Harken Powered Performa 80.3 STP EL/HY Manual

Powered Performa™Winch
80.3 STP EL/HY
Installation and Maintenance Manual
MRPW-A

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
Index
Introduction 3
Technical characteristics 3
Performance data 3
Weight 4
Maximum working load 4
Outline 5
Winch 80.3 STP 5
Horizontal electric motor 5
Vertical electric motor 5
Hydraulic motor 5
Installation 6
Installation procedure 7
Positioning the self-tailing arm 11
Motor installation procedure 11
Electric equipment 12
Hydraulic connections diagram 14
Maintenance 15
Washing 15
Maintenance table 15
Disassembly procedure 15
Winch exploded view with maintenance products 20
Winch assembly 21
Harken®limited worldwide warranty 22
Ordering spare parts 22
Exploded view 23
Performa Winch 80.3 STP EL/HY 23
Horizontal electric motor 26
Vertical electric motor 27
Hydraulic motor 28
Parts list 25
Performa Winch 80.3 STP EL/HY 25
Horizontal electric motor 26
Vertical electric motor 27
Hydraulic motor 28

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
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 8,01 : 1 2,76 : 1
2nd speed 28,85 : 1 9,94 : 1
3rd speed 93,24 : 1 32,12 : 1
The theoretical power ratio does not take friction into account.
Performance data
Winch 80.3 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)** 44,8 12,4 3,9 53,9 15,0 4,6
max load (Kg) 400 1500 4500 400 1500 4500
**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)** 51,3 14,2 4,4 61,7 17,1 5,3
max load (Kg) 400 1500 4500 400 1500 4500
**Line speed is measured with no load
Introduction - Technical characteristics - Outline

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
motor nominal power (W) current absorption at winch
MWL (A)
12 V 24 V 12 V 24 V
winch 80.3 ST EL horizontal 1500 2000 320
300
170
160
vertical
Winch 80.3 STP HY (hydraulic)
1st speed 2nd speed 3rd speed
line speed (m/min)* 59,7 16,6 5,1
max load (Kg)*** 400 1500 4500
* at 30 L/min oil ow (7,93 Gal/min)
*** at 110 bar at 30 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 A EV ST A H
weight (Kg) 33,5 34,2 31,6
Versions:
A = drum in anodised aluminium
EH = horizontal electric winch
EV = vertical electric winch
H = vertical hydraulic winch
Maximum working load
WARNING!
The maximum working load (MWL) for the 80.3 ST Performa™ Winch is 4500 Kg (9921 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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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
Line entry height
Vertical electric motor (12 V / 24 V)
Line entry height Line entry height
Line entry height
Outline
Hydraulic motor
Winch 80.3 STP EL/HY Horizontal electric motor (12 V / 24 V)

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Performa™Winch 80.3 STP EL/HY
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.
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°
Installation

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
Installation procedure
To install the winch, remove the drum support and use Socket Head (SH) bolts.
Tools needed:
One medium at-bladed screwdriver
A number six hex key
Rags
To identify the various parts refer to the exploded view at the end of this Manual.
Torque to apply when assembling
1. Slide out the disconnection rod n°44 2. Unscrew the assy socket n°43
4. Remove the cover plate n°423. Slide off the assy socket n°43

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
7. Unscrew the three screws n°40
10. Slide out the assy ange n°199. Unscrew the six screws n°23
8. Slide out the drum n°38 and roller bearing
n°17
5. Unscrew the three screws n°37 6. Remove the stripper arm n°41 by rotating
and lifting it

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
13. Unscrew the six screws n°22 14. Slide out the drum support n°15
11. Slide out the assy command tube n°30 12. Slide out the roller bearings n°18

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
The drilling cut out template is available on the Harken®website, www.harken.com
B. Remove the winch and drill the eight 10.2 mm and a 130 mm diameter holes.
C. Bolt the base of the winch to the deck using six M10 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
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.
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.
Ø233
44°
40°
37°
60°
37°
46°
50°
23°
Ø287
23°
final pinion
position
Ø10.2 n°8
Ø130 Cut out for All Versions

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Performa™Winch 80.3 STP EL/HY
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.
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 six hex key (only for vertical electric motor)
A number ten hex key (only for hydraulic motor)
Two number thirteen wrenches
1. Position the reduction gear and motor 2. Tighten four M6 precote coated screws
( 8 Nm/ 71 in-lb)

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
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 -10m
mm2
32.8 -49.2 ft
AWG
10 m- 15 m
mm2
49.2 -65.6 ft
AGW
15m -20 m
mm2
80.3 12 V 2 32 0 50 00 70 000 95
80.3 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
80.3 12 V HCP1720 135A
80.3 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.

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
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

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
Hydraulic connections diagram
The hydraulic motor must to 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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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
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.
WARNING!
Make sure that the power is switched off before installing or carrying out maintenance on
the winch.
In the case of doubt contact Harken®Tech Service at [e-mail]
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
Maintenance

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
15. Slide out the assy clutch 3rd speed
Carry out Installation procedure (page 7) as shown in the paragraph on winch installation and
then do the following:
16. Slide out the assy ratchet hub 2nd speed
17. Remove the washer n°10 18. Slide out roller bearings n°2 and gear n°13
19. Remove the roller bearing n°2 and the
washer n°14
20. Remove the roller bearing n°2 and the
washer n°10

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
21. Remove the gear n°12 22. Remove the washer n°10
23. Slide out the gear assy n°9 24. Remove the gear n°4
25. Remove the washer n°3 26. Remove the roller bearing n°2

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
27. Remove the central shaft n°25 and the
washer n°27
28. Remove the washer n°26
Important:The plastic washer must be posi-
tioned in contact with the winch base.

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
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!
If it is necessary to replace any jaws of the winch, proceed as follows:
I. Unscrew the 3 screws n°43
( 4Nm/35 in-lb)
II. Remove the jaws n°42

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Performa™Winch 80.3 STP EL/HY
Installation and Maintenance Manual - Mod.A
Exploded view with maintenance products
Harken®Grease
G
Harken®Pawl Oil
O
Anti-seize
A
G
G
G
G
G
G
G
O
O
O
A
A
G
A
A
A
G
1
G
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.