Harken Radial Winch 80.3 ST Manual

Radial Winch 80.3 ST
Installation and Maintenance Manual
MRW-02

2
Radial Winch 80.3 ST
Installation and Maintenance Manual
Index
Introduction 3
Technical characteristics 3
Weights 3
Maximum working load 3
Outline 3
Installation 4
Installation procedure 5
Positioning the self-tailing arm 8
Maintenance 9
Washing 9
Maintenance table 9
Disassembly procedure 9
Exploded view with maintenance products 13
Assembly 14
Harken®limited worldwide warranty 15
Ordering spare parts 15
Exploded view 16
Parts List 18
Radial Winch 80.3 STA 18
Radial Winch 80.3 STC 19

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Radial Winch 80.3 ST
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 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 8,01 : 1 2,76 : 1
2nd speed 28,85 : 1 9,94 : 1
3rd 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) 22,7 30,7
Versions: A = drum in anodised aluminium; C = drum in chrome bronze
Maximum working load
WARNING!
The maximum working load (MWL) for the 80.3 ST Radial Winch is 4500 Kg (9921 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
Introduction - Technical characteristics - Outline
Line entry height

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Radial Winch 80.3 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
drive gear
SHEET
8°

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Radial Winch 80.3 ST
Installation and Maintenance Manual
Installation procedure
To install the winch you must remove the drum support and use Hexagon Head (HH) cap screws.
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
1. Unscrew the assy socket n°50
3. Remove the cover plate n°48
2. Slide off the assy socket n°49
4. Unscrew the three screws n°43

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Radial Winch 80.3 ST
Installation and Maintenance Manual
6. Unscrew the three screws n°44
9. Slide out the assy ange n°19
8. Unscrew the siw screws n°237. Slide out the drum n°44
5. Remove the self-tailing arm n°47 by rotating
and lifting it
10. Slide out the assy command tube n°31

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Radial Winch 80.3 ST
Installation and Maintenance Manual
12. Unscrew the six screws n°22
13. Slide out the drum support n°15
11. Slide out the roller bearings n°18

8
Radial Winch 80.3 ST
Installation and Maintenance Manual
B. Remove the winch and drill the six 10 mm diameter holes.
C. Bolt the base of the winch to the deck using six M10 Socket Head (SH) bolts or six
hexagonal headed M10 bolts (neither is 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.
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.
Ø233
44°
40°
37°
60°
37°
46°
50°
23°
Ø287
23°
final pinion
position
Ø10 n°8
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.
The drilling cut out template is available on the Harken®website, www.harken.com

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Radial Winch 80.3 ST
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.
In the case of doubt contact Harken®Tech Service at [e-mail]
Disassembly procedure
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
Carry out Installation procedure (page 4) as shown in the paragraph on winch installation and
then do the following:
Maintenance
14. Slide out the assy clutch 3rd speed 15. Slide out the assy ratchet hub 2nd speed

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Radial Winch 80.3 ST
Installation and Maintenance Manual
16. Remove the washer n°10 17. Slide out roller bearings n°2 and gear n°13
18. Remove the roller bearing n°2 and the
washer n°14
19. Remove the roller bearing n°2 and the
washer n°10
20. Remove the gear n°12 21. Remove the washer n°10

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Radial Winch 80.3 ST
Installation and Maintenance Manual
22. Slide out the gear assy n°9 23. Remove the gear n°4
24. Remove the washer n°3 25. Remove the roller bearing n°2
26. Remove the central shaft n°25 and the
washer n°27
27. Remove the washer n°26
Important: The plastic washer must be
positioned in contact with the winch base.

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Radial Winch 80.3 ST
Installation and Maintenance Manual
I. Unscrew the 3 screws n°44
( 4Nm/35 in-lb)
II. Remove the jaws
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!

13
Radial Winch 80.3 ST
Installation and Maintenance Manual
Exploded view with maintenance products
Harken®Grease
G
Harken®Pawl Oil
O
Anti-seize
A
A
A
A
A
G
G
G
G
O
O
O
O
G
G
G
G
G
G
G
O
G
1
G
2
1.Apply Harken®grease on assy socket screw - 2.Apply Harken®grease on drum gear

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Radial Winch 80.3 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 Housing
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 clutch pin
Mount the spring with the pin pointing
upwards so that it is wound in an anti-
clockwise direction starting from the pin.
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]

15
Radial Winch 80.3 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
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.
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
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]
W XXXXX
XXXXXXXXX

16
Radial Winch 80.3 ST
Installation and Maintenance Manual
Exploded view
Exploded view
42
47
45
17
41
32
19
44
31
43
16
15
23
22
24
1
26
27
25
10
3
8
11
7
4
14
18
2
28
5
29
9
33 30
38
20
39
37
40
21
10
2
6
7
12
7
6
8
13
2
10
6
36
35
34
46
48
48
2
Radial Winch 80.3 STA, STC

17
Radial Winch 80.3 ST
Installation and Maintenance Manual
42
47
45
17
41
32
19
44
31
43
16
15
23
22
24
1
26
27
25
10
3
8
11
7
4
14
18
2
28
5
29
9
33 30
38
20
39
37
40
21
10
2
6
7
12
7
6
8
13
2
10
6
36
35
34
46
48
48
2
Radial Winch 80.3 STA, STC

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Radial Winch 80.3 ST
Installation and Maintenance Manual
Parts list
Radial Winch 80.3 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**
26 A74506900 Bearing Ø25xØ35x15
31 S434170081 Washer Ø69xØ45x1,5
41 S423870004 Gear Z=36 - Winch 990 PR 80
51 S402260041 Bushing 4th. gear pinion
612 S392440004 Pawl Ø10*
712 S285040001 Pawl Spring*
88 HFS753 plug-pawl retainer
91 S405580004 Pinion 3rd speed
10 3 S434110081 Washer Ø48xØ26x1,5
11 1 S405830004 Shaft -FD pinion
12 1 S405550004 Gear Z36 - Winch 990
13 1 S405540004 Final Drive Pinion
14 1 S438860081 Washer Ø54xØ35,2x3
15 1 A94158700 Assy Housing W80
Housing W80-1000
Bushing 39x32x22
Heli-coil M6x9
16 Winch Serial Number Sticker
17 1 A74059500 Roller Bearing lower 990
18 1 A74158900 Roller bearing Ø148x160x30
19 1 A94159600 Assy flange
Stripper arm support
Heli-coil M6x9
20 1 A73129200 ROLLER BEARING 50-62-20 ERTA P
21 1 S413880002 Washer Ø17.2xØ32x1.5
22 6 M0624603 Screw M8x40 UNI5931
23 6 M0635103 Socket head screw M6x16 UNI 5931
24 1 S386550097 Red line
25 1 S416400004 Shaft Z13 W80
26 1 S434160081 Washer Ø59xØ26x1,5
27 1 S402050004 Washer Ø25,2xØ61x2,4
Pos. Q.ty Code Description
28 1 S405860080 Spacer
29 1
1
A94055700
S455420081
Assy Pinion Z14
Pinion Z14
Bushing Ø24,5xØ28,5x27
30 1 S405620004 hub 2nd Ratchet
31 1
1
2
A94159500
S415420004
M6009463
Assy Clutch 3rd speed W80
Assy command tube W80
Dog Clutch 3 speed
Spring loaded ball plunger Ø6
32 1 S4155700A0 Stripper arm support
33 1 S415400004 Pawls Carrier 3 speed
34 1 S495120080 Washer Ø50,2xØ69x1,5
35 2 S000080003 Pawl Ø8*
36 2 S000380001 Pawl Spring Ø8*
37 1 S417990041 Ratchet Gear Z21xN4
38 1 S418000080 Flange 1st speed W80
39 1 S377510001 Clutch Spring
40 1 A73422600 Bearing 45x55x12
41 3 M0601903 Screw M6x16 UNI1207
42 1 A74159000 Drum assembly W80
43 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"
44 3 M0624703 Screw M8x50 UNI5931
45 1 A94159901 Kit stripper arm
Stripper-arm W80
Pin
46 1 S4180100B7 Cover W80.3 ST
47 1
1
1
A94154700
S415130085
M0614303
Assy Socket 3speed
Socket Handle 3 speed
Washer Ø7.7xØ25x5.8
Screw M8x20 UNI 6109
48 1
1
1
1
1
1
2
1
A96726500
S672650004
S414550081
S672840080
S417980004
M0679903
M0603103
M0632403
W80-1000 3 speed kit
winch 80-1000 3 Speed Pin
Bushing Ø22xØ25x15.5
Washer 3 speed W80-1000
Idler Gear Z12
Nut selflock UNI 7473:1975 - M8 - A4
WASHER 8.4 U1751 DIN127 A4
Screw M8x45 UNI 5931
Parts List
*Available with service kit; see website www.harken.com
**Winch product sticker

19
Radial Winch 80.3 ST
Installation and Maintenance Manual
Parts list
*Available with service kit; see website www.harken.com
**Winch product sticker
Radial Winch 80.3 STC
C=drum in chrome bronze
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**
26 A74506900 Bearing Ø25xØ35x15
31 S434170081 Washer Ø69xØ45x1,5
41 S423870004 Gear Z=36 - Winch 990 PR 80
51 S402260041 Bushing 4th. gear pinion
612 S392440004 Pawl Ø10*
712 S285040001 Pawl Spring*
88 HFS753 plug-pawl retainer
91 S405580004 Pinion 3rd speed
10 3 S434110081 Washer 48x26x1,5
11 1 S405830004 Shaft -FD pinion
12 1 S405550004 Gear Z36 - Winch 990
13 1 S405540004 Final Drive Pinion
14 1 S438860081 Washer Ø54xØ35,2x3
15 1 A94158700 Assy Housing W80
Housing W80-1000
Bushing 39x32x22
Heli-coil M6x9
16 Winch Serial Number Sticker
17 1 A74059500 Roller Bearing lower 990
18 1 A74158900 Roller bearing Ø148x160x30
19 1 A94159600 Assy flange
Stripper arm support
Heli-coil M6x9
20 1 A73129200 ROLLER BEARING 50-62-20 ERTA P
21 1 S413880002 Washer Ø17.2xØ32x1.5
22 6 M0624603 Screw M8x40 UNI5931
23 6 M0635103 Socket head screw M6x16 UNI 5931
24 1 S386550097 Red line
25 1 S416400004 Shaft Z13 W80
26 1 S434160081 Washer Ø59xØ26x1,5
27 1 S402050004 Washer Ø25,2xØ61x2,4
Pos. Q.ty Code Description
28 1 S405860080 Spacer
29 1
1
A94055700
S455420081
Assy Pinion Z14
Pinion Z14
Bushing Ø24,5xØ28,5x27
30 1 S405620004 Hub 2nd Ratchet
31 1
1
2
A94159500
S415420004
M6009463
Assy Clutch 3rd speed W80
Assy command tube W80
Dog Clutch 3 speed
Spring loaded ball plunger Ø6
32 1 S4155700A0 Stripper arm support
33 1 S415400004 Pawls Carrier 3 speed
34 1 S495120080 Washer Ø50,2xØ69x1,5
35 2 S000080003 Pawl Ø8*
36 2 S000380001 Pawl Spring Ø8*
37 1 S417990041 Ratchet Gear Z21xN4
38 1 S418000080 Flange 1st speed W80
39 1 S377510001 Clutch Spring
40 1 A73422600 Bearing 45x55x12
41 3 M0601903 Screw M6x16 UNI1207
42 1 A74159100 Drum assembly W80 C
43 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"
44 3 M0624703 Screw M8x50 UNI5931
45 1 A94159901 Kit stripper arm
Stripper-arm W80
Pin
46 1 S4180100B7 Cover W80.3 ST
47 1
1
1
A94154700
S415130085
M0614303
Assy Socket 3speed
Socket Handle 3 speed
Washer Ø7.7xØ25x5.8
Screw M8x20 UNI 6109
48 1
1
1
1
1
1
2
1
A96726500
S672650004
S414550081
S672840080
S417980004
M0679903
M0603103
M0632403
W80-1000 3 speed kit
winch 80-1000 3 Speed Pin
Bushing Ø22xØ25x15.5
Washer 3 speed W80-1000
Idler Gear Z12
Nut selflock UNI 7473:1975 - M8 - A4
WASHER 8.4 U1751 DIN127 A4
Screw M8x45 UNI 5931