Andersen 82-3ST User manual

Rev.0
PRODUCT MANUAL
82-3ST Winch
FOR USE WITH:
Manual Winch: RA2082010000
Winch Versions: ≥V.1.0

2
SAFETY NOTICES
Read All Safety Notices and Product Manuals
Do not install or operate this winch before reading and fully understanding the
contents of this Safety Notice Sheet and the Product Manual.
Stay Alert When Operating
Andersen winches are very powerful and have the potential to cause significant damage and/or
serious injury if used improperly or without due caution and vigilance.
Operators Must be Trained
Help prevent significant damage and/or serious injury by ensuring any person operating a winch
has a thorough understanding of its proper operation and is aware of the potential hazards
involved. As a minimum, all winch operators must read and understand this Safety Notice Sheet
and the Product Manual.
Particular attention is drawn to the following points:
Children and others not qualified to operate an electric winch must be kept at a safe
distance from the winch and any rigging or fittings that are under load.
Long hair and/or loose clothing must be tied back to avoid being caught in the winch.
In the event of a rope override or other fault, stop the winch and turn off power before
attempting to resolve the problem.
Avoid Accidental Operation
Always turn off power to electric winches at the circuit breaker and remove winch handles when
not in use, to help avoid unsupervised or unintentional operation. Failure to do so could result
in significant damage and/or serious injury.
Maintenance
Turn off power to electric winches before performing any maintenance or service tasks. Failure
to do so could result in significant damage and/or serious injury.
Lifting Operations
The winch must not be operated with the rope in the self-tailer when used in any kind of lifting
operation. Any lifting operations should be conducted by two persons in order to maintain
constant visual contact with the object being lifted. Furthermore the self-tailer must not be used
as a cleat for a rope used to lift or suspend any object. The rope must be secured properly by
tying off, or leading to a suitable fitting such as a cleat or bollard.
Failure to observe these precautions could result in serious injury or death.
DO NOT DISCARD

3
WINCH ASSEMBLY
EXPLODED VIEW & PARTS LIST
Item no.
Qty.
Description
Part no.
1
1
Main drive gear set 82-3ST
539604
2
1
3rd speed gear set 82-3ST
538003
3
1
Central gear set 82-3ST
539704
4
1
Base 82-3ST
741607
5
1
Centre stem assembly 82-3ST
741511
6
45
Torlon®ball dia. 1/4" (6.35mm)
501001
7
1
Ball retaining ring 82-3ST
539512
8
4
Torlon®roller bearing assembly 82-3ST
539210
9
1
Bearing spacer 82-3ST
538201
10
1
Base cover 82-3ST
751152
11
8
Bolt M10x25 hex head
DIN933-A4-M10X25
12
1
Drum 82-3ST
741321
13
1
Self-tailer top 82-3ST
545411
14
1
Self-tailer arm 82-3ST
733412
15
1
Bush, drum 78ST,82-3ST
538800
16
1
Circlip
590100U
18
1
Drive shaft 82-3ST
538415
20
3
Screw M8x20, CSK socket head
DIN7991-A4-M8X20
21
3
Screw M6x12, CYL socket head
DIN 912-A4-M6X12
Torlon®is a registered trademark of Solvay Advanced Polymers.

4
GEAR SET ASSEMBLY
EXPLODED VIEWS & PARTS LISTS
Central Gear Set 82-3ST
Item
no.
Qty.
Part no.
Description
1
1
539702
Lower center ratchet 82-
3ST
2
1
538501
Lower driveshaft 82-3ST
(manual drive)
3
1
539901
Center gear thrust bearing
82-3ST
4
2
539902
Collets
5
4
713200
Pawl for arm spring
6
4
713300
Pawl spring, arm
7
1
539903
Retainer ring
3rd Speed Gear Set 82-3ST
Item
no.
Qty.
Part no.
Description
1
1
538004
Small 3rd speed drive gear
2
1
537501
Large 3rd speed drive gear
3
1
537800
Cover washer 82-3ST
4
4
713200
Pawl for arm spring
5
4
DIN7991-A4-
M5X10
Screw M5X10 CSK socket
head
6
4
713300
Pawl spring, arm
7
2
537901
Hub bearing
8
2
537902
Thrust washer

5
Main Drive Gear Set 82-3ST
Item
no.
Qty.
Part no.
Description
1
1
542215
Cover plate/ bearing
2
2
532604
Thrust washer, top
3
1
542230
Pawl carrier,auto-switch
centerpiece
4
1
542210
Drive gear 82-3ST
5
8
713200
Pawl for arm spring
6
4
713201
Pawl for auto-switch 82-
3ST
7
12
713300
Pawl spring, arm
8
4
542235
Auto-switch angled
slider/plunger 82-3ST
9
72
542238
Auto-switch disc spring
10
1
532602
Overdrive hub bearing,
lower
11
1
542220
Overdrive gear 82-3ST
12
2
532603
Overdrive hub bearing,
upper
13
2
534810
Bearing, main ratchet
gear 82-3ST
14
1
537702
Freewheel gear 82-3ST
15
8
DIN912-A4-
M4X15
Screw, CYL socket head
16
1
532606
Clutch bearing 82-3ST
⑩
⑫
⑦
①
②
④
⑥
③
⑪
⑧
⑨
⑤
⑫
⑮
⑯
⑬
⑭

6
ANDERSEN Stainless Steel Winches®
Your Andersen winch is made with the care and craftsmanship that come from more than sixty
years of experience. Andersen winches are built to last, to retain their exceptional finish and to
deliver season after season of reliable performance and sailing pleasure to their owners through
the years.
INSTALLATION
Required for installation:
•Drilling/mounting templates for 82-3ST winch
•Hex key, 5mm (included)
•Hex key, 10mm for winch mounting bolts
•Drill bit Ø12.5mm
•6x ISO 4762-A4 M12 mounting bolts (length as required for deck thickness)
•6x M12 locking nuts and large washers (or backing plate to match drilling template)
•Spanner, 19mm for mounting bolt locking nuts
•Sealant / bedding compound
Step 1 Determine mounting location and orientation
Position the winch with the recommended line entry angle of 3-8° from horizontal. The self-
tailing arm should be positioned to allow the rope to drop clear of the winch as it feeds out of
the self-tailer. Positions will typically be as indicated by the shaded sectors in the diagram. The
self-tailing arm can be adjusted after installation into one of 12 different positions, as indicated
on the drilling template.
Note the drainage grooves on the underside of the winch base. If the mounting surface is not
horizontal due to deck camber or other factors, plan the installation such that water may drain
away from the winch base towards the lowest point in relation to the slope of the mounting
surface.
Drainage grooves

7
Step 2 Prepare the mounting surface
After confirming the mounting location and orientation of the winch,
clean the mounting surface and place the drilling template in the
required position on the deck. Ensure that the surface is flat and
there is adequate space and clearance below deck for access to
mounting bolts.
With the drilling template in the desired orientation, drill the
Ø12.5mm holes for the M12 mounting bolts.
Clean any wood or fibreglass splinters from the holes, and clean the deck thoroughly to ensure
deck sealant can adhere properly. Apply sealant to the deck around the mounting bolt locations,
taking care not to block the drainage grooves in the winch base. For aluminium boats use a
galvanic isolating ring/gasket.
Step 3 Install the winch
Use a hex key to remove the screws at the top of the winch, then lift off the self-tailing arm and
the drum to expose the centre stem, base and gears. See the exploded view for guidance.
Note that it is not necessary to completely disassemble all components shown in the diagram in
order to install the winch.
Position the winch base on the deck in the desired orientation,
with mounting holes aligned, and secure it to the deck using
appropriate length M12 bolts, large washers or backing plate,
and locking nuts.

8
OPERATION CHECKS
Check manual operation of the winch
First check the winch by rotating the drum by hand. Then use a winch handle to operate the
winch manually, turning the handle in both directions with no load on the drum. The winch
should operate smoothly in both gears, always with the drum rotating only in a clockwise
direction.
For normal operation start by using the winch in 1st gear (highest speed) by turning the handle
in a clockwise direction. As load increases and operation becomes more difficult, shift into 2nd
gear by turning the handle in the opposite direction so that you can continue to operate the
winch comfortably.
At low loads, reversing the direction of handle rotation from 2nd gear and turning
clockwise again will return the winch to 1st gear operation.
At higher loads, the winch will automatically shift so that reversing direction of handle
rotation from 2nd gear to clockwise again will put the winch into 3rd gear, allowing
continued operation under high load.
Note: The winch will only shift gear automatically to allow operation in 3rd gear if sufficient load has
been reached while operating in 2nd gear. You may manually assist this transition by turning the
handle in second gear until there is sufficient resistance to trigger the shift.

9
SERVICE & MAINTENANCE
Inspection and service of your Andersen winch is recommended at two year intervals. Service
dates can be recorded on the back page of this manual for future reference.
Required for service:
Hex key, 5 mm
Spanner, 17mm
Soft cloth
Andersen Winch Grease
Small flat screwdriver
White/mineral spirits
Small brush
1. Remove the screws (20) that secure the self-tailer arm (14).
2. Remove the self-tailer arm and drum assembly. It is not necessary to disassemble the spring
loaded self-tailer to perform a normal servicing.
3. Clean the bearing surfaces and the gear teeth in the drum with white/mineral spirits. Apply
Andersen Winch Grease to the gear teeth, but do not apply any grease to the bearing
surfaces.
4. Remove the drive shaft (18) by inserting a winch handle to help pull it out of the centre stem.
5. Remove and clean the roller bearings (8) in soapy water with a soft cloth.
6. Leaving the retaining ring (7) and the ball bearings (6) in place, clean the ball bearings with
soapy water using a small brush.
7. Remove the 8x M10 hex head bolts (11) and lift the centre stem (5) off the winch base (4).
8. Remove and dismantle the central gear set (3) and the 3rd speed gear set (2).
9. Clean the gears, pawls and springs in white/mineral spirits.
10. Reassemble the central gear set and the 3rd speed gear set, applying a very thin film of
Andersen Winch Grease to the pawls. Do not use any other kind of grease for this purpose.
Check the functioning of each pawl by pushing the pawl against the spring. The pawls should
move smoothly and automatically return to their normal position where the pawls engage
within the gears. If the pawls do not work correctly replace the springs and check again.
Malfunctioning pawls may lead to unexpected release of the winch force resulting in serious
injury to the user and others.
Note the curved spring “arm”
TYPICAL PAWL & SPRING
Correctly fitted in a pawl pocket

10
11. Apply grease to the gearwheels and teeth. Put these gear sets aside for the moment and
proceed with the next step.
12. Main Drive Gear Set Service
The main drive gear set (1) contains the clutch that engages and disengages to provide 3rd
gear or 1st gear operation when turning the winch handle in a clockwise direction. Remove
it from the winch base as a complete unit before disassembly.
a. The overdrive gear positioned at the top of the gear set can
be lifted off and cleaned. Check for wear on the gear teeth
and bearing surfaces. Set the overdrive gear aside and
proceed with the next steps.
b. Turn the lower part of the gear set upside down and remove
the 8 screws that hold it together. Lift off the closing plate
and the freewheel gear to expose the bronze pawl carrier.
Remove and clean the pawls and springs, checking the pawls
and pawl pockets for wear. With normal use these pawl
springs should be changed every two years or so.
c. Turn over the pawl drive assembly and separate the drive
gearwheel from the bronze pawl carrier to access the
springs that control the gear shifting torque. Lift out and
clean the springs; check the 4 angled sliders for wear.

11
d. Turn over the drive gearwheel and pull out the 4 special
auto-switch pawls. These pawls have a unique profile that is
quite distinct from standard winch pawls, so take care to
keep them separate. Clean the gearwheel, pawls and
springs and check for wear. Springs should be replaced
every two years or so.
e. Reassemble the complete main drive gear set in reverse order to the steps above, taking
care to ensure that the 4 angled sliders align with the corresponding slide paths
machined into the drive gearwheel. Use Andersen Winch Grease on the gear teeth,
bearing surfaces and slide paths, and a very thin film of the same grease on the pawls.
When fitting the overdrive gear into place, a flat screwdriver may be used to help move
the pawls into their engaged position to facilitate assembly.
13. See the exploded view for reference. To reinstall the 3 gear sets in the winch base: Insert
first the main drive gear set (1), then the central gear set (3) and then the 3rd speed gear
set (2). The two collets that secure the central gear must be fully inserted and secured in
position by the retainer. The collets fit within the recess on the underside of the retainer.
The central gear set assembly
is secured by two collets.
These must be fully inserted in
the groove of the shaft so that
they locate within the recess
of the retainer ring that holds
them in position.
14. Reinstall the centre stem, checking that all gears run freely before tightening the 8x M10
hex head bolts (11). After tightening the bolts, fit the bearings, drive shaft, drum and self-
tailing arm to complete the winch assembly. Before first use, check the operation of the
winch as described earlier in this manual.
Auto-switch pawls with
arm springs
Collets
Retainer ring
3
1
2
Groove in shaft

12
NOTES
CONTACT
Andersen Stainless Steel Winches®are manufactured by Ronstan Denmark ApS.
Jægervænget 36
7100 Vejle
Denmark
[e-mail]
WORLDWIDE DISTRIBUTION & SERVICE
andersenwinches.com
WARRANTY
andersenwinches.com
Andersen Stainless Steel Winches®is a registered trademark of Ronstan Denmark ApS