Harken 1111 HL Operating instructions

User and maintenance manual Winch 1111 HL –Mod.A
Winch 1111 HL
Self-Tailing
USER AND MAINTENANCE MANUAL

User and maintenance manual Winch 1111 HL –Mod.A
INDEX
1. Glossary.....................................................................................................................................................3
2. Symbols .....................................................................................................................................................3
3. Safety information................................................................................................................................... 3
4. General advice..........................................................................................................................................5
5. Harken®limited Worldwide warranty..................................................................................................5
6. Product information................................................................................................................................6
7. Product identification.............................................................................................................................7
8. Rope diameter ..........................................................................................................................................9
9. Product composition............................................................................................................................10
10. Winch Outline.....................................................................................................................................11
11. Technical characteristics ................................................................................................................11
12. Motorization........................................................................................................................................12
13. Installation...........................................................................................................................................13
13.1 Winch positioning.............................................................................................................................15
13.2 Installation procedure .....................................................................................................................16
13.3 Installation with sensors.................................................................................................................19
14. Use.........................................................................................................................................................20
14.1 Rope positioning ...........................................................................................................................20
14.2 Manual use......................................................................................................................................21
14.3 Motorized use.................................................................................................................................22
15. Cleaning and maintenance..............................................................................................................24
15.1 Internal maintenance procedure................................................................................................25
15.2 Disassemble procedure –winch 1111 HL –1st direct gear and 1st reduced gear......27
15.3 Disassemble procedure –Winch 1111 HL 1R........................................................................29
16. Assembling .........................................................................................................................................37
16.1 Marking....................................................................................................................................................38
17. Troubleshooting.................................................................................................................................39
18. Ordering spare parts.........................................................................................................................40
19. Contact us ...........................................................................................................................................41

User and maintenance manual Winch 1111 HL –Mod.A
1. Glossary
-Intended use: specific and proper use of the winch for which it is designed
-Improper use: use of the device in a different way from that indicated in the -
instructions for use specified in this manual
-Qualified operator: person who has attended specialization and training about the use of
the winch
-User: person who uses the winch regularly
-Maximum working load (MWL): maximum value of the load the winch can bear
2. Symbols
WARNING!
This denotes the existence of the potential danger, which could cause injury
or damage if the information or instructions are not followed
NOTE!
This denotes important information concerning the device
3. Safety information
WARNING! Read this manual carefully and fully understand before using the
system to avoid personal injury or property damage during system operation.
- This manual is an integral part of the device and provides all the information needed
for its safe and correct use and for proper maintenance.
- This manual gives technical information on winch installation and maintenance.
- This information is destined exclusively for qualified operators.
- Installation of the winch by personnel who are not experts may cause serious damage
to users and those in the proximity of the winch.
- Install and use the winch only as described in the technical information supplied.
- Improper use can cause severe harms to users, equipment and the boat.

User and maintenance manual Winch 1111 HL –Mod.A
- Never substitute any winch part with one that is not original. Even though they look
similar and are both made by Harken®, the non-original part may not be suitable and the
warranty will be invalidated.
- Modifications carried out by the user, without explicit written authorization from the
manufacturer, will invalidate the warranty and relieve the manufacturer of any
responsibility for damage or injury caused by the defective product.
- Failure to install the winch will void the warranty of the device itself and the Harken®
product to which it is connected.
- Refer to the warranty on the web site www.harken.com.
- Do not apply to the winch loads greater than the MWL (Maximum Working Load).
- If the winch is powered by an electric motor:
Make sure the power is switched off before installing or carrying out maintenance on the
winch
- If the winch is powered by a hydraulic motor:
Do not operate the hydraulic motor during installation or maintenance.
Do not let the oil in the system come into contact with your eyes or skin.
Harken®cannot be responsible for damage or injury resulting from unsafe product use,
lack of maintenance or incorrect product and /or system installation or operation.
- Wear suitable clothing when using the winch, to avoid loose ends of fabric becoming
entangled in the winch.
- Periodical maintenance must be carried out regularly as specified in the chapter on
Maintenance. In case of doubt, contact Harken Tech Service.
- 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. For any concerns,
questions or comments contact the Harken distributor nearest to you, Special Project
assistance, or contact the Harken Italy Technical Service by e-mail:
[email protected]
- See www.harken.com for additional safety information.

User and maintenance manual Winch 1111 HL –Mod.A
4. General advice
Intended use
This Harken winches are designed and manufactured for use on sail boats to control
sheets, halyards and related sail and rig systems.
For any other usage, contact the Harken Italy Technical Service by e-mail:
[email protected]
Improper use
- This Harken winch must not be used for purposes different from those outlined in
“Intended use” chapter, or for purposes not mentioned in this manual or different from
those mentioned.
- The Harken winch must not be used if unauthorized modifications or interventions have
been carried out.
- Do not use the winch for hauling, mooring the boat or weighing the anchor.
- Do not wind line turn around the base of the winch drum.
- Do not use the winch to divert a line (cross-sheeting).
5. Harken®limited Worldwide warranty
The Harken Winch is covered by a warranty: if during the warranty period the winch
proves defective or suffers breakages, as indicated in the warranty, the manufacturer,
after checking the device, will repair or replace the defective components.
NOTE!
Refer to the Harken®Limited Worldwide Warranty in the Harken Catalogue
and on the website www.harken.com

User and maintenance manual Winch 1111 HL –Mod.A
6. Product information
Winch 1111 HL is designed with a special care to the regatta’s needs, but it may be
effectively employed on cruiser yachts and used to trim and hoist sails.
It’s produced in the Self-Tailing version (ST).
It’s supplied with 3 speeds or with the reduced first gear.
Winch 1111 HL can be operated differently:
- manually, with the Winch handle
- by an under-deck transmission (Coffee Grinder)
- by an electric motor or a hydraulic motor

User and maintenance manual Winch 1111 HL –Mod.A
Legend
Reduction:
1R = 1st reduced speed
Version:
HL = High load
Top version:
ST = Self-Tailing
Materials:
A = Aluminum
S = Stainless Steel
C = Carbon (not available for drums)
Handling rotation:
Omitted = Right Hand
LH = Left Hand
Motorization:
HY = Hydraulic
EL = Electric
7. Product identification
The product identification is based on the Winch composition and technical functions:
7.1 Speed
Each speed of the Winch 1111 HL is used for different load performances.
First speed is used to recover a lot of line with very low loads.
Second speed recovers a fair amount of line with medium loads.
Third speed provides the slowest speed but allows higher loads to recover small
amounts of line.
7.2 Reduction
Winch 1111 HL can be chosen with direct (omitted notation) or reduced first gear (‘1R’
notation).
The first gear reduced Winch 1111 HL has higher gear ratio and higher power ratio than
the first direct gear Winch.
Specify the requested version at the order in the Winch description pointing out the ‘1R’
indication.
For gear ratios and power ratios, see paragraph ‘Technical characteristics’ of this
manual.
Product
Size
Speed
Top
version
Materials
Handling
rotation
Motorization
Winch
1111HL
.3
ST
Base
Drum
Top
Right /Left
hand
Hydraulic/
Electric
Top
Drum
Skirt

User and maintenance manual Winch 1111 HL –Mod.A
7.3 Version
Winch 1111 HL is designed to put a maximum working load (MWL) of 7000Kg.
WARNING!
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.
7.4 Materials
Available versions
CSC = carbon skirt; aluminum drum; carbon top
SSS = stainless steel skirt; stainless steel drum; stainless steel top
ASA = aluminum skirt; stainless steel drum; aluminum top
NOTE!
If other versions are required, contact Harken Customer Service at
[email protected]
Stainless steel
Aluminum
Carbon
Stainless steel
Aluminum
Carbon
Top versions
Skirt versions

User and maintenance manual Winch 1111 HL –Mod.A
Weights
NOTE!
Weights refer to the Winch without the motorization. For motors weights,
refer to the
Winch 1111 Motorization manual available on request from the Harken Italy
Tech Service at [email protected].
7.5 Handling rotation
NOTE!
Winch 1111 HL is available in the right-hand version and in the left-hand
version.
In the right-hand winch, drum rotates clockwise; in the left-hand winch, drum
rotates counterclockwise.
8. Rope diameter
WARNING!
For safety and correct performances, use ropes of the diameters indicated
below.
NOTE!
Harken Self-Tailing winches have jaws preloaded with springs that adapt
automatically to the following rope diameters range: 11-19mm.
Version
Weight [Kg]
CSC
38
SSS
54
ASA
42
Right-hand
Left-hand (LH)

User and maintenance manual Winch 1111 HL –Mod.A
9. Product composition
Winch 1111 HL is composed by the following groups:

User and maintenance manual Winch 1111 HL –Mod.A
10. Winch Outline
NOTE!
The following dimensions refer to ST EL/HY Winch (all material versions).
See the ‘Winch 1111 motorization manual’ for dimensions of the motorized
versions.
All dimensions are in [mm]
11. Technical characteristics
Gear ratios and Power ratios
NOTE!
The theoretical power ratio is calculated without taking account of friction.
1st direct speed Winch
Gear
Gear ratio
Power ratio
1st
2.63
4.76
2nd
9.69
17.58
3rd
44.67
81.05
1st reduced speed Winch
Gear
Gear ratio
Power ratio
1st
1
1.81
2nd
9.69
17.58
3rd
44.67
81.05
Deck

User and maintenance manual Winch 1111 HL –Mod.A
12. Motorization
Hydraulic equipment (HY)
Hydraulically operated winches have a load capacity proportional to the working
pressure of the system, while the recovery speed of the winch is proportional to the oil
flow.
The hydraulic vertical versions of the Winch 1111 HL can be equipped by:
- hydraulic motor of 80cc displacement
- hydraulic motor of 100cc displacement
- hydraulic motor of 160cc displacement
Electric equipment (EL)
The electric version of the Winch 1111 HL can be equipped by:
- electric motor powered at 24V, DC, horizontal mounting.
- electric motor powered at 24V, DC, vertical mounting.
- electric motor powered at 48V, DC, horizontal mounting.
- electric motor powered at 48V, DC, vertical mounting.
- electric motor powered at 400V, AC, horizontal mounting.
NOTE!
For the electric connections Winch 1111 HL-electric powered unit, see the
‘Winch 1111 motorization manual’.
For any other information, contact Harken Tech Service at
[email protected]
NOTE!
For motor performances, weights, parts lists and exploded views of the
gearmotor assemblies and other details, refer to the ‘Winch 1111
motorization manual’.

User and maintenance manual Winch 1111 HL –Mod.A
13. Installation
WARNING!
Install the winch correctly and solidly on a flat area of the deck and ensure
that the deck is robust enough to support the working loads of the winch.
Consult the boatbuilder if you have any doubts about a suitable location for
the winch.
NOTE!
Before installation the winch must be partially disassembled.
Follow the steps of the ‘Disassembly procedure’illustrated in the chapter
‘Maintenance’ of this manual until the drum support is removed.
Once the drum support is removed and the base of the winch is revealed,
deck installation can begin.
WARNING!
In deciding where to install the winch make sure that the rope is not parallel
to the base of the winch to avoid turns of the rope fouling around the drum,
which could seriously damage the winch and/or put the crew in danger. This
dangerous fouling can be avoided by ensuring an entry angle for the rope of
8°.
NOTE!
The correct entry line angle is: 8°
CORRECT!

User and maintenance manual Winch 1111 HL –Mod.A
WARNING!
Situation to avoid: incorrect entry angle for the rope of more than 8°.
Beware of the rope chafing on the base of the winch.
WARNING!
Situation to avoid: incorrect entry angle with the rope parallel to the base of
the winch.
Beware of turns of the rope fouling on the drum.
INCORRECT!
INCORRECT
!

User and maintenance manual Winch 1111 HL –Mod.A
13.1 Winch positioning
NOTE!
Install the winch bearing in mind that the final pinion should be placed,
relative to the point where the first turn of the rope touches the drum, so that
the tangent to this point and the direction in which the load is applied forms
an angle of between 0° and 30°, if this is compatible with the space available
below deck.
NOTE!
For the rope positioning, see the ‘Use’ chapter of this manual
After correctly positioning the final pinion with respect to the load, check that the motor,
gearing, electrical wiring or hydraulic pipes can be housed below decks.
Once you have decided on the correct placing of the winch on the deck and checked the space
available below deck, proceed with the installation procedure steps, making reference to the
mounting template.
VIEW FROM ABOVE

User and maintenance manual Winch 1111 HL –Mod.A
13.2 Installation procedure
A. Place the drilling cut-out template over the point chosen for installation.
The template in DWG format for Winch 1111 HL is available on request from the Harken
Italy Tech Service at [email protected].
Small-scaled mounting template for Winch 1111 HL versions is shown below.
For mounting templates of custom Winch 1111 HL version, refer to the boat custom
manual provided by Harken.
For 1:1 mounting templates, contact Harken at techser[email protected]
VIEW FROM ABOVE
MOUNTING TEMPLATE

User and maintenance manual Winch 1111 HL –Mod.A
A.1 A hole of Ø132mm is needed to house the base of the winch
A.2 The 8 Ø11mm holes are on a circumference of Ø 271mm and of Ø278mm
B. Mark the position of the holes to be drilled in the deck.
C. Drill the holes.
D. Seal the external part of the main holes and all the fixing holes with a suitable marine
adhesive sealant as shown in the following image (green lines).
To apply the adhesive sealant: clean and remove all grease from winch bottom surface and
apply the sealant.
NOTE!
Make sure the drainage holes in the base of the winch are not obstructed by the
sealant so as to avoid water collecting in the base of the winch.
NOTE!
If the winch is equipped with riser, seal the external parts of all fixing holes with a
suitable marine adhesive sealant following the mounting template of the riser.
After sealing the riser, proceed with the sealing of the winch base as shown above.
For the mounting template of the riser, contact Harken at techse[email protected]
VIEW FROM ABOVE
SEALING TEMPLATE

User and maintenance manual Winch 1111 HL –Mod.A
E. Disassemble the winch until fig. # of the ‘Maintenance’ chapter of this manual.
F. Position the base of the winch on the deck and bolt it in place using through M10 screws
of a suitable length for the thickness of the deck.
NOTE!
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.
WARNING!
Fix the winch to the deck using screws in A4-70 stainless steel.
G. Remove excess marine sealant.
H. Reassemble the winch following the various steps of the disassembly procedure in
reverse order.
For the disassembly procedure, refer to the ‘Disassembly procedure’ chapter of this manual.
WARNING!
The mounting bolts must be isolated with anti-corrosive lubricants.
It is mandatory to prevent any direct contact between the aluminum captive frame
from other conductive materials such as carbon fiber (deck or hull); in that case a
fiberglass lamination is required to avoid any galvanic corrosion.

User and maintenance manual Winch 1111 HL –Mod.A
13.3 Installation with sensors
If required, Winch 1111 HL can be equipped with encoder sensor or with 1st gear
recognition sensor.
Sensors are installed as cables pass through the slots in correspondence of the
drainage passages of the winch base, as shown below:
For any other information about the sensor kits, refer to the sensors manuals by
contacting Harken Tech Service at [email protected].
VIEW FROM ABOVE

User and maintenance manual Winch 1111 HL –Mod.A
14. Use
14.1 Rope positioning
NOTE!
The following instructions are available for right-hand winches; for left-hand
versions all the rotations are opposite.
Before use, verify that:
- The correct rope diameter is used, as indicated in the ‘Installation’ chapter of this
manual
- The most comfortable position of the peeler relative to the user of the winch is chosen.
- The correct line entry (8°) is guaranteed.
NOTE!
Take turns of the rope around the drum: the more turns are taken, the lower
the load the user has to handle.
The more turns around the drum are taken, the more the winch can reach the
Maximum Working Load (MWL).
After the proper verifies, user can insert rope into the Self-tailing jaws, as described
below:
1. Put rope of the final turn on the peeler
2. Insert rope between the jaws of the Self-Tailing
NOTE!
For right-hand winches, rope must be wrapped around the drum clockwise
Rop
e