Harken 20.2 PTBBB Manual

Radial Winch 20.2 PT
BBB / CCC
Installation and Maintenance Manual
MRW-A

2
Radial Winch 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
Index
Introduction 3
Technical characteristics 3
Weights 3
Maximum working load 3
Outline 3
Installation 4
Procedure 5
Installation procedure 6
Maintenance 7
Washing 7
Maintenance table 7
Disassembly procedure 7
Exploded view with maintenance products 10
Assembly 11
Harken®limited worldwide warranty 11
Ordering spare parts 11
Exploded view 13
Parts List 15
Radial Winch 20 PTBBB 15
Radial Winch 20 PTCCC 16

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Radial Winch 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
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 6,95 : 1 1 : 1
2nd speed 19,20 : 1 2,76 : 1
The theoretical power ratio does not take friction into account.
Weights
PT BBB/CCC versions
Weight (Kg) 3,60
Versions:
BBB = all bronze
CCC = All-Chrome bronze
Maximum working load
WARNING!
The maximum working load (MWL) for the 20.2 PT Radial Winch is 550 Kg (1213 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
Line entry height
128 mm
Ø73,5 mm
Ø137 mm
61 mm

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Radial Winch 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
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 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
The winch can be installed following the procedure below:
Procedure
To install the winch you must remove the drum and use Socket Head (SH) and 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.
Torque to apply when assembling
Install the winch on the deck in the position you have chosen, keeping in mind the limits described
on page 3.
1. Unscrew the central screw ( 2Nm/18 in-lb) 2. Lift off the drum n°12 with the socket n°18

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Radial Winch 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
Installation procedure
Carry out the 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
B. Remove the winch and drill the ve 6.2 mm diameter holes.
C. Bolt the base of the winch to the deck using ve M6 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.
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 the Procedure in the reverse order, and apply the
products indicated in the section on maintenance.

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Radial Winch 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
NOTICE
Before closing the winch, make sure the holes and drainage channels in the base of the winch
are not obstructed.
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.
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 ve hex key
Rags
To identify the various parts refer to the exploded view at the end of this Manual.
Torque to be applied in assembly phase
Maintenance

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Radial Winch 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
Carry out the Procedure as shown in the paragraph on winch installation and then do the following:
5. Slide out the central shaft n°6 6. Remover the pin n°5
7. Slide off gear n°2 8. Slide off gear n°10
3. Completely unscrew the three screws n°17 4. Remove the socket support n°11

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Radial Winch 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
Once the winch is completely disassembled, clean the parts with a degreasing that does not leave
residues, proper to clean metal components; 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!
9. Unscrew the screw n°9 and remove the
washer n°8 ( 4Nm/35 in-lb)

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Radial Winch 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
Exploded view with maintenance products
G
G
A
A
Harken ®Grease
G
Harken ®Pawl Oil
O
Axial Threadlocker
T
Anti-seize
A
G
G
G
T
O
O
1
2
Apply Harken®grease where indicated above
Apply Harken®grease: 1. on assy socket screw - 2. on drum gear
NOTICE
On every gear and every component that must be greased, apply Harken®grease with a brush in a proper
quantity as shown below:
NOTICE
Harken®grease to apply on all
teeth: do not use excessive
quantity of product to void wastes.
If in contact with the pawls, an
excess of grease can compromise
the safety of the winch.

11
Radial Winch 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
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.
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]
Harken®limited worldwide warranty
Refer to the Harken®Limited Worldwide Warranty in the Harken®Catalogue and on the website www.
harken.com
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.
OIL
W XXXXX
XXXXXXXXX
Harken®limited worldwide warranty - Ordering spare parts

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Radial Winch 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
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]

13
Radial Winch 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
Exploded view
Radial Winch 20.2 PTBBB, PTCCC
1
3
4
10
3
4
6
2
5
9
8
13
12
14
11
17
18
19
20
7
3
4
4
3
16
15

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Radial Winch 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
1
3
4
10
3
4
6
2
5
9
8
13
12
14
11
17
18
19
20
7
3
4
4
3
16
15
Exploded view
Radial Winch 20.2 PTBBB, PTCCC

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Radial Winch 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
Parts list
*Available with service kit; see website www.harken.com
**Winch product sticker
Radial Winch 20.2 PTBBB
BBB = all bronze
Pos. Q.ty Code Description
11
1
1
1
1
1
A96874100
S413740085
S413960085
S413720080
S4137300B2
S4137100A7
Assy housing Winch 20
Housing W20 CCC
Bushing Ø9xØ11x9
Bushing Ø9xØ11x12
Bushing Ø55xØ62x34
Washer Ø33.5xØ58x5.5
Bushing Ø28xØ33x25
21
2
A94136700
S418730080
Assy Gear Z18
Gear Z18
Bushing Ø9xØ11x7
36 S000080003 Pawl Ø8*
46 S000380001 Pawl Spring Ø8*
51 S413700004 Pin
61 S415660002 Central Shaft W20 PT
7 Winch Serial Number Sticker
81 S268890080 Washer
91 M0604003 Screw M6x12 UNI 5933
10 1 S413620041 Gear Z21
11 1 S7027000A0 Socket support Winch 20 PT
12 1 S416650043 Drum 20 BBB
13 1 S281670097 Red line
14 1 S416670043 Plain top W20 BBB
15 1 S678720082 Washer Ø56.5xØ75x1.5
16 3 M0638803 Screw M5x14 UNI 5931
17 3 M0601903 Screw M6x16 UNI1207
18 1 S416640046 Socket PT BBB
19 1 S415130085 Washer Ø7.7xØ25x5.8
20 1 M0614303 Screw M8x20 UNI 6109
21 Winch Product Sticker**

16
Radial Winch 20.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
Parts list
*Available with service kit; see website www.harken.com
**Winch product sticker
Radial Winch 20.2 PTCCC
CCC = All-Chrome bronze
Pos. Q.ty Code Description
11
1
1
1
1
1
A96874100
S413740085
S413960085
S413720080
S4137300B2
S4137100A7
Assy Housing Winch 20
Housing W20 CCC
Bushing Ø9xØ11x9
Bushing Ø9xØ11x12
Bushing Ø55xØ62x34
Washer Ø33.5xØ58x5.5
Bushing Ø28xØ33x25
21
2
A94136700
S418730080
Assy Gear Z18
Gear Z18
Bushing Ø9xØ11x7
36 S000080003 Pawl Ø8*
46 S000380001 Pawl Spring Ø8*
51 S413700004 Pin
61 S415660002 Central Shaft W20 PT
7 Winch Serial Number Sticker
81 S268890080 Washer
91 M0604003 Screw M6x12 UNI 5933
10 1 S413620041 Gear Z21
11 1 S7027000A0 Socket support Winch 20 PT
12 1 S416690043 Drum C W20
13 1 S281670097 Red line
14 1 S416710043 Plain Top W20 C
15 1 S678720082 Washer Ø56.5xØ75x1.5
16 3 M0638803 Screw M5x14 UNI 5931
17 3 M0601903 Screw M6x16 UNI1207
18 1 S416680046 Socket PT C
19 1 S415130085 Washer Ø7.7xØ25x5.8
20 1 M0614303 Screw M8x20 UNI 6109
21 Winch Product Sticker**