Harken Radial Winch 80.2 STA Manual

Radial Winch 80.2 ST
Installation and Maintenance Manual
MRW-05

2
Radial Winch 80.2 ST
Installation and Maintenance Manual
Index
Introduction 3
Technical characteristics 3
Weights 3
Maximum working load 3
Outline 3
Installation 4
Installation Procedure 4
Disassembly Procedure 5
Positioning the self-tailing arm 10
Maintenance 10
Washing 10
Maintenance table 10
Exploded view with maintenance products 12
Assembly 13
Harken®limited worldwide warranty 14
Ordering spare parts 14
Exploded view 15
Parts List 17
Radial Winch 80.2 STA 17
Radial Winch 80.2 STC 18

3
Radial Winch 80.2 ST
Installation and Maintenance Manual
Introduction - Technical characteristics - Outline
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 techser[email protected]
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 28,85 : 1 9,94 : 1
2nd speed 93,24 : 1 32,12 : 1
The theoretical power ratio does not take friction into account.
Weights
ST A version ST C version
Weight (Kg) 21,2 28,8
Versions: A = drum in anodised aluminium; C = drum in chrome bronze
Maximum working load
WARNING!
The maximum working load (MWL) for the 80.2 ST Radial Winch is 4500 Kg (9920 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.
Outline
320
164
Ø287
320
Ø177
164
Ø287
Ø177
320
164
Ø287
Ø177
320
164
Ø287
Ø177
320
164
Ø287
Ø177
181
69
394
140
130
250
Line entry height

4
Radial Winch 80.2 ST
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.
Once you have chosen the correct mounting position for the winch on the deck proceed with
installation.
Installation Procedure
To install the winch you must follow and complete the Disassembly procedure.
Installation
drive gear
SHEET
8°

5
Radial Winch 80.2 ST
Installation and Maintenance Manual
1. Unscrew the central screw ( 2Nm/18 in-lb) 2. Slide off the assy socket n°39
3. Slide off the assy cover n°38 4. Unscrew the three screws n°37
(4Nm/35 in-lb) and remove the stripper
arm n°36 by rotating and lifting it.
Disassembly Procedure
To install the winch you must remove the drum and use Socket Head (SH) bolts.
Tools needed:
One medium at-bladed screwdriver
A number six hex key
Rags
To identify the various parts, refer to the exploded view at the end of this Manual.
Torque to apply when assembling

6
Radial Winch 80.2 ST
Installation and Maintenance Manual
5. Lift off the drum n°15
7. Lift off the assy housing n°18
9. Slide out the inner spacer n°34 and the
roller bearing n°23
6. Completely unscrew the six screws n°25
(20Nm/177 in-lb)
8. Slide out the washer n°24
10. Slide out the assy pinion n°32 and the
spacer n°31

7
Radial Winch 80.2 ST
Installation and Maintenance Manual
11. Disassemble the Assy pinion n°33 and the
hub n°32
13. Remove washers n°30 and n°29
Important: The plastic washer must be posi-
tioned in contact with the winch base.
15. Slide out the washer n°5
12. Slide out the shaft n°28
14. Slide out the roller bearing n°6 and the
washer n°5
16. Slide out the nal drive pinion n°9

8
Radial Winch 80.2 ST
Installation and Maintenance Manual
17. Slide out the gear n°10
19. Remove the shaft n°7
21. Remove the gear n°14
18. Slide out roller bearings n°6 and washer
n°8
20. Remove the pinion n°13
22. Remove the roller bearing n°6 and the
washer n°11

9
Radial Winch 80.2 ST
Installation and Maintenance Manual
The drilling cut out template is available on the Harken®website, www.harken.com
B. Remove the winch and drill the eight 10.2 mm diameter holes.
C. Bolt the base of the winch to the deck using eight M10 Socket Head (SH) bolts (not supplied
by Harken®), 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.
Carry out Installation procedure then install the winch on the deck in the chosen position.
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.
Ø233
44°
40°
37°
60°
37°
46°
50°
23°
Ø287
23°
final pinion
position
Ø10 n°8

10
Radial Winch 80.2 ST
Installation and Maintenance Manual
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 Installation procedure (page 5) in the reverse
order, and apply the products indicated in the section on maintenance.
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.
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.
In the case of doubt contact Harken®Tech Service at [e-mail]
Maintenance

11
Radial Winch 80.2 ST
Installation and Maintenance Manual
If it is necessary to replace any jaws of the winch, proceed as follows:
Inspect balls inside the drum and carefully check the correct position; if it is necessary to put back
any balls, push balls in the race (as shown below):
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!
I. Unscrew the 3 screws n°17
( 4Nm/35 in-lb)
II. Remove the jaws

12
Radial Winch 80.2 ST
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
GG
O
O
O
A
A
G
1
G
2

13
Radial Winch 80.2 ST
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.
The icon on the Stripper Arm Hou-
sing indicates the Stripper Arm nal
position.
Change the Stripper Arm Housing
angle to modify the Stripper Arm nal
position.
When positioning the stripper arm,
align the peeler with 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.
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.
In case of doubt concerning the assembly procedure contact Harken®Tech Service:
[e-mail]

14
Radial Winch 80.2 ST
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
Harken® limited worldwide warranty - Ordering spare parts
Headquarters
Harken®, Inc.
1251 East Wisconsin Avenue
Pewaukee, Wisconsin 53072-3755 USA
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Web: www.harken.com
Manufacturer
Harken®Italy S.p.A.
Via Marco Biagi, 14
23570 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.
W XXXXX
XXXXXXXXX

15
Radial Winch 80.2 ST
Installation and Maintenance Manual
Exploded view
Exploded view
38
39
36
15
37
16
17
16
24
26
21
18
25
20
19
27
29
30
1
7
10
13
4
31
32
8
5
3
9
2
6
33
23
34
6
12
4
28
5
5
6
11
6
14
35
22
Radial Winch 80.2 STA, STC

16
Radial Winch 80.2 ST
Installation and Maintenance Manual
38
39
36
15
37
16
17
16
24
26
21
18
25
20
19
27
29
30
1
7
10
13
4
31
32
8
5
3
9
2
6
33
23
34
6
12
4
28
5
5
6
11
6
14
35
22
Radial Winch 80.2 STA, STC

17
Radial Winch 80.2 ST
Installation and Maintenance Manual
*Available with service kit; see website www.harken.com
**Winch product sticker
Parts lists
Radial Winch 80.2 STA
A= drum in anodised aluminium
Pos. Q.ty Code Description
11
1
1
1
A94158200
A74506900
S476030004
M0620697
Base assembly
Base winch 80
Bearing Ø25xØ35x15
Plug for instrumented base Ø13x4
Heli-coil M8x10
Centering bushing Ø12
Heli-coil M10x10
Bush gear shaft Ø32xØ39x22
Bushing Ø39xØ32x22
Seal Ø25xØ47x7
Winch Product Sticker**
212 S285040001 Pawl Spring*
312 S392440004 Pawl Ø10*
48 HFS753 plug-pawl retainer
53 S434110081 Washer Ø48xØ26x1,5
66 A74506900 Bearing Ø25xØ35x15
71 S405830004 Shaft -FD pinion
81 S438860081 Washer Ø54xØ35,2x3
91 S405540004 Final Drive Pinion Winch 990
10 1 S405550004 Gear Z36 - Winch 990
11 1 S434170081 Washer Ø69xØ45x1,5
12 1 S402260041 Bushing 4th.gear pinion
13 1 S405580004 Pinion 3rd speed
14 1 S423870004 Gear Z=36 - Winch 990 PR 80
15 1 A74159000 Drum assembly W80
16 1
6
1
44
A94159200
S385970001
S6876800C0
M0610280
Assy Jaws Winch 80
Upper Jaw ST W80
Lower Jaw ST W80
SPRING
Peeler winch 80
Ball 5/16"
17 3 M0624703 Screw M8x50 UNI5931
18 1 A94158700 Assy Housing W80
Housing W80-1000
Bushing Ø39xØ32x22
Heli-coil M6x9
19 1 A74059500 Roller Bearing lower 990
Parts List
Pos. Q.ty Code Description
20 1 A74158900 Roller bearing Ø148x160x30
21 1 A94159600 Assy flange
Stripper arm support
Heli-coil M6x9
22 1 S4144300A0 Stripper Arm Housing W60/70
23 1 A73129200 ROLLER BEARING 50-62-20 ERTA P
24 1 S413880002 Washer Ø17.2xØ32x1.5
25 6 M0624603 Screw M8x40 UNI5931
26 6 M0635103 Socket head screw M6x16 UNI 5931
27 1 S386550097 Red line
28 1 S416400004 Shaft Z13 W80
29 1 S434160081 Washer Ø59xØ26x1,5
30 1 S402050004 Washer Ø25,2xØ61x2,4
31 1 S405860080 Spacer
32 1
1
A94055700
S455420081
Assy Pinion Z14
Pinion Z14
Bushing Ø24,5xØ28,5x27
33 1 S405620004 Hub 2nd Ratchet
34 1 S415860080 Inner spacer
35 Winch Serial Number Sticker
36 1 A94159901 Kit stripper arm
Stripper-arm W80
Pin
37 3 M0601903 Screw M6x16 UNI1207
38 1
1
1
A94136400
S415130085
M0614303
Assy Socket W20-80
Socket Handle W20/80
Washer Ø7.7xØ25x5.8
Screw M8x20 UNI 6109
39 1 S4160000B7 Cover W80.2 ST

18
Radial Winch 80.2 ST
Installation and Maintenance Manual
Radial Winch 80.2 STC
C=drum in chrome bronze
*Available with service kit; see website www.harken.com
**Winch product sticker
Pos. Q.ty Code Description
11
1
1
1
A94158200
A74506900
S476030004
M0620697
Base assembly
Base winch 80
Bearing Ø25xØ35x15
Plug for instrumented base Ø13x4
Heli-coil M8x10
Centering bushing Ø12
Heli-coil M10x10
Bush gear shaft Ø32xØ39x22
Bushing Ø39xØ32x22
Seal Ø25xØ47x7
Winch Product Sticker**
212 S285040001 Pawl Spring*
312 S392440004 Pawl Ø10*
48 HFS753 plug-pawl retainer
53 S434110081 Washer Ø48xØ26x1,5
66 A74506900 Bearing Ø25xØ35x15
71 S405830004 Shaft -FD pinion
81 S438860081 Washer Ø54xØ35,2x3
91 S405540004 Final Drive Pinion Winch 990
10 1 S405550004 Gear Z36 - Winch 990
11 1 S434170081 Washer Ø69xØ45x1,5
12 1 S402260041 Bushing 4th.gear pinion
13 1 S405580004 Pinion 3rd speed
14 1 S423870004 Gear Z=36 - Winch 990 PR 80
15 1 A74159100 Drum assembly W80 C
16 1
6
1
44
A94159200
S385970001
S6876800C0
M0610280
Assy Jaws Winch 80
Upper Jaw ST W80
Lower Jaw ST W80
SPRING
Peeler winch 80
Ball 5/16"
17 3 M0624703 Screw M8x50 UNI5931
18 1 A94158700 Assy Housing W80
Housing W80-1000
Bushing 39x32x22
Heli-coil M6x9
19 1 A74059500 Roller Bearing lower 990
Pos. Q.ty Code Description
20 1 A74158900 Roller bearing Ø148x160x30
21 1 A94159600 Assy flange
Stripper arm support
Heli-coil M6x9
22 1 S4144300A0 Stripper Arm Housing W60/70
23 1 A73129200 ROLLER BEARING 50-62-20 ERTA P
24 1 S413880002 Washer Ø17.2xØ32x1.5
25 6 M0624603 Screw M8x40 UNI5931
26 6 M0635103 Socket head screw M6x16 UNI 5931
27 1 S386550097 Red line
28 1 S416400004 Shaft Z13 W80
29 1 S434160081 Washer Ø59xØ26x1,5
30 1 S402050004 Washer Ø25,2xØ61x2,4
31 1 S405860080 Spacer
32 1
1
A94055700
S455420081
Assy Pinion Z14
Pinion Z14
Bushing Ø24,5xØ28,5x27
33 1 S405620004 Hub 2nd Ratchet
34 1 S415860080 Inner spacer
35 Winch Serial Number Sticker
36 1 A94159901 Kit stripper arm
Stripper-arm W80
Pin
37 3 M0601903 Screw M6x16 UNI1207
38 1
1
1
A94136400
S415130085
M0614303
Assy Socket W20-80
Socket Handle W20/80
Washer Ø7.7xØ25x5.8
Screw M8x20 UNI 6109
39 1 S4160000B7 Cover W80.2 ST