. Pry retaining clip off and dump balls in box.
4. Hold car on edge and load lower side with
correct number of balls. DO NOT OVERLOAD.
Consult chart to confirm quantity.
6. Put one (1) clip on "open" end of loader.
Load rest of balls through ball loading port
into empty bearing race. Consult chart to
confirm quantity. Line up car loader with
track and gently roll car onto track.
Order car loader
Car length Loader
5 3/8" 136 mm HBB1
7 7/16" 188 mm HBB28
9 1/8" 231 mm HBB25

M1010 09/15
Traveler cars: Clean by frequently flushing with fresh water. Periodically clean
car by squirting a detergent/water solution into center openings. Roll car back
and forth to distribute evenly. Flush bearings with fresh water.
Do not use spray lubricants; ball bearings will skid, not roll. Once car and track are
dry, apply one (1) to two (2) drops of McLube®OneDrop™ball bearing
conditioner to ball contact surfaces of track. Roll car back and forth through
OneDrop conditioner several times to distribute onto bearings. Wipe remaining
OneDrop off track. OneDrop conditioner is preferred, but you can also use one (1)
to two (2) drops of a light machine oil. Too much oil attracts dirt.
Track: Clean with detergent and 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.
Maintenance
Warranty
Inspect
Frequently inspect shackles and control block fittings for signs of fatigue. Replace as necessary.
Make sure every installation includes Harken track endstops. Arrange control tackle so cars do
not hit endstops under load.
For additional safety, maintenance, and warranty information see www.harken.com/manuals
or the Harken catalog.
McLube OneDrop is a trademark of McLube, a division of McGee Industries, Inc.