Harken Radiial 40.2 ST Manual

Radial Winch 40.2 ST
Installation and Maintenance Manual
MRW-D

2
Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
Index
Introduction 3
Technical characteristics 3
Weights 3
Maximum working load 3
Outline 3
Installation 4
Procedure 1 5
Procedure 2 6
Installation procedure 8
Positioning the self-tailing arm 9
Maintenance 9
Washing 9
Maintenance table 9
Disassembly procedure 9
Exploded view with maintenance products 13
Assembly 14
Harken®limited worldwide warranty 15
Ordering spare parts 15
Exploded view 16
Radial Winch 40.2 STA, STC, STCW 16
Parts List 18
Radial Winch 40.2 STA 18
Radial Winch 40.2 STC 19
Radial Winch 40.2 STCW 20
Exploded view 21
Radial Winch 40.2 STBBB, STCCC 21
Parts List 23
Radial Winch 40.2 STBBB 23
Radial Winch 40.2 STCCC 24

3
Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
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
ST A version ST C/CW versions ST BBB/CCC versions
Weight (Kg) 3,8 5,4 6,2
Versions: A = drum in anodised aluminium; C = drum in chrome bronze; CW = chrome/white;
BBB = all bronze; CCC = All-Chrome bronze
Maximum working load
WARNING!
The maximum working load (MWL) for the 40.2 ST 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
175
Ø80,5
82
Ø156
152
Ø80,5
82
Ø156
175
Ø80,5
82
Ø180
Ø154,0
175
Ø80,5
82
Ø156
175
Ø80,5
82
Ø156
155
43
175
Ø80,5
82
Ø156
130
234
Line entry height

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Radial Winch 40.2 ST
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.
NOTICE
For winch STA, STC and STCW versions only
you can nd the icon on the skirt to identify the drive
gear position.
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 ST
Installation and Maintenance Manual - Mod.D
The winch can be installed following one of the two procedures below (Procedure1 or Procedure 2):
Procedure 1
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
1. Unscrew the central screw ( 2Nm/18 in-lb) 2. Slide off the assy socket n°28 and the cover
n°29
3. Unscrew the three screws n°27
(4Nm/35 in-lb)
4. Remove the self-tailing arm n°26 by rotating
and lifting it.

6
Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
Procedure 2 (not pertinent for ST BBB/CCC versions)
To install, you must remove the winch skirt and use hexagonal headed 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
See (paragraph on installation) the limits described on page 4 and using socket head (SH) bolts.
2.Take off the skirt n°21. Remove the skirt n°2 with the help of the
screwdriver placed as shown by the
symbol
5. Lift off the drum n°22
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.

7
Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
NOTICE
Make sure the skirt is correctly clipped on to the base of the winch.
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 bolts (HH).
4. Reposition the skirt n°2 in its housing 5. Press down the skirt to position it correctly
3. Position the 5 M6 hexagonal headed bolts
in their holes

8
Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
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®) as
described at Procedure 1 or Procedure 2, 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 Procedure 1 or Procedure 2 in the reverse
order, and apply the products indicated in the section on maintenance.
Installation procedure
Carry out Procedure 1 or Procedure 2, 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
Ø123
35°
105°
50°
70°
50°
50°
Winch outside Ø157
final pinion
position
Ø6
n°5

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Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
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 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.
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

10
Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
Carry out Procedure 1 as shown in the paragraph on winch installation and then do the following:
6. Completely unscrew the three screws n°27
8. Slide out the central shaft n°19
10. Remove the drum support n°15
Important: washer n°12 may remain inside the
drum support!
7. Remove the self-tailing arm support n°21
and slide out the bushing
9. Unscrew the 6 hex screws n°16
(8Nm/71 in-lb)
11. Remove the washer n°12

11
Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
12. Remove the gearing n°7 and remove the
pawls n°5.To facilitate the operation press
the spring against the pawl with a blade.
14. Slide off gear n°14
16. Remove the pawls n°5.To facilitate the
operation press the spring against the pawl
with a blade.
13. Slide off gear n°3
15. Slide off gear n°10
17. Remove washer n°9

12
Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
If it is necessary to replace any jaws of the winch, proceed as follows:
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°24

13
Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
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.

14
Radial Winch 40.2 ST
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.
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.
OIL
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]

15
Radial Winch 40.2 ST
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
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
23570 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]
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.
W XXXXX
XXXXXXXXX

16
Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
Exploded view
Exploded view
2
1
14
13
9
10
5
6
11
8
3
4
6
5
7
12
20
19
16
15
17
18
23
22
24
25
21
26
27
28
29
Radial Winch 40.2 STA, STC, STCW

17
Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
2
1
14
13
9
10
5
6
11
8
3
4
6
5
7
12
20
19
16
15
17
18
23
22
24
25
21
26
27
28
29
Radial Winch 40.2 STA, STC, STCW

18
Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
*Available with service kit; see website www.harken.com
**Winch product sticker
Parts lists
Radial Winch 40.2 STA
A= drum in anodised aluminium
Pos. Q.ty Code Description
11
1
1
1
1
A94141300
S413350080
S4152300A7
S413960085
S413330085
Winch 40 Base Assy
Base W40
Roller Ø6x19
Bushing Ø22xØ25x9.5
Bushing Ø9xØ11x12
Bushing Ø12xØ14x11
21 A94141400 Assembly Skirt Winch 40
Skirt W40
Winch Product Sticker**
31 S413020004 Gear Z12
41 S413030004 Pawls Carrier Ø8xN2
54 S000080003 Pawl Ø8*
64 S000380001 Pawl Spring Ø8*
71 S412830041 Gear Z23
81 S413000004 Pin Ø9x55
91 S279090002 Washer Ø36xØ9,5x1
10 1 S412970004 Gear Z20
11 1 S412850041 Pinion Z13
12 1 S413120002 Washer Ø22.5xØ45x1
13 1 S413070004 Pin Ø9xØ12x32.5
14 1
2
A94130500
S414900080
Assy Gear Z20
Gear Z20
Bushing Ø12xØ14x8
15 1
2
1
A94141500
S414890080
S4130900A7
Assy Housing Winch 40
Housing W40
Bushing Ø9xØ11x7
Bushing Ø22xØ25x8.5
16 6 M0635103 Socket head screw M6x16 UNI 5931
Parts List
Pos. Q.ty Code Description
17 1 S413150082 Washer Ø62xØ80x1.5
18 2 A74136000 Bearing Ø56xØ68x24
19 1
1
A94139000
S413880002
Assy Central Shaft W35/40
Central shaft W35/40 ST
Washer Ø17.2xØ32x1.5
20 Winch Serial Number Sticker
21 1 S4129400A0 Stripper arm Housing
22 1 S414170053 Drum A W40
23 1 S281680097 Red line
24 1
1
4
A94131800
S413610080
S385970001
Assy Winch 40 Jaws
Lower Jaw W35/40
Upper Jaw W35/40
Peeler W20 - 40
Spring
25 4 M0601803 Screw UNI EN ISO 1207 - M6x35 - A4
26 1 S414200019 Stripper Arm W35/40
27 3 M6007103 Screw M6x50 UNI6107
28 1
1
1
A94136400
S415130085
M0614303
Assy Socket W20-80
Socket Handle W20/80
Washer Ø7.7xØ25x5.8
Screw M8x20 UNI 6109
29 1 S4141900A5 Cover 2 speed W40

19
Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
Radial Winch 40.2 STC
C=drum in chrome bronze
*Available with service kit; see website www.harken.com
**Winch product sticker
Pos. Q.ty Code Description
11
1
1
1
1
A94141300
S413350080
S4152300A7
S413960085
S413330085
Winch 40 Base Assy
Base W40
Roller Ø6x19
Bushing Ø22xØ25x9.5
Bushing Ø9xØ11x12
Bushing Ø12xØ14x11
21 A94141400 Assembly Skirt Winch 40
Skirt W40
Winch Product Sticker**
31 S413020004 Gear Z12
41 S413030004 Pawls Carrier Ø8xN2
54 S000080003 Pawl Ø8*
64 S000380001 Pawl Spring Ø8*
71 S412830041 Gear Z23
81 S413000004 Pin Ø9x55
91 S279090002 Washer Ø36xØ9,5x1
10 1 S412970004 Gear Z20
11 1 S412850041 Pinion Z13
12 1 S413120002 Washer Ø22.5xØ45x1
13 1 S413070004 Pin Ø9xØ12x32.5
14 1
2
A94130500
S414900080
Assy Gear Z20
Gear Z20
Bushing Ø12xØ14x8
15 1
2
1
A94141500
S414890080
S4130900A7
Assy Housing Winch 40
Housing W40
Bushing Ø9xØ11x7
Bushing Ø22xØ25x8.5
16 6 M0635103 Socket head screw M6x16 UNI 5931
Pos. Q.ty Code Description
17 1 S413150082 Washer Ø62xØ80x1.5
18 2 A74136000 Bearing Ø56xØ68x24
19 1
1
A94139000
S413880002
Assy Central Shaft W35/40
Central shaft W35/40 ST
Washer Ø17.2xØ32x1.5
20 Winch Serial Number Sticker
21 1 S4129400A0 Stripper arm Housing
22 1 S414180043 Drum W40 C
23 1 S281680097 Red line
24 1
1
4
A94131800
S413610080
S385970001
Assy Winch 40 Jaws
Lower Jaw W35/40
Upper Jaw W35/40
Peeler W20 - 40
Spring
25 4 M0601803 Screw UNI EN ISO 1207 - M6x35 - A4
26 1 S414200019 Stripper Arm W35/40
27 3 M6007103 Screw M6x50 UNI6107
28 1
1
1
A94136400
S415130085
M0614303
Assy Socket W20-80
Socket Handle W20/80
Washer Ø7.7xØ25x5.8
Screw M8x20 UNI 6109
29 1 S4141900A5 Cover 2 speed W40

20
Radial Winch 40.2 ST
Installation and Maintenance Manual - Mod.D
Radial Winch 40.2 STCW
CW = chrome/white
*Available with service kit; see website www.harken.com
**Winch product sticker
Pos. Q.ty Code Description
11
1
1
1
1
A94141300
S413350080
S4152300A7
S413960085
S413330085
Winch 40 Base Assy
Base W40
Roller Ø6x19
Bushing Ø22xØ25x9.5
Bushing Ø9xØ11x12
Bushing Ø12xØ14x11
21 A94141400W Assembly Skirt Winch 40
Skirt W40 RAL9003
Winch Product Sticker**
31 S413020004 Gear Z12
41 S413030004 Pawls Carrier Ø8xN2
54 S000080003 Pawl Ø8*
64 S000380001 Pawl Spring Ø8*
71 S412830041 Gear Z23
81 S413000004 Pin Ø9x55
91 S279090002 Washer 36x9,5x1
10 1 S412970004 Gear Z20
11 1 S412850041 Pinion Z13
12 1 S413120002 Washer Ø22.5xØ45x1
13 1 S413070004 Pin Ø9xØ12x32.5
14 1
2
A94130500
S414900080
Assy Gear Z20
Gear Z20
Bushing Ø12xØ14x8
15 1
2
1
A94141500
S414890080
S4130900A7
Assy Housing Winch 40
Housing W40
Bushing Ø9xØ11x7
Bushing Ø22xØ25x8.5
16 6 M0635103 Socket head screw M6x16 UNI 5931
Pos. Q.ty Code Description
17 1 S413150082 Washer Ø62xØ80x1.5
18 2 A74136000 Bearing Ø56xØ68x24
19 1
1
A94139000
S413880002
Assy Central Shaft W35/40
Central shaft W35/40 ST
Washer Ø17.2xØ32x1.5
20 Winch Serial Number Sticker
21 1 S4129400A0 Stripper arm Housing
22 1 S414180043 Drum C W40
23 1 S281680097 Red line
24 1
1
4
A94131800W
S413610080W
S385970001
Assy Winch 40 Jaws
Lower Jaw W35/40 RAL9003
Upper Jaw W35/40 RAL9003
Peeler W20 - 40 RAL9003
Spring
25 4 M0601803 Screw UNI EN ISO 1207- M6x35 - A4
26 1 S414200019 Stripper Arm W35/40
27 3 M6007103 Screw M6x50 UNI6107
28 1
1
1
A94136400
S415130085
M0614303
Assy Socket W20-80
Socket Handle W20/80
Washer Ø7.7xØ25x5.8
Screw M8x20 UNI 6109
29 1 S4141900A5W Cover 2 speed W40 RAL9003