Harken Performa Winch 40.2 STP Manual

Performa™Winch 40.2 STP
Installation and Maintenance Manual
MRPW-03

2
Performa™Winch 40.2 STP
Installation and Maintenance Manual
Index
Introduction 3
Technical characteristics 3
Weight 3
Maximum working load 3
Outline 3
Installation 4
Installation procedure 6
Positioning the self-tailing arm 7
Maintenance 7
Washing 7
Maintenance table 7
Disassembly procedure 7
Exploded view with maintenance products 11
Assembly 12
Harken®limited worldwide warranty 13
Ordering spare parts 13
Exploded view 14
Parts list 16

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Performa™Winch 40.2 STP
Installation and Maintenance Manual
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 13,50 : 1 2,13 : 1
2nd speed 39,90 : 1 6,28 : 1
The theoretical power ratio does not take friction into account.
Weight
ST Version
Weight (Kg) 3,8
Maximum working load
WARNING!
The maximum working load (MWL) for the 40.2 ST Performa™ Winch is 850Kg (1874 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
175
Ø80,5
82
Ø156
Line entry height

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Performa™Winch 40.2 STP
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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Performa™Winch 40.2 STP
Installation and Maintenance Manual
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
Install the winch on the deck in the position you have chosen, keeping in mind the limits described
on page 3. (See paragraph on installation)
1. Unscrew the central screw ( 2Nm/18 in-lb)
3. Unscrew the three screws n°24
(4Nm/35 in-lb)
5. Lift off the drum n°21
2. Slide off the socket n°25 and the cover n°26
4. Remove the stripper arm n°28 by
rotating and lifting it.

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Performa™Winch 40.2 STP
Installation and Maintenance Manual
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 Socket Head (SH) 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
final pinion
position
Ø123
35°
105°
50°
70°
50°
50°
Ø6.2
n°5
Winch outside Ø157

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Performa™Winch 40.2 STP
Installation and Maintenance Manual
F. Reassemble the winch following the steps of the Procedure 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.
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, on the stickers on the winches or on
any anodized, chrome plated and plastic 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 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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Performa™Winch 40.2 STP
Installation and Maintenance Manual
Carry out procedure as shown in the paragraph on winch installation and then do the following:
6. Completely unscrew the three screws n° 24
8. Slide out the central shaft n°18
10. Remove the drum housing n°14
Important: washer n°11 may remain
inside the drum support!
7. Remove the stripper arm support n°20
9. Unscrew the 6 hex screws n°15
(8Nm/71 in-lb)
11. Remove washer n°11

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Performa™Winch 40.2 STP
Installation and Maintenance Manual
12. Remove gear n°6 and remove the pawls
n°4.To facilitate the operation press the
spring against the pawl with a blade.
14. Slide off gear n°13
16. Slide off gear n°9
13. Slide off gear n°2
15. Remove pin n°7
17. Remove the pawls n°4. To facilitate the
operation press the spring against the
pawl with a blade.

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Performa™Winch 40.2 STP
Installation and Maintenance Manual
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!
I. Unscrew the 4 screws n°23
(4Nm/35 in-lb)
II. Remove the jaws n°22

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Performa™Winch 40.2 STP
Installation and Maintenance Manual
Exploded view with maintenance products
G
G
A
A
A
Harken®Grease
G
Harken®Pawl Oil
O
Anti-seize
A
G
G
G
G
G
A
OO
G
G
G
G
1
1Apply Harken®grease on assy socket screw

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Performa™Winch 40.2 STP
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.
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]
OIL
If the jaws have been disassembled,
insert peeler between the two jaws,
taking care that the letters TOP on the
peeler are facing upwards.
When positioning the stripper arm,
align the peeler with it.

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Performa™Winch 40.2 STP
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
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.
Harken®limited worldwide warranty - Ordering spare parts
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: tec[email protected]
Customer Service
Tel: [phone]
Email: [e-mail]
Tech Service
Email: tec[email protected]
Customer Service
Tel: [phone]
Email: [e-mail]
W XXXXX
XXXXXXXXX

14
Performa™Winch 40.2 STP
Installation and Maintenance Manual
Exploded view 1/2
25
26
24
28
20
23
22
17
16
14
19
21
15

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Performa™Winch 40.2 STP
Installation and Maintenance Manual
Exploded view 2/2
18
11
6
4
5
3
2
12
13
1
7
27
10
4
5
9
8

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Performa™Winch 40.2 STP
Installation and Maintenance Manual
Parts list
Performa Winch 40.2 STP
*Available with service kit; see website www.harken.com
**Winch product sticker
Pos Q.ty Code Description
1 1
1
1
1
1
A96633200
S413350080
S4152300A7
S413960085
S413330085
PERFORMA Winch 40 Base Assy
PERFORMA Base W40
Heli-coil M6x9
Roller Ø6x19
Bushing Ø22xØ25x9.5
Bushing Ø9xØ11x12
Bushing Ø12xØ14x11
2 1 S413020004 Gear Z12
3 1 S413030004 Pawls Carrier Ø8xN2
4 4 S000090004 Pawl Ø8*
5 4 S000380001 Pawl Spring Ø8*
6 1 S412830041 Gear Z23
7 1 S657380004 Performa Pin Ø9-10 W40
8 1 S279090002 Washer 36x9,5x1
9 1 S412970004 Gear Z20
10 1 S657370041 Performa Pinion Z13 W40
11 1 S413120002 Washer Ø22.5xØ45x1
12 1 S413070004 Pin Ø9xØ12x32.5
13 1
2
A94130500
S414900080
Assy Gear Z20
Gear Z20
Bushing Ø12xØ14x8
14 1
2
3
1
A94141500
S414890080
M0649802
S4130900A7
Assy Housing Winch 40
Support W40
Bushing Ø9xØ11x7
Heli-coil M6x9
Bushing Ø22xØ25x8.5
15 6 M0635103 Socket head screw M6x16 UNI 5931
16 1 S657280052 Performa Shim W40
Pos Q.ty Code Description
17 2 A74136000 Bearing Ø56xØ68x24
18 1
1
A94139000
S413880002
Assy Central Shaft W35/40
Central shaft W35/40 ST
Washer Ø17.2xØ32x1.5
19 1 Winch Serial Number Sticker
20 1 S4129400A0 Stripper arm support
21 1
1
49
A96572600
S6572700A3
M0619580
Performa Drum W40
Performa Drum W40
Winch Product Sticker**
Bearing ring W40
Ball 3/16"
22 1
1
4
A94131800
S413610080
S385970001
Assy Winch 40 Jaws
Lower Jaw W35/40
Upper Jaw W35/40
Peeler W20 - 40
SPRING
23 4 M0601803 Screw UNI EN ISO 1207:1996 - M6x35 - A4
24 3 M6007103 Screw M6x50 UNI6107
25 1
1
1
A94136400
S415130085
M0614303
Assembly Socket W20-80
Socket Handle W20/80
Washer Ø7.7xØ25x5.8
Screw M8x20 UNI 6109
26 1 S4141900A5 Cover 2 speed W40
27 1 M6033794 Bushing XSM-1012-20
28 1 S657360019 Performa Black Stripper Arm W40