Harken 60.3 ST E Manual

Installation and Maintenance Manual
MRW-04
Powered Radial Winch
60.3 ST E/HY

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Radial Winch 60.3 ST E/HY
Installation and Maintenance Manual
Index
Introduction 3
Technical characteristics 3
Performance data 3
Weight 4
Maximum working load 4
Outline 5
Installation 6
Installation procedure 7
Winch installation procedure 9
Positioning the self-tailing arm 10
Motor installation procedure 10
Electric wiring diagrams 11
Hydraulic connections diagram 13
Maintenance 14
Washing 14
Maintenance table 14
Disassembly procedure 14
Exploded view with maintenance products 18
Assembly 19
Harken®limited worldwide warranty 20
Ordering spare parts 20
Exploded view 21
Parts List 25
Radial Winch 60.3 STA 25
Radial Winch 60.3 STC 26
Radial Winch 60.3 STCW 27
Radial Winch 60.3 STBBB 28
Radial Winch 60.3 STCCC 29
Horizontal electric motor 30
Vertical electric motor 31
Hydraulic motor 32

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Radial Winch 60.3 ST E/HY
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 [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 9,20 : 1 2,20 : 1
2nd speed 20,30 : 1 4,80 : 1
3rd speed 61,00 : 1 14,40 : 1
The theoretical power ratio does not take friction into account.
Performance data
Winch 60.3 ST E (electric)
horizontal motor
12 V (1500 W) 24 V (2000 W)
1st
speed
2nd
speed
3rd
speed
1st
speed
2nd
speed
3rd
speed
line speed (m/min)** 38,8 17,7 5,9 46,8 21,4 7,1
max load (Kg) 290 600 1800 290 600 1800
**Line speed is measured with no load
vertical motor
12 V (1500 W) 24 V (2000 W)
1st
speed
2nd
speed
3rd
speed
1st
speed
2nd
speed
3rd
speed
line speed (m/min)** 44,5 20,3 6,8 53,5 24,4 8,1
max load (Kg) 290 600 1800 290 600 1800
**Line speed is measured with no load
Introduction - Technical characteristics - Outline

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Radial Winch 60.3 ST E/HY
Installation and Maintenance Manual
motor nominal power (W) current absorption at winch
MWL (A)
12 V 24 V 12 V 24 V
winch 60.3 ST E horizontal 1500 2000 250
225
140
120
vertical
Winch 60.3 ST HY (hydraulic)
1st speed 2nd speed 3rd speed
line speed (m/min)* 66,5 30,3 10,1
max load (Kg)*** 290 600 1800
* at 20 l/min oil ow (5,28 Gal/min)
*** at 140 bar at 20 l/min
NOTE
The ratio of the line load - pressure is evaluated at nominal ow rate.
The performance is evaluated measuring the pressure and ow on the motor ports.
The performance data are based on oil with a viscosity of 35mm2/s [165 SUS] and
temperature of 50°C [120°F].
Weight
ST A EH ST C/CW EH ST A EV ST C/CW EV ST A H ST C/CW H
weight (Kg) 23,2 26,9 22,1 25,9 19,2 22,9
ST BBB EH ST CCC EH ST BBB EV ST CCC EV ST BBB H ST CCC H
weight (Kg) 27,7 27,7 28,4 28,4 24,4 24,4
Versions:
A = drum in anodised aluminium
C = drum in chrome bronze
CW = chrome/white
BBB = all bronze
CCC = All-Chrome bronze
EH = horizontal electric winch
EV = vertical electric winch
H = vertical hydraulic winch
Maximum working load
WARNING!
The maximum working load (MWL) for the 60.3 ST Radial Winch is 1800 Kg (3968 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.

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Radial Winch 60.3 ST E/HY
Installation and Maintenance Manual
Outline
Vertical electric motor (12 V / 24 V)
Hydraulic motor
Winch 60.3 ST E/HY Horizontal electric motor (12 V / 24 V)
Line entry height
Line entry height
Line entry height
Line entry height

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Radial Winch 60.3 ST E/HY
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.
After correctly positioning the  nal drive gear with respect to the load, check that the motor,
gearing, electrical wiring and/or hydraulic pipes can be housed below decks. To help  nd the
optimal compromise, remember that, to make the installation of the motor easier, it can be
coupled to the winch in any one of four different positions that differ by 60° from each other.
Once you have decided the correct mounting position for the winch on the deck and checked the
space available below deck, proceed with the installation.
drive gear
SHEET
8°
Installation

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Radial Winch 60.3 ST E/HY
Installation and Maintenance Manual
Installation procedure
To install the winch you must remove the drum and use Socket Head (SH) 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
1. Pull out the disconnect rod n°39 2. Unscrew the central screw ( 2Nm/18 in-lb)
3. Slide off the assy socket n°30 and the cover
n°29
4. Unscrew the three screws n°28
( 4Nm/35 in-lb)
5. Remove the self-tailing arm n°27 by rotating
and lifting it.
6. Lift off the drum n°24
Install the winch on the deck in the position you have chosen, keeping in mind
the limits described on page 4 and using socket head (SH) bolts.

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Radial Winch 60.3 ST E/HY
Installation and Maintenance Manual
11. Remove the drum support n°16
7. Remove the stripper arm housing n°21
Install the winch on the deck in the
position you have chosen, keeping
in mind the limits described on page
4 and using hexagonal headed M8
bolts.
9. Slide out the central shaft n°19 10. Unscrew the 6 hex screws n°17
( 20Nm/177 in-lb)
Follow steps below only to install the winch using hexagonal headed bolts
8. Slide out the assy clutch n°37

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Radial Winch 60.3 ST E/HY
Installation and Maintenance Manual
B. Remove the winch and drill the six 8.5 mm and a 80 mm diameter holes.
C. Bolt the base of the winch to the deck using six M8 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 sufcient 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 7) in the reverse
order, and apply the products indicated in the section on maintenance.
Winch installation procedure
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
44°
21°
55°
60°
62°
60°
58°
Ø204
Winch outside Ø236
final pinion
position
Ø9
n°6
Ø80 cut out for
powered winches

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Radial Winch 60.3 ST E/HY
Installation and Maintenance Manual
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.
Motor installation procedure
WARNING!
Make sure that the power is switched off before installing or carrying out maintenance on
the winch.
Once you have installed the winch on the deck, proceed with motor installation. The motor can be
coupled to the winch in different positions. Check the space available below deck and choose the
suitable position.
Tools needed:
A number  ve hex key
A number six hex key (only for vertical electric motor)
A number ten hex key (only for hydraulic motor)
Two number thirteen wrenches
1. Position the  ange (see Page 12) 2. Tighten six M6 precote coated screws
( 8 Nm/ 71 in-lb)
3. Position the reduction gear and motor 4. Tighten the two screws ( 8 Nm/ 71in-lb).
Be sure to align the  ange.

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Radial Winch 60.3 ST E/HY
Installation and Maintenance Manual
After winch is assembled and before sailing, test the powered winch functioning: insert the lock-in
winch handle in the handle socket and check that the disconnect rod must disconnect gearbox.
Electric wiring diagrams
To guarantee greater ef ciency in terms of safety and long life, for every winch model is
mandatory to install the Dual Function Control Box.
For more information, refer to the Dual Function Control Box manual.
Refer to the following diagrams for the electric wiring:
NOTICE
Before positioning the  ange, check to
make sure that seals (the  rst one is
above the  ange and the second one is
under the  ange) are seated correctly.
WARNING!
Read the Dual Function Control Box manual carefully before installing and using the device.
NOTICE
For other installations, refer to the Dual Function Control Box manual.

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Radial Winch 60.3 ST E/HY
Installation and Maintenance Manual
Fasten the Dual Function Control Box containing solenoids to bulkhead or wall: refer to the
Dual Function Control Box manual. Install remote circuit breaker between power supply
and Dual Function Control Box. Locate push-buttons on deck in a convenient spot for easy winch
operation: refer to the Digital System Switch manual.
Refer to the following chart for wire size:
Total distance between winch and battery
Winch
size
Current
voltage
Under16.4ft
AWG
Under5m
mm2
16.4- 32.8ft
AWG
5m - 10 m
mm2
32.8- 49.2ft
AWG
10m - 15m
mm2
49.2- 65.6ft
AGW
15m- 20m
mm2
60.3 12 V 2 32 0 50 00 70 000 95
60.3 24 V 5 16 3 25 2 35 0 50
NOTICE
To connect motor, attach cable terminals to clamps
between nut and lock nut. Hold nut in contact
with motor using a spanner and tighten other nut
with second spanner. Take special care not to
turn the central spindles. Be careful not to turn
central spindles. These instructions apply when
assembling and disassembling. We recommend
using a torque wrench so as to obtain a torque
equal to and no greater than 10 Nm (88 in-lb).
NOTICE
Note that correct electrical contact sequence is:
Nut – Cable Terminal – Self-Locking Washer –
Lock Nut

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Radial Winch 60.3 ST E/HY
Installation and Maintenance Manual
Hydraulic connections diagram
The hydraulic motor must be connected to a hydraulic system using two high-pressure tubes
which serve for input or output according to the direction in which the motor will be run. The motor
also needs a third connection with a low pressure tube for drainage, so that excess oil can return
to the main tank to avoid shortening the life of the motor. This motor uses an open centre valve.
Refer to the following chart for the hydraulic system:
For the hydraulic motor:
Input/output pipe thread: G 1/2 – depth 15 mm
Drainage pipe thread: G 1/4 – depth 12 mm
WARNING!
Refer to the Hydraulic Power Unit and Control Box manual.
WARNING!
Refer to the Digital System Switch manual.

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Radial Winch 60.3 ST E/HY
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]
WARNING!
Make sure thatv the power is switched off before installing or carryng out maintenance on
the winch.
Disassembly procedure
Tools needed:
One medium  at-bladed screwdriver
A number six hex key
Brush
Rags
To identify the various parts refer to the exploded
view at the end of this Manual.
Torque to be applied in assembly phase
Carry out Installation procedure (page 7) as
shown in the paragraph on winch installation and
then do the following:
7. Remove the stripper arm housing n°21
Maintenance

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Radial Winch 60.3 ST E/HY
Installation and Maintenance Manual
10. Unscrew the 6 hex screws n°17
( 20Nm/177 in-lb)
11. Slide out the drum support n°16
12. Remove the gear n°31, pawls carrier n°33,
the bearings n°34 and 36 and the
spring n°35
Important: washer n°7 may remain inside the
drum support!
9. Slide out the central shaft n°198. Slide out the assy clutch n°37
13. Remove the gear n°6, pawls carrier n°3
and the washer n°7

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Radial Winch 60.3 ST E/HY
Installation and Maintenance Manual
16. Remove gear n°10 17. Remove the gear n°2
18. Remove the roller bearing n°12
14. Remove the idler and pinion n°14 15. Remove the pawl carrier n°11
18. Remove roller bearings n°15

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Radial Winch 60.3 ST E/HY
Installation and Maintenance Manual
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):
I. Unscrew the 4 screws n°26
( 4Nm/35 in-lb)
II. Remove the jaws n°23
If it is necessary to replace any jaws of the winch, proceed as follows:
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!

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Radial Winch 60.3 ST E/HY
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
O
O
G
G
G
G
O
O
G
1
G
2

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Radial Winch 60.3 ST E/HY
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.
In case of doubt concerning the assembly procedure contact Harken® Tech Service:
[email protected]
The icon on the Stripper Arm Housing
indicates the Stripper Arm fi nal position.
Change the Stripper Arm Housing angle
to modify the Stripper Arm fi 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 fi nger.
NOTICE
Before screw the central screw, check
the correct position of the o-ring in the
assy socket and apply Harken®grease.

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Radial Winch 60.3 ST E/HY
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
W XXXXX
XXXXXXXXX
Harken®limited worldwide warranty - Ordering spare parts
Headquarters
Harken®, Inc.
1251 East Wisconsin Avenue
Pewaukee, Wisconsin 53072-3755 USA
Tel: [phone]
Fax: [phone]
Email: [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: [email protected]
Web: www.harken.com
Tech Service
Email: [email protected]
Customer Service
Tel: [phone]
Email: [email protected]
Tech Service
Email: [email protected]
Customer Service
Tel: [phone]
Email: [email protected]
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.