Harken Radial Winch 40.2 PT BBB Manual

Installation and Maintenance Manual
MRW-A
Radial Winch 40.2 PT
BBB / CCC

2
Radial Winch 40.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
Index
Introduction 3
Technical characteristics 3
Weights 3
Maximum working load 3
Outline 3
Installation 4
Procedure 5
Installation procedure 6
Maintenance 7
Washing 7
Maintenance table 7
Disassembly procedure 7
Exploded view with maintenance products 11
Assembly 12
Harken®limited worldwide warranty 12
Ordering spare parts 12
Exploded view 14
Parts List 16
Radial Winch 40 PTBBB 16
Radial Winch 40 PTCCC 17

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Radial Winch 40.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
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.
Weights
PT BBB/CCC versions
Weight (Kg) 6,10
Versions:
BBB = all bronze
CCC = All-Chrome bronze
Maximum working load
WARNING!
The maximum working load (MWL) for the 40.2 PT Radial Winch is 850 Kg (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
Line entry height
152 mm
Ø80,5 mm
82 mm
Ø157 mm

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Radial Winch 40.2 PT BBB / CCC
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.
Once you have chosen the correct mounting position for the winch on the deck proceed with
installation.
Installation
drive gear
SHEET
8°

5
Radial Winch 40.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
The winch can be installed following the Procedure below:
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.
1. Unscrew the central screw ( 2Nm/18 in-lb)
3. Lift off the drum n°21
2. Slide off the socket n°29 and the cover
n°27

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Radial Winch 40.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
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 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 the Procedure in the reverse order, and apply the
products indicated in the section on maintenance.

7
Radial Winch 40.2 PT BBB / CCC
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.
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.
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

8
Radial Winch 40.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
Carry out Procedure as shown in the paragraph on winch installation and then do the following:
6. Slide out the central shaft n°18 7. Unscrew the 6 hex screws n°15
( 8Nm/71 in-lb)
8. Remove the housing n°14
Important: washer n°11 may remain
inside the housing!
9. Remove the washer n°11
4. Completely unscrew the three screws n° 26 5. Remove the socket support n°20

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Radial Winch 40.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
12. Slide off gear n°13 13. Slide off gear n°9
14. Remove the pinion n°10 and the pawls
n°3. To facilitate the operation press the
spring against the pawl with a blade.
15. Remove washer n°8
10. Remove the gear n°6 and remove the
pawls n°3.To facilitate the operation press
the spring against the pawl with a blade.
11. Slide off gear n°2

10
Radial Winch 40.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
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!

11
Radial Winch 40.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
Exploded view with maintenance products
G
G
A
A
Harken ®Grease
G
Harken ®Pawl Oil
O
Anti-seize
A
G
A
G
G
G
G
G
G
O
O
G
G
A
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.

12
Radial Winch 40.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
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]
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.
OIL
Harken®limited worldwide warranty - Ordering spare parts
W XXXXX
XXXXXXXXX

13
Radial Winch 40.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
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: [e-mail]
Customer Service
Tel: [phone]
Email: [e-mail]
Tech Service
Email: [e-mail]
Customer Service
Tel: [phone]
Email: [e-mail]

14
Radial Winch 40.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
Exploded view 1/2
Radial Winch 40.2 PTBBB, PTCCC
21
29
28
27
17 26
20
16
25
23
15
14
19
1
8
3
13
5
12 9
4
610
11
18
7
30
4
5
24
22
2

15
Radial Winch 40.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
21
29
28
27
17 26
20
16
25
23
15
14
19
1
8
3
13
5
12 9
4
610
11
18
7
30
4
5
24
22
2
Exploded view 2/2
Radial Winch 40.2 PTBBB, PTCCC

16
Radial Winch 40.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
Parts list
Radial Winch 40.2 PTBBB
BBB = all bronze
*Available with service kit; see website www.harken.com
**Winch product sticker
Pos. Q.ty Code Description
11
1
1
1
1
A96633200
S413350080
S4152300A7
S413960085
S413330085
Winch 40 Base Assy
Base W40
Roller Ø6x19
Bushing Ø22xØ25x9.5
Bushing Ø9xØ11x12
Bushing Ø12xØ14x11
21 S413020004 Gear Z12
31 S413030004 Pawls Carrier Ø8xN2
44 S000080003 Pawl Ø8*
54 S000380001 Pawl Spring Ø8*
61 S412830041 Gear Z23
71 S413000004 Pin Ø9x55
81 S279090002 Washer Ø36xØ9,5x1
91 S412970004 Gear Z20
10 1 S412850041 Pinion Z13
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
1
A94141500
S414890080
S4130900A7
Assy Housing Winch 40
Support W40
Bushing Ø9xØ11x7
Bushing Ø22xØ25x8.5
15 6 M0635103 Socket head screw M6x16 UNI 5931
16 1 S413150082 Washer Ø62xØ80x1.5
Pos. Q.ty Code Description
17 2 A74136000 Bearing Ø56xØ68x24
18 1
1
A94151900
S413880002
Assy Central Shaft W35
Central shaft W35/40 PT
Washer Ø17.2xØ32x1.5
19 Winch Serial Number Sticker
20 1 S4151400A0 Socket Support PT
21 1 S688160043 Drum W40 BBB
22 1 S281680097 Red line
23 1 S688040043 Plain Top W35/40 BBB
24 1 S678720082 Washer Ø56.5xØ75x1.5
25 4 M0603703 Screw M6x12 UNI 5931
26 3 M0600903 Screw M6x20 UNI5931
27 1 S688120043 Cover W40 PT BBB
28 1 S415220080 PT spacer
29 1
1
1
A94136400
S415130085
M0614303
Assy Socket W20-80
Socket Handle W20/80
Washer Ø7.7xØ25x5.8
Screw M8x20 UNI 6109
30 Winch Product Sticker**

17
Radial Winch 40.2 PT BBB / CCC
Installation and Maintenance Manual - Mod.A
Parts list
Radial Winch 40.2 PTCCC
CCC = All-Chrome bronze
*Available with service kit; see website www.harken.com
**Winch product sticker
Pos. Q.ty Code Description
11
1
1
1
1
A96633200
S413350080
S4152300A7
S413960085
S413330085
Winch 40 Base Assy
Base W40
Roller Ø6x19
Bushing Ø22xØ25x9.5
Bushing Ø9xØ11x12
Bushing Ø12xØ14x11
21 S413020004 Gear Z12
31 S413030004 Pawls Carrier Ø8xN2
44 S000080003 Pawl Ø8*
54 S000380001 Pawl Spring Ø8*
61 S412830041 Gear Z23
71 S413000004 Pin Ø9x55
81 S279090002 Washer 36x9,5x1
91 S412970004 Gear Z20
10 1 S412850041 Pinion Z13
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
1
A94141500
S414890080
S4130900A7
Assy Housing Winch 40
Housing W40
Bushing Ø9xØ11x7
Bushing Ø22xØ25x8.5
15 6 M0635103 Socket head screw M6x16 UNI 5931
16 1 S413150082 Washer Ø62xØ80x1.5
Pos. Q.ty Code Description
17 2 A74136000 Bearing Ø56xØ68x24
18 1
1
A94151900
S413880002
Assy Central Shaft W35
Central shaft W35/40 PT
Washer Ø17.2xØ32x1.5
19 Winch Serial Number Sticker
20 1 S4151400A0 Socket Housing PT
21 1 S681050043 Drum W40 CCC
22 1 S281680097 Red line
23 1 S688000043 Plain top W35/W40 CCC
24 1 S678720082 Washer Ø56.5xØ75x1.5
25 4 M0603703 Screw M6x12 UNI 5931
26 3 M0600903 Screw M6x20 UNI5931
27 1 S688080043 Cover W40 PT CCC
28 1 S415220080 PT spacer
29 1
1
1
A94136400
S415130085
M0614303
Assy Socket W20-80
Socket Handle W20/80
Washer Ø7.7xØ25x5.8
Screw M8x20 UNI 6109
30 Winch Product Sticker**