Harken CLR 600 Manual

Installation and Maintenance Manual
Compact Light Retractable (CLR)
Mooring Winch 600 - 1200 - 2500
Mod.A

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
Index
1. Glossary 5
2. Symbols 5
3. Safety information 6
4. General advices 7
Intended use
Improper use
5. Product identication 7
6. Technical characteristics 8
Performance data - electric motor 8
Performance data - hydraulic motor 9
Weights 9
Maximum loads 10
7. Outline 11
7.1 Outline dimensions of the top for wood grain version 14
8. Installation 15
8.1 CLR installation procedure 16
8.2 Electric wiring diagrams - Dual Function Control Box (DFCB) 28
8.3 Functional test 31
8.4 Led lights installation 31
8.5 Led lights - electric wiring diagrams 32
8.6 Hydraulic connections diagrams 32
9. Maintenance 34
9.1 Washing 34
9.2 Maintenance products 35
9.3 Disassembly procedure 36
9.4 Assembly 41
10. Harken limited worldwide warranty 42
11. Ordering spare parts 42
12. Exploded view - CLR Mooring Winch 600 43
13. Parts lists - CLR Mooring Winch 600 44
14. Electric motor - CLR Mooring Winch 600 47
15. Hydraulic motor - CLR Mooring 600 48
15. Exploded view - CLR Mooring Winch 1200 49
16. Parts lists - CLR Mooring Winch 1200 50
17. Electric motor - CLR Mooring Winch 1200 53

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
18. Hydraulic motor - CLR Mooring 1200 54
19. Exploded view - CLR Mooring Winch 2500 55
20. Parts lists - CLR Mooring Winch 2500 56
21. Electric motor - CLR Mooring Winch 2500 58
22. Hydraulic motor - CLR Mooring Winch 2500 59

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
1. Glossary
- Intended use: specic and proper use of the winch for which it is designed.
- Improper use: use of the winch in a different way from that indicated in the instructions for use
specied in this manual.
- Qualied operator: person who has attended specialisation 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 in a dynamic
working condition.
- Maximum holding load (MHL): maximum value of the load the winch can bear in a static working
condition.
2. Symbols
WARNING!
This denotes the existence of a potential danger, which could cause injury or damage if the
information or instructions are not followed.
DANGER!
This denotes the existence of a potential danger, which could cause serious injury or death if
the instructions are not followed.
NOTE!
This denotes particularly important information concerning the device.

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
3. Safety information
WARNING! Read this manual carefully and fully understand it before using the system to
avoid personal injury or property damage during system operation.
- This manual is an integral part of the device and it aims to provide all 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 to qualied 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.
- Do not apply to the winch loads greater than the MWL (Maximum Working Load) in dynamic
conditions.
- Do not apply to the winch loads greater than the MHL (Maximum Holding Load) in static conditions.
- 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.
- Modications 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 caused by
the defective product.
- Failure to install the winch will void the warranty of the winch itself and the Harken®products to
which it may be connected.
- Refer to the warranty on the web site www.harken.com.
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 specied in the chapter on Maintenance.
In case of doubt, contact Harken Tech Service by e-mail: 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. For any doubts, questions or comments contact
the Harken distributors nearest to you, or contact the Harken Italy Technical Service by e-mail:
[e-mail]
- See www.harken.com for additional safety information.
DANGER!
Do not put ngers, hands or feet near the winch during the working of the winch:

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
4. General advices
Intended use
The Compact Light Rectratable (CLR) Mooring Harken Winches are designed and manufactured to
moor the sailing boats and the motor boats on which they are installed.
For any other usage, contact Harken Italy Technical Service by e-mail: techser[email protected].
Improper use
- The 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 modications or interventions have been
carried out.
- Do not use the winch to divert a line (cross-sheeting).
- Do not apply to the winch loads greater than the MWL (Maximum Working Load) in dynamic
conditions.
- Do not apply to the winch loads greater than the MHL (Maximum Holding Load) in static conditions.
NOTE!
See the User Manual for all details about the use of the winch. User manual is available in
paper form, included into the packaging of the purchased winch, and available on our website
www.harken.com.
5. Product identication
Top
Drum
Motor
This manual is destined for the following product versions:
- CLR Mooring Winch 600
- CLR Mooring Winch 1200
- CLR Mooring Winch 2500
Motor carter

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
6. Technical characteristics
Performance data - electric motor
CLR Mooring Winch 600
electric horizontal motor
12 V (700 W) 24 V (900 W)
line speed [m/min]* 24 27
current absortion [A]** 200 110
*Line speed is measured with no load
**Current absorption measured at Maximum Working Load (MWL)
CLR Mooring Winch 1200
electric horizontal motor
12 V (1500 W) 24 V (2000 W)
line speed [m/min]* 23 25
current absortion [A]** 350 200
*Line speed is measured with no load
**Current absortion measured at Maximum Working Load (MWL)
CLR Mooring Winch 2500
electric horizontal motor
24 V (2000 W)
line speed [m/min]* 17
current absorption [A]** 230
*Line speed is measured with no load
**Current absorption measured at Maximum Working Load (MWL)
Technical characteristics

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
7. Technical characteristics
Performance data - hydraulic motor
CLR 600 CLR 1200 CLR 2500
line speed [m/min]* 14 11 10
Oil ow [l/min] 24 24 24
max load [Kg] 400 800 1200
Pressure [bar] 60 90 160
*Line speed is measured with no load
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].
Weights [Kg] (lb)
CLR size A EH A HY C EH C HY SS EH SS HY TC EH TC HY
CLR 600 18 (39.7) 14.7 (32.4) 22 (48.5) 18.7 (41.2) - - 19.5 (43) 15.7 (34.6)
CLR 1200 22 (48.5) 18.7 (41.2) 26 (57.3) 22.7 (50) - - 19.6 (43.2) 21.2 (46.7)
CLR 2500 30 (66.1) 26 (57.3) - - 36 (79.4) 32 (70.5) - -
Weights
Versions:
A = all anodised aluminum
C = all chrome
TC = Top custom
SS = Stainless Steel
EH = horizontal electric winch
HY = hydraulic winch

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
Weights [Kg] (lb)
CLR size A EH C EH W EH
CLR 600 18 (39.7) 22 (48.5) 19 (42)
CLR 1200 22 (48.5) 26 (57.3) 24.5 (54)
Maximum loads
The maximum working load (MWL) is the maximum load the winch can bear in a dynamic working
condition.
The maximum holding load (MHL) is the maximum load the winch can bear with a line loaded in a static
working condition.
Maximum loads [Kg] (lb)
CLR size MHL MWL
CLR 600 600 (1322.8) 400 (881.8)
CLR 1200 1200 (2645.6) 800 (1763.7)
CLR 2500 2500 (5511.6) 1200 (2645.5)
WARNING!
Subjecting the winch to loads above the maximum working load and the maximum holding 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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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
323
383
Ø144
Ø200
106,7
75
Max deck thickness
Ø100
250,5
114
Drain plug
Winch CLR 600 EL
NOTE!
All dimensions are in [mm]
7. Outline
Winch CLR 600 HY
Drain port size: 1/4 GAS
Inlet / Outlet ports size: 3/8'' GAS
Ø144
Ø200
106,7
Ø100
114
Drain plug
250
95

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
351,8
347,4
55
Max deck thickness
Ø107,5
Ø174
120,7 128
237
Ø250
Drain plug
Winch CLR 1200 EL
Winch CLR 1200 HY
55
Max deck thickness
107,5
174
120,7 128
237
250
Drain plug
Drain port size: 1/4 GAS
Inlet / Outlet ports size: 1/2 GAS
323
351

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
405
420
129.5
247.5
310
209
141
53
Drain plug
Winch CLR 2500 EL
Winch CLR 2500 HY
129.5
247.5
Ø310
Ø209
Ø141
53
Drain plug
375,5
420,5
Drain port size: 1/4 GAS
Inlet / Outlet ports size: 3/8'' GAS

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
7.1 Outline dimensions of the custom top version
Winch CLR 600
Winch CLR 1200

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
8. 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®assumes no responsibility for incorrect installation of its winches.
WARNING!
Before using the winch, pay attention to follow scrupulously the steps shown in the CLR
installation procedure in the sequence written below.
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!
Keep the columns support in the position found at the moment of the opening of the
packaging.
Remove the columns support only when indicated.
NOTE!
Before drilling the deck, check the space available below deck for the gearmotor assembly.
NOTE!
Do not use the drain plug in case the winch is installed in a peak tank already used for the
drain (the forepeak of a motor boat for example).

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
8.1 CLR installation procedure
Tools needed:
- One number 5 allen wrench
- Two number 13 adjustable spanner
- One number 10 adjustable spanner
1. Choose the position of the deck where user decides to place the winch.
2. Place the mounting template over the point chosen for installation.
NOTE!
Below is a reduced scale diagram.
The drilling cut out template is available on the Harken®website www.harken.com
Winch CLR 600
NOTE!
Redlined slots are six: three slots are used to choose the position of the CLR Winch; the other
three slots are the passages of the cables of the led lights.
For all info regarding the installation of the led lights, refer to the installation chapter of this
manual.
View from above

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
NOTE!
Orientation of the winch must be chosen taking into account 2 factors:
- The overall dimensions shown in the Outline section of this manual.
- There is only one orientation available for the coupling of the assembly support with the motor.
Right mounting - Internal motor poles

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
Winch CLR 1200
View from above
NOTE!
Below is a reduced scale diagram.
The drilling cut out template is available on the Harken®website www.harken.com

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
NOTE!
Orientation of the winch must be chosen taking into account 2 factors:
- The overall dimensions shown in the Outline section of this manual.
- There is only one orientation available for the coupling of the assembly support with the motor.
Right mounting - Internal motor poles

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CLR Mooring Winch
Installation and Maintenance Manual - Mod.A
Winch CLR 2500
View from above
NOTE!
Below is a reduced scale diagram.
The drilling cut out template is available on the Harken®website www.harken.com