Harken 35.2 ST E Manual

Installation and Maintenance Manual
MRW-00
Powered Radial Winch
35.2 ST E

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
Index
Introduction 3
Technical characteristics 3
Performance data 3
Weight 4
Maximum working load 4
Outline 5
Installation 6
Procedure 1 7
Procedure 2 8
Winch installation procedure 10
Positioning the self-tailing arm 11
Motor installation procedure 11
Electric wiring diagrams 12
Maintenance 14
Washing 14
Maintenance table 14
Disassembly procedure 14
Exploded view with maintenance products 18
Assembly 19
Harken®limited worldwide warranty 20
Ordering spare parts 20
Exploded view 21
Parts List 25
Radial Winch 35.2 STA 25
Radial Winch 35.2 STC 26
Radial Winch 35.2 STCW 27
Radial Winch 35.2 STBBB 28
Radial Winch 35.2 STCCC 29
Horizontal electric motor 12V/24V 30

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
Introduction
This manual gives technical information on winch installation and maintenance, including
disassembling and reassembling.
This information is DESTINED EXCLUSIVELY for specialised personnel or expert users.
Installation, disassembling and reassembling of the winch by personnel who are not experts may
cause serious damage to users and those in the vicinity of the winch.
Harken®accepts no responsibility for defective installation or reassembly of its winches.
In case of doubt the Harken®Tech Service is at your disposal at [e-mail]
This Manual is available only in English. If you do not fully understand the English language, do
not carry out the operations described in this Manual.
Technical characteristics
Power ratio Gear ratio
1st speed 13,50 : 1 2,13 : 1
2nd speed 35,90 : 1 5,65 : 1
The theoretical power ratio does not take friction into account.
Performance data
Winch 35.2 ST E (electric)
horizontal motor
12 V (700 W) 24 V (900 W)
1st speed 2nd speed 1st speed 2nd speed
line speed (m/min)** 23,2 8,8 29,2 11
max load (Kg) 260 650 260 650
**Line speed is measured with no load
motor nominal power (W) current absorption at
winch MWL (A)
12 V 24 V 12 V 24 V
winch 35.2 ST E horizontal 700 900 170 90
Introduction - Technical characteristics - Outline

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
Weight
ST A EH ST C/CW EH ST BBB EH ST CCC EH
weight (Kg) 13,3 14,5 15,2 15,2
Versions:
A = drum in anodised aluminium
C = drum in chrome bronze
CW = chrome/white
BBB = all bronze
CCC = all-chrome bronze
EH = horizontal electric winch
Maximum working load
WARNING!
The maximum working load (MWL) for the 35.2 ST Radial Winch is 650 Kg (1433 lb).
Subjecting the winch to loads above the maximum working load can cause the winch to fail or
pull off the deck suddenly and unexpectedly during high loads causing severe injury or death.

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
Outline
Winch 35.2 ST E/HY
Horizontal electric motor (12 V / 24 V)
170
Ø80,5
80
Ø149
152
Ø80,5
82
Ø156
175
Ø80,5
82
Ø180
Ø154,0
175
Ø80,5
82
Ø156
170
Ø80,5
80
Ø149
155
43
175
Ø80,5
82
Ø156
130
234
Line entry height
170
Ø80,5
80
Ø149
152
Ø80,5
82
Ø156
175
Ø80,5
82
Ø180
Ø154,0
175
Ø80,5
82
Ø156
170
Ø80,5
80
Ø149
155
43
175
Ø80,5
82
Ø156
130
234
Line entry height

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
Installation
The winch must be installed on a at area of the deck, reinforced if necessary to bear a load equal to
at least twice the maximum working load of the winch.
It is the installer's responsibility to carry out all structural tests needed to ensure that the deck can
bear the load.
Harken®does not supply the screws needed to install the winch since these may vary depending on
the deck on which it is to be installed.
It is the installer's responsibility to choose the correct screws taking account of the loads they will
have to bear.
Harken®assumes no responsibility for incorrect installation of its winches or for an incorrect choice
of mounting screws.
DANGER!
Incorrect installation of the winch may cause severe injury or death. Consult the yard that built
the boat in the case of doubt over the correct positioning of the winch.
WARNING!
Failure to use the correct number and type of mounting fasteners or failure to ensure the correct
deck strength can result in the winch pulling off the deck suddenly and unexpectedly during high
loads causing severe injury or death.
WARNING!
Verify the entry angle of the sheet. This must be 8° with tolerance of ±2°,
to avoid sheet overrides and damaging the winch or making the winch
inoperable leading to loss of control of the boat which can lead to severe
injury or death.
WARNING!
Mount the winch on the deck so that the drive gear is positioned where
the sheet enters the winch drum.
Incorrect position of drive gear can weaken winch leading to failure which
can cause an accident leading to severe injury or death.
NOTICE
For winch STA, STC and STCW versions only
You can find the icon on the skirt to identify
the drive gear position.
After correctly positioning the nal drive gear with respect to the load, check that the motor, gearing,
electrical wiring and/or hydraulic pipes can be housed below decks. To help nd the optimal
compromise, remember that, to make the installation of the motor easier, It can be
coupled to the winch in different positions.
Once you have decided the correct mounting position for the winch on the deck and checked the
space available below deck, proceed with the installation.
drive gear
SHEET
8°
Installation

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
The winch can be installed following one of the two procedures below (Procedure1 or Procedure 2):
Procedure 1
To install the winch you must remove the drum and use Socket Head (SH) bolts.
Tools needed: One medium at-bladed screwdriver
To identify the various parts, refer to the exploded view at the end of this Manual.
Torque to apply when assembling
1. Pull out the disconnect rod n°30 2. Unscrew the central screw ( 2Nm/18 in-lb)
3. Slide off the assy socket n°28 and the cover
n°29.
Pay attention to the o-ring in the socket.
4. Unscrew the three screws n°27
(4Nm/35 in-lb)

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
5. Remove the self-tailing arm n°26 by rotating
and lifting it.
1. Remove the skirt n°2 with the help of the
screwdriver placed as shown by the sym-
bol
6. Lift off the drum n°22
2.Take off the base n°2
Install the winch on the deck in the position you have chosen, keeping in mind
the limits described on page 6 and using socket head (SH) bolts.
Procedure 2 (not pertinent for ST BBB/CCC versions)
To install, you must remove the winch skirt and use hexagonal headed (HH) bolts.
Tools needed: One medium at-bladed screwdriver
To identify the various parts, refer to the exploded view at the end of this Manual.
See (paragraph on installation) the limits described on page 6 and using socket head (SH) bolts.
Torque to apply when assembling

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
3. Position the 5 M6 hexagonal headed bolts
in their holes
4. Reposition the skirt n°2 in its housing 5. Press down the skirt to position it correctly
NOTICE
Make sure the skirt is correctly clipped on to the base of the winch.
Install the winch on the deck in the position you have chosen, keeping in mind the limits described
on page 6 and using hexagonal headed bolts.
(See paragraph on winch installation)

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
Winch installation procedure
Carry out Procedure 1 or Procedure 2,then install the winch on the deck in the chosen position.
NOTICE
Before drilling the deck, check the space available below deck for the ange and the motor
A. Position the base of the winch on the deck and mark the position of the holes or use the
drilling cut-out template at the point where you have decided to place the winch.
Below is a reduced scale diagram.
Ø123
50°
50°
70°
50°
35°
Winch outside Ø149
final pinion
position
Ø6
n°5
105°
Ø80 cut out for
powered winches
The drilling cut out template is available on the Harken®website, www.harken.com
B. Remove the winch and drill the ve 6.2 mm and a 80 mm diameter holes.
C. Bolt the base of the winch to the deck using ve M6 bolts (not supplied by Harken®) as
described at Procedure 1 or Procedure 2, correctly chosen for the thickness and type of the boat
deck. Consult the yard that built the boat in case of doubt.
WARNING!
To install the winch on the deck, use only bolts in A4 stainless steel (DIN 267 part11).
Bolts made of other materials may not have sufficient strength or may corrode which can result in
winch pulling off deck suddenly and unexpectedly during high loads causing severe injury or death.
NOTICE
To mount winches on the deck, do not use countersunk bolts.
D. Fill the mounting holes with a suitable marine sealant.
E. Remove the excess adhesive/sealant from the holes and base drainage channels
F. Reassemble the winch following the steps in Procedure 1 or Procedure 2 in the reverse order,
and apply the products indicated in the section on maintenance.

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
NOTICE
Before closing the winch, make sure the holes and drainage channels in the base of the winch
are not obstructed.
Positioning the self-tailing arm
Position the self-tailing arm so that the line leaving the winch is led into the cockpit.
Motor installation procedure
WARNING!
Make sure that the power is switched off before installing or carrying out maintenance on
the winch.
Once you have installed the winch on the deck, proceed with motor installation. The motor can be coupled
to the winch in different positions. Check the space available below deck and choose the suitable position.
Tools needed
A number ve hex key
A number six hex key (only for vertical electric motor)
A number ten hex key (only for hydraulic motor)
Two number thirteen wrenches
1. Position the ange (see Page 12) 2.Tighten six M6 precote coated screws
( 8 Nm/ 71 in-lb)
3. Position the reduction gear and motor 4.Tighten the two screws ( 8 Nm/ 71in-lb).
Be sure to align the ange.

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
After winch is assembled and before sailing, test the powered winch functioning: insert the lock-in
winch handle in the handle socket and check that the disconnect rod must disconnect gearbox.
Electric wiring diagrams
To guarantee greater efficiency in terms of safety and long life, for every winch model is mandatory
to install the Dual Function Control Box.
For more information, refer to the Dual Function Control Box manual.
Refer to the following diagrams for the electric wiring:
NOTICE
Before positioning the ange, check to
make sure that seals (the rst one is above
the ange and the second one is under the
ange) are seated correctly.
WARNING!
Read the Dual Function Control Box manual carefully before installing and using the device.
NOTICE
For other installations, refer to the Dual Function Control Box manual.

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
Fasten the Dual Function Control Box containing solenoids to bulkhead or wall: refer to the
Dual Function Control Box manual. Install remote circuit breaker between power supply
and Dual Function Control Box. Locate push-buttons on deck in a convenient spot for easy winch
operation: refer to the Digital System Switch manual.
Refer to the following chart for wire size:
Total distance between winch and battery
Winch
size
Current
voltage
Under 16.4 ft
AWG
Under 5 m
mm2
16.4 - 32.8 ft
AWG
5m - 10 m
mm2
32.8 - 49.2 ft
AWG
10m - 15 m
mm2
49.2 - 65.6 ft
AGW
15m - 20 m
mm2
40.2 12 V 2 32 0 50 00 70 000 95
40.2 24 V 5 16 3 25 2 35 0 50
NOTICE
To connect motor, attach cable terminals to clamps
between nut and lock nut. Hold nut in contact
with motor using a spanner and tighten other nut
with second spanner. Take special care not to
turn the central spindles. Be careful not to turn
central spindles. These instructions apply when
assembling and disassembling. We recommend
using a torque wrench so as to obtain a torque
equal to and no greater than 10 Nm (88 in-lb).
NOTICE
Note that correct electrical contact sequence is:
Nut – Cable Terminal – Self-Locking Washer –
Lock Nut

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
Maintenance
Washing
Winches must be washed frequently with fresh water, and in any case after each use.
Do not allow teak cleaning products or other cleaners containing caustic solutions to come into
contact with winches and especially anodised, chrome plated or plastic parts.
Do not use solvents, polishes or abrasive pastes on the logos or stickers on the winches. Do not
use polishes or abrasive pastes on anodised, chromed plated or plastics surfaces.
Make sure that the holes and drainage channels in the base of the winch are not obstructed so
that water does not collect.
Maintenance table
Winches must be visually inspected at the beginning and end of every season of sailing or racing.
In addition they must be completely overhauled, cleaned and lubricated at least every 12 months.
After an inspection, replace worn or damaged components. Do not replace or modify any part of
the winch with a part that is not original.
WARNING!
Periodic maintenance must be carried out regularly. Lack of adequate maintenance shortens
the life of the winch, can cause serious injury and also invalidate the winch warranty.
Installation and maintenance of winches must be carried out exclusively by specialized
personnel.
WARNING!
Make sure that the power is switched off before installing or carrying out maintenance on
the winch.
In the case of doubt contact Harken®Tech Service at [e-mail]
Disassembly procedure
Tools needed:
One medium at-bladed screwdriver
A number ve hex key
Brush
Rags
To identify the various parts refer to the exploded view at the end of this Manual.
Torque to be applied in assembly phase
Carry out Procedure 1 as shown in the paragraph on winch installation and then do the following:
Maintenance

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
9. Remove the assy housing n°15
Important: washer n°12 may remain inside the
drum support!
10.Remove the washer n°12 11. Remove the gear n°7
8. Unscrew the 6 hex screws n°16
( 20Nm/177 in-lb)
7. Slide out the central shaft n°19
6. Completely unscrew the three screws n° 27
and remove the stripper arm support n°21

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
15. Remove the gear n°10
16. Remove the pawls carrier n°11 18. Remove the washer n°9
13. Remove the gear n°3
14. Remove the gear n°14
12. Remove the pawls carrier n°4

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
I. Unscrew the 4 screws n°25
( 4Nm/35 in-lb)
II. Remove the jaws n°24
If it is necessary to replace any jaws of the winch, proceed as follows:
Once the winch is completely disassembled, clean the parts: use a basin of diesel oil to soak
metal components and rinse plastic parts in fresh water. Once you have done this, dry the parts
with cloths that do not leave residue.
Inspect gears, bearings, pins and pawls for any signs of wear or corrosion.
Carefully check the teeth of gears and ring gears to make sure there are no traces of wear.
Check the roller bearings and check there are no breaks in the bearing cages.
Replace worn or damaged components.
Carry out maintenance on components using the products listed below.
For more information on which products to use where, refer to the exploded diagram below.
Use a brush to lightly lubricate all gears, gear pins, teeth and all moving parts with grease.
Lightly lubricate the pawls and springs with oil. Do not use grease on the pawls!

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
Exploded view with maintenance products
1. Apply Harken®grease on assy socket screw - 2. Apply Harken®grease on drum gear
Harken®Grease
G
Harken®Pawl Oil
O
Anti-seize
A
G
A
A
A
G
G
G
G
G
G
O
O
G
G
A
G
1
G
2

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
Assembly
Make sure that the holes and drainage channels in the base of the winch are not obstructed.
Assemble the winch in the reverse order of the sequence in the section on disassembly.
To tighten bolts, use the torque indicated in the disassembly procedure.
In case of doubt concerning the assembly procedure contact Harken® Tech Service: techservice@
harken.it
If the jaws have been disassembled,
insert peeler between the two jaws,
taking care that the letters TOP on the
peeler are facing upwards.
When positioning the stripper arm, align
the peeler with it.
OIL
To assemble the pawls
Correctly position the spring in its
housing as shown at left. Hold the
spring closed and slide the pawl into its
housing. Once in position, check that the
pawls can be easily opened and closed
with a nger.
NOTICE
Before screw the central screw, check
the correct position of the o-ring in the
assy socket and apply Harken®grease.

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Radial Winch 35.2 ST E/HY
Installation and Maintenance Manual
Harken®limited worldwide warranty
Refer to the Harken®Limited Worldwide Warranty in the Harken®Catalogue and on the website
www.harken.com
W XXXXX
XXXXXXXXX
Harken®limited worldwide warranty - Ordering spare parts
Headquarters
Harken®, Inc.
1251 East Wisconsin Avenue
Pewaukee, Wisconsin 53072-3755 USA
Tel: [phone]
Fax: [phone]
Email: hark[email protected]
Web: www.harken.com
Manufacturer
Harken®Italy S.p.A.
Via Marco Biagi, 14
22070 Limido Comasco (CO) Italy
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Web: www.harken.com
Tech Service
Email: [e-mail]
Customer Service
Tel: [phone]
Email: [e-mail]
Tech Service
Email: [e-mail]
Customer Service
Tel: [phone]
Email: [e-mail]
Ordering spare parts
Spare parts can be requested from Harken®as
described in the Harken®Limited Worldwide
Warranty, indicating the part number in the
Parts List and including the serial number of the
winch for which the parts are required.
The serial number of the winch is printed on
a plate on the drum support of the winch.