Harken Powered Performa 60.3 STP E Manual

Powered Performa™Winch
60.3 STP E/HY
Installation and Maintenance Manual
MRPW-D

2
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
Index
Introduction 3
Technical characteristics 3
Performance data 3
Weight 4
Maximum working load 4
Outline 5
Winch 60.3 STP 5
Horizontal electric motor 5
Vertical electric motor 5
Hydraulic motor 5
Installation 6
Installation procedure 7
Winch installation procedure 9
Positioning the self-tailing arm 10
Motor installation procedure 10
Electric equipment 11
Hydraulic connections diagram 13
Maintenance 14
Washing 14
Maintenance table 14
Winch disassembly procedure 14
Winch exploded view with maintenance products 18
Winch assembly 19
Harken®limited worldwide warranty 20
Ordering spare parts 20
Exploded view 21
Performa Winch 60.3 STP EL/HY 21
Horizontal electric motor 24
Vertical electric motor 25
Hydraulic motor 26
Parts list 23
Performa Winch 60.3 STP EL/HY 23
Horizontal electric motor 24
Vertical electric motor 25
Hydraulic motor 26

3
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
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 9,2 : 1 2,2 : 1
2nd speed 20,3 : 1 4,8 : 1
3rd speed 61,0 : 1 14,4 : 1
The theoretical power ratio does not take friction into account.
Performance data
Winch 60.3 STP EL (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

4
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
Installation
motor nominal power (W) current absorption at winch
MWL (A)
12 V 24 V 12 V 24 V
winch 60.3 ST EL 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 EH ST EV ST H
weight (Kg) 23,2 22,1 19,2
Versions:
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 Performa™ 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.

5
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
Ø236
253
Ø121
116
Ø236
253
Ø121
116
140
394
233
130
Ø236
253
Ø121
116
Ø236
253
Ø121
116
181
69
Ø236
253
Ø121
116
Ø236
253
Ø121
116
181
69
Ø236
253
Ø121
116
Ø236
253
Ø121
116
140
394
233
130
Outline
Vertical electric motor (12 V / 24 V)
Hydraulic motor
Winch 60.3 STP EL/HY Horizontal electric motor (12 V / 24 V)
Line entry height
Line entry height
Line entry height
Line entry height

6
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
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 different positions.
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°

7
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
Installation procedure
To install the winch, 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 4 and using socket head (SH) bolts.
1. Pull out the disconnect rod n°37 2. Unscrew the central screw ( 2Nm/18 in-lb)
3. Slide off the assy socket n°29 and the
cover n°28
4. Unscrew the three screws n°27
( 4Nm/35 in-lb)
5. Remove the self-tailing arm n°26 by
rotating and lifting it.
6. Lift off the drum n°23

8
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
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 (HH) 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°36

9
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
B. Remove the winch and drill the six 8.5 mm diameter holes.
C. Bolt the base of the winch to the deck using ve M8 Socket Head (SH) bolts (no 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 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
final pinion
position
¯80 cut out for
powered winches
44¡
21¡
55¡
60¡
62¡
60¡
58¡
¯204
¯8.5
n¡6
Winch outside ¯236

10
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
NOTICE
Before closing the winch, makesurethe holes and drainage channels in the base of the winch are notobstructed.
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 10)
3. Position the reduction gear and motor
2. Tighten six M6 precote coated screws
( 8 Nm/ 71 in-lb)
4.Tighten the two screws ( 8 Nm/ 71in-lb).
Be sure to align the ange.

11
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
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 equipment
To guarantee greater efficiency in terms of safety and long life, for every winch model is mandatory
to install the Dual Function Control Box.
To fasten the Dual Function Control Box containing solenoids to bulkhead or wall, for all
installation details and for all electric wiring schemes, refer to the Dual Function Control Box
manual.
WARNING!
Before installing and using the device, read carefully the Dual Function Control Box manual
available on web site www.harken.com
Refer to the following chart for wire size:
Total distance between winch and battery
Winch
size
Current
voltage
Under 16.4 ft
AWG
Under 5m
mm2
16.4 - 32.8 ft
AWG
5m -10 m
mm2
32.8 -49.2 ft
AWG
10 m- 15 m
mm2
49.2 -65.6 ft
AGW
15m -20 m
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
Refer to the following chart for HCP model:
Winch
size
Current
voltage
HCP model Ampere
rating
60.3 12 V HCP1720 135A
60.3 24 V HCP1717 80A
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.

12
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
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. 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

13
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
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.

14
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
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]
WARNING!
Make sure that the power is switched off before installing or carrying out maintenance on
the winch.
Winch disassembly procedure
Tools needed
One medium at-bladed screwdriver
A number ve 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

15
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
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°30, pawls carrier n°32,
the bearings n°33 and 35 and the pin n°34
Important: washer n°7 may remain inside
the drum support!
9. Slide out the central shaft n°198. Slide out the assy clutch n°36
13. Remove the gear n°6, pawls carrier n°3
and the washer n°7

16
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
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

17
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
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 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!
I. Unscrew the 4 screws n°25
( 4Nm/35 in-lb)
II. Remove the jaws n°22

18
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
Exploded view with maintenance products
G
A
A
G
A
Harken®Grease
G
Harken®Pawl Oil
O
Anti-seize
A
O
G
G
G
O
O
O
G
G
G
G
G
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.

19
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
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.
The icon on the Stripper Arm Housing
indicates the Stripper Arm nal position.
Change the Stripper Arm Housing angle
to modify the Stripper Arm 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.
In case of doubt concerning the assembly procedure contact Harken® Tech Service:
[e-mail]
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 nger.
NOTICE
Before screw the central screw, check
the correct position of the o-ring in the
assy socket and apply Harken®grease.

20
Performa™Winch 60.3 STP EL/HY
Installation and Maintenance Manual - Mod.D
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: 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: 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