INTRODUCTION... p. 3. SAFETY INFORMATION... p. 5

Transcription

1 WINCH MANUAL B1140

2 Index INTRODUCTION... p. 3 SAFETY INFORMATION... p. 5 TECHNICAL INFORMATION AND CHARACTERISTICS... p. 6 Exploded view of winch B 1140 ST ASA HY (F )... p. 6 Parts list winch B 1140 ST ASA HY (F )... p. 9 Exploded view of B 1140 ST ASA E 380 V (F )... p. 12 Parts list winch B 1140 ST ASA E 380 V (F )... p. 13 Exploded view of winch B 1140 ST Racing (F )... p. 14 Parts list winch B 1140 ST Racing (F )... p. 17 Characteristics... p. 20 Dimensions... p. 21 Weights... p. 23 Technical information on hydraulic motor... p. 23 Performance graphs... p. 25 Information on electric motor... p. 28 Performance graphs... p. 28 INSTALLATION... p. 29 USE... p. 33 MAINTENANCE... p. 36 External maintenance... p. 36 Internal maintenance... p. 36 Disassembling... p. 37 Maintenance products... p. 41 Exploded view for maintenance... p. 43 Backwind maintenance... p. 46 TROUBLESHOOTING... p. 47 WARRANTY... p. 48 APPENDIX A... p. 49 B1140 Winch 2

3 Introduction B 1140 winches are used as primary winches on mega yachts. They are produced in a self-tailing version and, together with the B 1150, are the only non Top-Drive winches we make (that is, they cannot be operated by a winch handle). This limitation is due to the fact that they are designed for use on very big boats, where human strength alone would not be enough to operate them. The B 1140 winch has three speeds plus reverse (backwind). The backwind system makes a right-hand winch turn anticlockwise, thus lessening the tension before the sheet is eased. This means the line can be handled at loads within the safety margin, and also prevents excessive wear on the sheet itself. The B 1140 winch uses two hydraulic motors: a main one and one for backwind. On request it can also be powered by electric motors of both 24 and 380 V, through specially made control boxes. But here it is important to take into account the need for greater space below decks compared with that required by the equivalent hydraulic units. In addition to hydraulic or electric power, the B 1140 can also be driven by coffee grinders or by a hybrid combination. The 1140 self-tailing hydraulic winch is available in various configurations as shown in table 1 below: Winch model Code Description Motors Base and top in aluminium, Main: hydraulic B 1140 ST ASA HY F drum in stainless steel, Backwind: hydraulic stripper arm in stainless steel Base, drum and top in Main: hydraulic B 1140 ST SSS HY F stainless steel, stripper Backwind: hydraulic arm in stainless steel Base and drum in stainless Main: hydraulic B 1140 ST SSC HY F steel, top in carbon, stripper Backwind: hydraulic arm in stainless steel Table 1 The B V electric winch is available in configuration shown in table 2, below: Winch model Code Description Motors Base and top in aluminium, Main: electric B 1140 ST ASA E 380 V F drum in stainless steel, Backwind: hydraulic strippe arm in stainless steel (on request) Table 2 B1140 Winch 3

4 Introduction The gears and pawls of B 1140 winches are made in 17-4 PH stainless steel, the drum support in high resistance aluminium. The steel used is tempered by thermal processes carried out under our close supervision. There is also a Racing version of the B 1140 winch. To reduce weight, it is made from materials different from those of the preceding versions (table 3): Winch model Code Description Motors Base and drum in aluminium, Main: hydraulic B 1140 ST RACING F top in carbon, stripper arm Backwind: hydraulic in carbon. Table 3 The racing winch is also made in a left-hand version in the following configuration (table 4): Winch model Code Description Motors Base and drum in aluminium, Main: hydraulic B 1140 LH RACING F L top in carbon, stripper arm Backwind: hydraulic in carbon. Table 4 The 1140 winch can be ordered with a base sheave, which is especially useful on boats fitted with a reduced number of winches, for example easy sailing yachts. It can be used to feed a line to another winch. B1140 Winch 4

5 Safety information! WARNING!: Read carefully before installing or using your winch: install and use the winch only as described in the technical information supplied. Improper use can cause severe harm to users, equipment and the vessel. never place yourself between the winch and its load. take special care when the line is released, because the working load of the 1140 is very high. use all the space available to take as many turns as possible round the winch drum. The more turns taken, the lighter the load for the user. wear suitable clothing when using powered winches, to avoid loose ends of fabric becoming entangled in the drum. when using any Harken equipment to hoist a person, you must have a safety factor of 10:1 with respect to the actual working load. A second line with the same safety factor must always be used. we strongly recommend having installation and maintenance, as described below, carried out by highly qualified staff. Periodical maintenance must be carried out regularly as specified in the chapter on Maintenance. In case of doubt, contact Harken Tech Service. never substitute any winch part with one that is not original. Even though they look similar and are both made by Harken, the non-original part may not be suitable and the Warranty will be invalidated. do not apply loads greater than the SWL (Safe Working Load) of the winch and line. use backwind when the winch is under tension and the sheet is to be eased so as to reduce the residual load the user will have to take. to avoid accidents, take special care when removing the winch drum during installation or maintenance: it is very heavy! If the winch is powered by an electric motor: make sure that the power is switched off before installing or carrying out maintenance on the winch. take special care when carrying out maintenance on 380 V electric winches. An electric shock from them can be fatal. If the winch is powered by a hydraulic motor: do not operate the hydraulic motor during installation or maintenance. do not let the oil in the system come into contact with your eyes or skin. Technical product specifications and the content of this manual are subject to change without notice. Any updates will be made available on our website, in the section dedicated to manuals. This manual is an integral part of the product and must be kept in a safe place for future reference. For any doubts, questions or comments contact the Harken Point nearest to you, Special Project assistance, or contact the Harken Italy Technical Service by techservice@harken.it B1140 Winch 5

6 Technical information and characteristics Exploded view WINCH B 1140 ST ASA HY (F ) Fig. 2 B1140 Winch 6

7 Technical information and characteristics Exploded view Fig. 3 B1140 Winch 7

8 Technical information and characteristics Exploded view Fig. 4 B1140 Winch 8

9 Technical information and characteristics Parts list WINCH B 1140 ST ASA HY (F ) POS. Q.TY CODE DESCRIPTION MATERIAL 1 1 A Aluminium base A Roller bearing 35x45x22 AISI /4 Ph Tr. 3 1 M Seal 35x50x7 ELASTOMERO 4 1 S Central shaft 17-4 PH 5 1 S Dog clutch - lower 17-4 PH 6 1 S Dog clutch - upper 17-4 PH 7 5 A Bearing 50x62x A Roller bearing 9 1 S Washer 94x50,5x4 UNI 5275 XANTAL B 10 1 S Gear z35-1st speed 17-4 PH 11 2 A Thrust bearing 12 1 S Upper thrust bearing ring 17-4 PH 13 1 S Washer UNI 5275 XANTAL B 14 1 S Pawl carrier 17-4 PH 15 2 M Smalley ring SSR0137-S17 AISI S Pawl Ø PH S Pawl Spring AISI M Smalley ring ES50-S02 AISI S Washer 71,5x50,5x2,25 UNI 5275 XANTAL B 20 1 S Gear z24-2nd speed 17-4 PH 21 1 S Washer 80x58,5x3 UNI 5275 XANTAL B 22 2 M Set screw M10x10 - UNI A2 AISI M Ball 5/16 inox AISI S Spring AISI M Cotter Pin 2x25 U1336 DIN94 INOX AISI S Control rod - 1st speed AISI M Nut M8 - UNI A4 AISI A Housing S Drum support-center 17-4 PH 30 2 S Washer 128x81x3, PH 31 1 A Lower jaw assembly S Washer 180x81x1,5 PTFE 33 1 A Drum assembly S Pinion shaft 17-4 PH 35 1 S Washer 128x81x1.5 UNI 5275 XANTAL B 36 1 A Pinion assy z S rd-ratchet-gear-39t 17-4 PH 38 1 S Spacer DELRIN NERO 39 1 M Seal 30x52x7 ELASTOMERO 40 1 S Planet carrier - upper 17-4 PH 41 1 S Final drive pinion 17-4 PH 42 1 S Ring gear 17-4 PH 43 2 S Washer 58x38x2 UNI 5275 XANTAL B 44 3 S Planet Gear z PH 45 1 S Washer 80x58,5x5 UNI 5275 XANTAL B B1140 Winch 9

10 Technical information and characteristics Parts list 46 1 S Planet carrier - lower 17-4 PH 47 1 S Gear 17-4 PH 48 8 S Washer 38x21x1,5 UNI 5275 XANTAL B 49 6 M Screw M 10x45 U5739 DIN933 A4 AISI S Inner planet gear shaft 17-4 PH 51 4 A Roller bearing 20x26x S Washer 84x50,5x3 UNI 5275 XANTAL B 53 4 S Pawl 12 mm 17-4 PH 54 4 S Pawl Spring 12mm AISI M Ball 3/8 AISI 304 AISI M Ball 3/8 BRONZE UNI 5275 XANTAL B 57 1 S Idler gear - 1st speed 17-4 PH 58 1 S Bushing-1st speed-idler 17-4 PH 59 1 M Screw M 10x50 U5739 DIN933 A4 AISI S Washer 38x10,5x PH 61 7 M Screw M10x30 UNI 5931 AISI A Roller bearing 63 1 S Spacer AISI A Drum support assembly M Screw M8x20 UNI5931 AISI M Screw M8x25 UNI 5931 AISI S Washer AISI S Washer DELRIN 69 8 S Spacer AISI 304 Al G.Al.Si. 4,5 UNI S Upper jaw T S Stripper arm support AISI 316 Al G.Al.Si. 4,5 UNI S Cover with logo T M Cover gasket mt1,25 ELASTOMERO 74 1 S Stripper DELRIN NERO 75 1 S Stripper arm AISI S Logo ring AISI S Control button - 1st speed DELRIN NERO 78 2 M Screw M 6x10 UNI 6110 DIN 964 AISI M Screw M8x16 UNI5931 AISI S Line guide AISI S Stripper arm block AISI S Roller retaining screw 17-4 PH M Ball 1/4 AISI M Screw M10x25 UNI 5931 AISI M Screw M8x45 UNI 5931 AISI 316 HY motor Parker series 111A G Y AS0 NO MATERIAL IDR A Backwind System M Screw M12x30 UNI5739 AISI M Washer D.13 UNI1751 AISI 316 Fig. 5 B1140 Winch 10

11 Technical information and characteristics Parts list The different configurations of the 1140 ST HY winch have bases and tops in different materials. Table 5 (below) shows the codes of the parts that are different in the various configurations referring to the exploded views and the parts list of the B 1140 ST ASA HY winch: B 1140 ST ASA HY B 1140 ST SSS HY B 1140 ST SSC HY (F ) (F ) (F ) Position Code Qty. Code Qty. Code Qty. BASE 1 A S S S S TOP 72 S S A Table 5 B1140 Winch 11

12 Technical information and characteristics Exploded view WINCH B 1140 ST ASA E 380 V (F ) Fig. 6 B1140 Winch 12

13 Technical information and characteristics Parts list WINCH B 1140 ST ASA E 380 V (F ) POS. Q.TY CODE DESCRIPTION MATERIAL 1 1 F Winch 1140 ST... Vertical Gear Motor Box 2 1 G MAS 45 F15.83 P132 B5 NO MATERIAL Al UNI S Flange T6 4 1 S Drive shaft 17-4 PH 5 4 S Stud screw M14x PH Al UNI S Linking tube T6 Nut UNI EN ISO 7 4 M : M14 - A2 AISI M Washer 15x28x2.5 ISO 7089 AISI S Stud screw M12x46 AISI M Nut M12 UNI5588 AISI M Washer dia.12x24 AISI S Winch 1140 claw cutch 17-4 PH 13 1 S Bushing 17-4 PH 14 1 M Spring pin 5x40 DIN1481 AISI A Backwind System... Fig. 7 B1140 Winch 13

14 Technical information and characteristics Exploded view WINCH B 1140 ST RACING (F ) Fig. 8 B1140 Winch 14

15 Technical information and characteristics Exploded view Fig. 9 B1140 Winch 15

16 Technical information and characteristics Exploded view Fig. 10 B1140 Winch 16

17 Technical information and characteristics Parts list WINCH B 1140 ST RACING (F ) POS. Q.TY CODE DESCRIPTION MATERIAL 1 1 A Aluminium base... AISI /4 Ph 2 1 A Roller bearing 35x45x22 Tr. 3 1 M Seal 35x50x7 ELASTOMERO 4 1 S Washer 80x58,5x3 UNI 5275 XANTAL B 5 1 M Smalley ring ES50-S02 AISI S Pawl carrier 17-4 PH 7 12 S Pawl Ø PH 8 12 S Pawl Spring AISI S Gear z24-2nd speed PH 10 2 S Washer 71,5x50,5x2,25 UNI 5275 XANTAL B 11 5 A Roller bearing 50x62x S Central shaft 17-4 PH 13 2 M Smalley ring SSR0137-S17 AISI S Washer UNI 5275 XANTAL B 15 1 S Upper thrust bearing ring 17-4 PH 16 2 A Thrust bearing 17 4 A Roller bearing 18 1 S Gear z35, 1st speed 17-4 PH 19 1 S Dog clutch - lower 17-4 PH 20 1 S Washer 94x50,5x4 UNI 5275 XANTAL B 21 2 M Set screw M10x10 - UNI A2 AISI M Ball 5/16 inox AISI S Dog clutch - upper 17-4 PH 24 2 M Spring pin 2x10 DIN 1481 AISI S Spring AISI A Housing S Drum support-center 17-4 PH 28 1 S Washer 180x81x1,5 PTFE 29 1 S Control rod - 1st speed AISI M Nut M8 - UNI A4 AISI S Pinion shaft 17-4 PH 32 1 S Spacer DELRIN NERO 33 1 A Pinion assy z S rd-ratchet-gear-39t 17-4 PH 35 1 S Washer 128x81x1.5 UNI 5275 XANTAL B 36 1 M Seal 30x52x7 ELASTOMERO 37 2 S Washer 84x50,5x3 UNI 5275 XANTAL B 38 1 S Planet carrier - lower 17-4 PH 39 2 S Washer 58x38x2 UNI 5275 XANTAL B 40 8 S Washer 38x21x1,5 UNI 5275 XANTAL B 41 6 S Inner planet gear race 17-4 PH 42 3 S Planet Gear z PH B1140 Winch 17

18 Technical information and characteristics Parts list 43 4 A Roller bearing 20x26x19 (x W.1140) 44 1 S Gear 17-4 PH 45 1 S Gear ring 17-4 PH M Ball 3/8 AISI 304 AISI M Ball 3/8 BRONZE UNI 5275 XANTAL B 48 1 S Planet carrier - upper 17-4 PH 49 6 M Screw M 10x45 U5739 DIN933 A4 AISI S Pawl 12mm 17-4 PH 51 4 S Pawl Spring 12mm AISI S Washer 80x58,5x5 UNI 5275 XANTAL B 53 1 S Final pinion 17-4 PH 54 1 S Bushing-1st speed-idler 17-4 PH 55 1 S Idler gear - 1st speed 17-4 PH 56 1 S Washer 38x10,5x PH 57 1 M Screw M 10x50 U5739 DIN933 A4 AISI M Screw M10x30 UNI 5931 AISI A Roller bearing 60 1 S Washer 128x81x3, PH 61 1 S Control button - 1st speed DELRIN NERO 62 7 M Screw M10x25 UNI 5931 AISI S Spacer P.V.C A Drum assembly A Upper jaw 66 1 S Logo ring Ti 6Al 4V 67 1 S Stripper arm support AISI S Stripper arm CARBON FIBER 69 1 S Stripper DELRIN NERO 70 4 M Screw M8x25 UNI 5931 AISI S Stud screw M8x55 AISI S Spring AISI M Washer D.8 ISO 7089 AISI 304 HY motor Parker series 111A G Y AS0 NO MATERIAL IDR A Backwind System M Screw M12x30 UNI5739 AISI M Washer D.13 UNI1751 AISI 316 Fig. 11 B1140 Winch 18

19 Technical information and characteristics Parts list The left-hand version of the B 1140 LH RACING winch has some parts that are different from those of the right-hand B 1140 ST RACING winch. Table 6 (below) shows the codes of the parts that differ in the two versions. For the position of the various parts refer to the exploded view of the B 1140 ST RACING winch. POSITION DESCRIPTION B 1140 STR HY B 1140 STR HY LH (F ) (F L) 64 Drum assembly A A L 33 Pinion assy z17 A A Stripper arm S S L 66 Logo ring S S Gear z24-2 nd speed S S Gear Z35-1 st speed S S rd- ratchet- gear- 39t S S Final pinion S S L 48 Upper planet carrier S S Pawl carrier S S Dog clutch - lower S S Dog clutch - upper S S Table 6 B1140 Winch 19

20 Characteristics Power ratio Speed ratio 1 st speed 4 : 1 2,9 : 1 2 nd speed 16,4 : 1 11,6 : 1 3 rd speed 60,1 : 1 42,6 : 1 Table 7 The theoretical power ratio was obtained by ignoring friction. The third speed gives the lowest rotation speed, recovering little line but permitting the maximum working load. The second speed recovers a reasonable amount of line with medium load, while the first speed recovers a lot of line with very low load. B1140 Winch 20

21 Dimensions Drawing with overall dimensions of hydraulically powered 1140 winch F Fig. 12 B1140 Winch 21

22 Dimensions Drawing with overall dimensions of 1140 winch F powered by 380 V vertical electric motor. Fig. 13 B1140 Winch 22

23 Dimensions The outline of the various versions is available in DWG format and can be requested from Harken Italy Tech Service by Electrically powered winches take up far more space below decks than their hydraulically operated equivalents. This is because electric motors are bigger than hydraulic ones, because a reduction gear is needed between the motor and the winch, and because a special extension flange has to be used on one of the two motors to connect the reduction gear to the winch since there is physically not enough room between the two shafts. Further information will be supplied on request. Weights Winch Winch Winch B 1140 ST ASA B 1140 ST ASA B 1140 ST RACING hydraulically with 380 V electric hydraulically powered motor powered Estimated weight 134 Kg 217 Kg 113 Kg Table 8 Technical information on hydraulic motor Both hydraulic motors need to be connected to a hydraulic circuit by two high pressure tubes that are used for inlet and outlet, according to the direction in which the motor is running. Both motors also require a third connection with a low pressure tube for drainage, so that excess oil can return to the system reservoir so as to avoid shortening the life of the motor. Backwind is engaged by a special motor, separate from the one connected to the central shaft and connected to a secondary gearing through a reduction gear. The backwind button, when pressed, will activate an electric valve in the hydraulic circuit that will direct the flow of oil to the backwind hydraulic motor. Obviously the oil will return from the motor to the system reservoir. The backwind hydraulic motor runs in one direction only and also needs a closed centre valve so that the flow from the motor is blocked when the valve is not operated. However, the motor connected to the central shaft of the winch, which makes the drum revolve in one direction only (clockwise for a right-hand winch and anticlockwise for a left-hand winch), will operate in both direction so as to allow the winch to operate at the three speeds for which it was designed. This motor can use both a closed centre valve, which is generally preferable, or an open centre one. B1140 Winch 23

24 Technical information on hydraulic motor Characteristics of the Parker hydraulic motors installed to operate the 1140 winch (table 9): Capacity Maximum Recommended flow recommended range (1) pressure Backwind motor (Parker 111A-071 AS-O) Main motor (Parker 111A-129 AS-OSW) 116 c.c. 160 bar (2400 psi) 211 c.c. 200 bar (3000 psi) From 15 to 60 Lt/min (from 4 to 16 gal/min) From 15 to 60 Lt/min (from 4 to 16 gal/min) Table 9 For both hydraulic motors: Input/return tube thread: 7/8 14 SAE Drainage tube thread: 7/16 20 straight thread Note (1): any flow range within the limits indicated is acceptable Hydraulically operated winches have a load capacity proportional to the working pressure of the system, while the line recovery speed is proportional to the oil flow. 1 st speed 2 nd speed 3 rd speed Maximum load (at 200 bar with 20 mm line) Maximum recovery speed (with 15 Lt/min flow and 20 mm line) Maximum recovery speed (with 60 Lt/min flow (2) and 20 mm line) 900 kg 3420kg 9750kg 29 mt/min 7 mt/min 2 mt/min 98 mt/min 24 mt/min 7 mt/min Table 10 Note (2): with very high flow values, for example 60 Lt/min, the gearing will need a more frequent maintenance cycle. B1140 Winch 24

25 Technical information on hydraulic motor Performance graphs Pressure-line load graph for main motor: Winch Line Load with 111A-129 AS-OSW Fig. 14 Oil flow - line speed graph for main motor: Winch Line speed with 111A-129 no load on the line Fig. 15 B1140 Winch 25

26 Technical information on hydraulic motor Performance graphs Oil flow- pressure graph for main motor: Winch max Hydraulic power input Fig. 16 Hydraulic connections diagram for main motor and backwind of winch 1140: BLACK BUTTON MAIN HIDRAULIC MOTOR BACKWIND ELECTRIC BUTTONS * SEE NOTE 1 OIL DRAINAGE ELECTRIC BOX HIDRAULIC POWER UNIT BATTERY Fig. 17 Note 1: connect the input and output of the backwind as shown in figure 18. B1140 Winch 26

27 Technical information on hydraulic motor Performance graphs Fig. 18 Indicative diagram of electric button and electrical valve connections: EL EL B. W. 1 = First/third speed button 2 = Second speed button 3 = Backwind button EL 1 a 2 a 3 a = First, second and third speed electrical valves EL B.W. = Backwind electrical valve Fig. 19 B1140 Winch 27

28 Technical information on electric motor Performance graphs The electric version of winch B 1140 has a 380 V, 50 Hz main motor delivering 5.5 KW. This is connected to the winch by an endless thread reduction gear. In this case too, the backwind motor will be hydraulically powered. Performance graphs of winch 1140 with 380 V electric motor. Winch 1140 electric version line speed. line load maximum line loads are limited by maximum motor current. Winch electric version 380 V 5,5 kw Line Load /Line speed Fig. 20 Winch electric version 380 V 5,5 kw Current /Line speed Fig. 21 The electric box is not supplied with the 380 V electric version of winch B1140 Winch 28

29 Installation The winch needs to be disassembled before being installed. Follow the disassembling procedure described in the chapter on Maintenance, using the tools specified there. Remove the drum assembly and the drum support. Once the drum support has been removed and the base of the winch can be accessed, installation on the deck can begin.! DANGER!: When deciding how to place the winch, make sure the entry angle of the sheet is not parallel to the base of the winch, for this would lead to turns of the sheet overlapping, risking serious damage to the winch itself and putting the crew in danger. An angle of 8 between the sheet and the base of the winch will avoid these dangerous overlaps. 8 Correct entry path for the sheet, at an angle of 8. Fig. 22 Avoid the following:! Incorrect angle of entry of more than 8. The sheet may chafe on the base of the winch. Fig. 23 B1140 Winch 29

30 Installation! 0 Incorrect angle of entry with sheet parallel to base of winch. Turns of the sheet round the drum risk overlapping. Fig. 24! Photograph of turns of the sheet overlapping on the drum because the sheet entered parallel to the base of the winch. Fig. 25 WARNING!: Place the winch bearing in mind that the final drive pinion (n 41 in the exploded view on page 7) must be positioned relative to the point where the first turn of the sheet touches the drum so that the angle between the tangent of the pinion position and the load direction is between 0 and ± 15, depending on the space available below deck. Load Direction Final Drive Pinion 30 Load direction for a right-hand winch 1140 Fig. 26 B1140 Winch 30

31 Installation After correctly positioning the final drive pinion with respect to the load direction, you need to check that there is room below deck for the motors, the reduction gear, the electrical cables and the hydraulic tubes. In seeking the best compromise bear in mind that, to make installation easier, the motor unit can be fitted to the winch in four different positions differing by 90.! WARNING!: When there are a number of different load directions, bear in mind that the greatest loads are created by the sheets and halyard of the code zero, the spinnaker guys, the runners and the 100% genoa sheets.! DANGER!: Install the winch correctly and soundly on a flat part of the deck and make sure that the deck is strong enough to support the working loads of the winch. Ask the boatbuilder if you are in any doubt about the positioning of the winch.! WARNING!: If the winch is used to turn a line by 90 on to another winch, the load increases by almost 50%! Once you have determined the correct placing of the winch on the deck and verified the space below deck, proceed with the installation: 1. Position the drilling cut-out template in the position you have selected for the winch. This manual contains a printed copy of the drilling cut-out template for the right-hand winch You can a request to Harken Italy Tech Service (techservice@harken.it) for the drilling cut-out template in DWG format both for the right-hand and left-hand winch Mark the position of the holes to be drilled in the deck. Bear in mind that: A hole of Ø 350 mm is required to house the base of the winch The 8 holes of Ø 13 mm for the M12 screws (not supplied) used to fix the base to the deck are on a circumference of Ø 460 mm. 3. Drill the holes. 4. Seal the exterior of the main hole and all the fixing holes with a suitable marine adhesive sealant such as 3M s Marine Adhesive Sealant 5200 FC. To apply the sealant, remove grease from both surfaces with acetone or an equivalent product and apply the sealant to both surfaces. 5. Remove the top and the first speed button. Disassemble the stripper arm, the drum and drum support, following the procedure described in the chapter on maintenance. 6. Position the base of the winch on the deck and bolt it in place using through-bolts chosen on the basis of the deck thickness.!! WARNING!: to fix the winch to the deck of the boat use bolts in A4-70 quality stainless steel. WARNING!: If the deck is in aluminium, use a suitable reinforcement below the deck to fix the winch. If the deck is in sandwich composite material, use any suitable reinforcement system around each hole so that the deck can support the concentration of stress in the immediate area. 7. Remove excess marine sealant. 8. Reassemble the winch following the various steps of the disassembling procedure in the reverse order. B1140 Winch 31

32 Installation! WARNING!: Before reassembling the winch make sure that the drainage holes in the base are not obstructed. Below is a scale drawing of the right-hand winch 1140 drilling cut-out template: La HARKEN SPA fi proprietaria esclusiva di questo disegno e di tutte le informazioni in esso contenute. A norma di legge fi vietata la riproduzione senza autorizzazione scritta rilasciata dalla HARKEN SPA. HARKEN SPA is the sole owner of this drawning and of all included information. According to law it is forbidden to reproduce this drawing whithout a written authorization issued by HARKEN SPA DISEGNATO CONTROLLO DATA NOTE (#42438) DRAWN CHECK DATE 14/12/06 sheet format ISO A1 DESCRIZIONE TITLE right-handed1140 drilling cut-out template MATERIALE FINITURA SCALA MATERIAL FINISH SCALE DT DIS. N REV. 1: mm Output gear and load direction Locate the winch so that the line with the highest load comes to the winch from this area Deck cut-out diameter Ø 562 mm Ø 460 mm n 8 drill through equally spaced Base diameter. Ø 350 mm Ø 360 mm 30 Drum diameter Ø 13 mm R 70 mm Right-hand winch 1140 drilling cut-out template. Fig. 27 B1140 Winch 32

33 Use! WARNING!: The winch 1140 is designed to put a maximum dynamic load on the line of Kg. Diameter of line suitable for the self-tailing of the hydraulic and electric 1140: minimum 19 mm - maximum 32 mm. Diameter of line suitable for the self-tailing of the 1140 Racing: minimum 16 mm - maximum 25 mm. To work, the winch 1140 needs two hand- or foot-operated electric buttons (BRS 102 P). To activate backwind, a further hand- or foot-operated electric button needs to be installed on the deck mm mm Harken BRS 102 P button Fig. 28 ENGAGING FIRST SPEED Press the first button Press the black button The winch rotates in first speed Scene 1 Fig. 29 To engage first speed: Press the black button on top of the winch in the centre of the stripper arm, identified as n 77 in the exploded view on page 6. If the button does not engage, rotate the winch briefly to permit mechanical coupling. Press the first of the three electrical buttons mounted on the deck. The winch will rotate at first speed (very fast but not powerful). Use this to recover a lot of line under low load, as after tacking. B1140 Winch 33

34 Use ENGAGING SECOND SPEED Press the second button The black button disengages automatically The winch rotates at second speed To engage second speed: Scene 2 Fig. 30 Press the second of the three electrical buttons mounted on the deck The black button on top of the winch disengages automatically The winch will rotate at second speed (fairly fast and fairly powerful). Use this when the load increases but there is still a lot of line to recover. ENGAGING THIRD SPEED Press the first button again The black button remains disengaged The winch rotates at third speed To engage third speed: Scene 3 Fig. 31 Press once again the first of the three electrical buttons mounted on the deck The black button on top of the winch will remain in the disengaged position The winch will rotate at third speed (slow, but very powerful). This speed is particularly suitable when load is very high and there is little line to recover, as when trimming. ENGAGING BACKWIND Press the third button The black button remains disengaged The winch rotates reverse direction Scene 4 Fig. 32 B1140 Winch 34

35 Use To engage backwind: Press the third of the three electrical buttons mounted on the deck The black button on top of the winch will remain in the disengaged position The winch will rotate in the reverse direction. Right-hand winches will rotate anti-clockwise, allowing the load on the line to be lightened before the sheet is eased. The winch can ease the amount of line contained in the self-tailing sheave.! WARNING!: Backwind functions only if the black button in the centre of the stripper arm is not engaged. If the black button has been pressed accidentally, it must be disengaged manually before operating backwind.!! WARNING!: Backwind only works if there is a load on the winch. WARNING!: Only use top quality line for reasons of safety and winch performance. During sea trials of the equipment installed, the flow in the hydraulic system will be regulated according to the requirements of the trimmer. B1140 Winch 35

36 Maintenance Winches must undergo careful maintenance at the beginning and end of each season of sailing/racing. Moreover they must undergo complete maintenance, cleaning and lubrification every twelve months. They must also be washed with fresh water frequently, and in any case after being used.! WARNING!: Lack of adeguate maintenance shortens the life of the winch and may cause serious accidents and invalidate the winch warranty. If for any reason you cannot carry out this maintenance, the Harken Italy Tech Service They will provide you with the Special Project Team list of authorised technicians who can do a professional job on your equipment. Our technicians will carry out the maintenance in a competent and professional manner. Maintenance External maintenance Cleanse the drum grip with a high pressure hose to eliminate any threads from lines and traces of oil or other slippery substances that could reduce the grip of the turns on the drum. Clean stainless steel drums with these Harken products: Stainless Steel Cleaner BK 4522 and Winch Polish for all metal surface BK Rinse the winch frequently with fresh water.! WARNING!: Make sure the drainage holes in the base of the winch are not obstructed so as to avoid water collecting in the base of the winch.! WARNING!: Do not allow teak cleaning products or other cleaners containing caustic solutions to come into contact with winches and especially anodized, chrome plated or plastic parts. Maintenance Internal maintenance Tools needed to disassemble the winch: N. 1 medium flat-bladed screwdriver N. 1 large flat-bladed screwdriver Set of Harken BK 4510 allen wrenches N.1 spanner 17 N.1 hammer with plastic head N. 1 pair of plyers Rags Fig. 33 B1140 Winch 36

37 Maintenance Disassembling procedure To identify the various parts refer to the exploded view on page Unscrew the two screws (n 78). Remove the logo ring (n 76). 3 4 To make the stripper arm support easier to remove, tap it a few times in an anticlockwise direction with plastic headed hammer. Unscrew the four hex headed screws (n 79). 5 6 Remove the stripper arm (n 75). Slide out the first speed button unit B1140 Winch 37

38 Maintenance Disassembling procedure 7 8 Remove the winch top (n 72). Unscrew the stripper arm support (n 71) Remove washer (n 30) and washer (n 32). Unscrew the 8 (n 85) screws Remove the drum (n 33). Remove washer (n 30) and thrust bearing (n 11) Remove the roller bearings (n 62) and the spacer (n 63). Unscrew the 7 (n 61) screws. B1140 Winch 38

39 Maintenance Disassembling procedure Remove the drum support and housing (n 29 and n 28). At the point you can disassemble, check and carry out maintenance on the gearing, bearings and pawls in the base of the winch Remove the roller bearing (n 7). Remove the unit connected to gear n Remove the unit connected to gear n 37. remove washer (n 35), remove gearing (n 37) and check the pawls (n 16). B1140 Winch 39

40 Maintenance Disassembling procedure Remove the unit connected to the ring gear (n 42). Remove roller bearing (n 7) and washer (n 52) Remove the final pinion drive (n 41). Remove roller bearing (n 7), washer (n 45) and check the pawls (n 53) Unscrew the 6 (n 49) screws and remove the upper planet carrier (n 40). Remove the three washers (n 48) and the three planet gears (n 44) and check the roller bearings (n 51) Slide out the central shaft (n 4). Remove the unit connected to gear n 20 and check the pawls (n 16) it contains. B1140 Winch 40

41 Maintenance Disassembling procedure 29 Once the winch is completely disassembled, clean the parts in an ultrasound bath. If this is not available, immerse the parts in a basin of naphtha. If this is not possible, clean the parts with a rag. Once cleaning is finished, dry the parts with a cloth that leaves no residue. Inspect gearings, bearings, shafts and pawls for traces of wear or corrosion. Carefully inspect the teeth of the ring gears to censure there is no trace of damage or wear. Check the roller bearings and make sure there are no breakages in the ball races. Replace any worn or damaged parts. For parts maintenance, use the products listed below. For further details on which products to use where, refer to the exploded view in fig Maintenance Maintenance products STRONG THREADLOCKER GREEN (i.e. LOCTITE 270). Clean the parts and apply the adhesive, spreading it all over the joint. Assemble the parts and wait at least 45 minutes before use. To remove screws sealed with threadlocker, you may need to heat the parts to reduce the effect. Caution: do not apply this product to screws driven into carbon components. Fig. 34 MEDIUM THREADLOCKER BLUE (i.e. LOCTITE 243). Clean the parts and apply the adhesive, spreading it all over the joint. Assemble the parts and wait at least 45 minutes before use. Generally for use on all screws, requires no heating before removal. Fig. 35 B1140 Winch 41

42 Maintenance Maintenance products OIL HARKEN BK Apply the oil to the parts indicated, taking care to lubricate the surfaces completely. Rotate or slide the oiled parts to distribute the product in a uniform way. Remember to oil the pawls and not to use grease on them. Fig. 36 SYNTHETIC GREASE HARKEN BK Apply a film of grease with a brush to all the parts indicated, and make sure that the film is visible. Take special care when greasing the teeth of the ring gears, the gears and the roller bearings. It is important to keep the teeth of the ring gears of our winches greased to increase their efficiency and life.! WARNING!: Parts, and especially the gears of the winch that are not sufficiently greased will undergo irreversible wear that is not covered by the warranty. ANTI CORROSIVE LUBRICANTS (i.e. DURALAC or TEFGEL). Apply sacrificial anodes or anti corrosive lubricants to prevent electrolytic corrosion between different metals in contact with one another. Apply the anti corrosive lubricant with a brush on clean surfaces. Fig. 37 ANTI SEIZING (i.e. SAF-T-EZE Anti Seize or LANOCOTE). This product is used to prevent problems of seizing caused by oxidation. We recommend using this or similar products on stainless steel screws where the use of Loctite is not specifically requested. Apply the anti-seize with a brush. Fig. 38 Fig. 39 B1140 Winch 42

43 Maintenance Esploded view Showing products to use for correct maintenance: Symbols: O= oil A= anti seize G= grease D= anti corrosive lubricant V= strong threadlocker B = medium threadlocker Note 1: On the screws in position 61 of the exploded view in fig. 2 on p. 6, apply anti corrosive lubricant on the heads of the screws and anti-seize on the thread. Fig. 40 B1140 Winch 43

44 Maintenance Esploded view Fig. 41 B1140 Winch 44

45 Maintenance Esploded view Once maintenance is finished, reassemble the winch following the sequence described above in reverse order. Before closing the winch, make sure the drainage holes in the base of the winch are not obstructed. If you use self-locking nuts to fix the base of the winch and they have already been unscrewed more than one, they must be replaced. Check that the 16 screws of the drum gear ring (fig. 40) and the screws in fig. 41 are correctly tightened. Fig. 42 Fig. 43! WARNING!: Position the pawls and springs correctly in their housing, as shown in the photographs below. Fig. 44 Fig. 45 B1140 Winch 45

46 Maintenance Esploded view Check that all the pawls can be easily opened and closed with a finger. Fig. 46 Once the drum support is repositioned, screw on the stripper arm support, using gentle taps of the plastic headed hammer to help you. For any doubts over the maintenance procedure, contact the Harken Tech Service. Maintenance Maintenance products Check the oil level on the indicator on the side of the backwind: Fig. 47 If the oil needs topping up, have this done by highly qualified personnel using Mobil SHC 634 synthetic oil. For more information on this procedure, the Harken Tech Service (techservice@harken.it). B1140 Winch 46

47 Troubleshooting To identify the various parts refer to the exploded view on page 6. PROBLEM POSSIBLE CAUSE POSSIBILE SOLUTIONS The winch does not engage second or third speed: The first speed button (n 77) does not disengage. Check whether the outer edge of the button is rubbing against the inner edge of the stripper arm support(n 71). If it is, contact the Harken Italy Tech Service Team. Check the height of the first speed button by adjusting how far it is screwed on to the control rod (n 26). If it is too high, the button will touch the logo ring (n 76) and thus cannot disengage. Slightly unscrew the set screws (n 22) so as to ease the pressure on the balls housed in the upper dog clutch (n 6). This will help to disengage the first speed button as the ball bearings will slide more easily in the upper race of the central shaft (n 4).! Fig. 48 WARNING!: Do not unscrew the set screws excessively, because you risk not having the upper dog clutch tight enough against the upper race of the shaft. Once the first speed button is disengaged,check that the teeth of the upper dog clutch (n 6) do not touch the lower dog clutch (n 5). B1140 Winch 47

48 Warranty The winch and all related products are covered by warranty for three years from the date of purchase, with the exception of the electric and hydraulic motors, which are covered by warranty for one year from the date of purchase. Custom products, products in carbon and/or high performance installations of normal catalogue products for extraordinary usage are covered for one year from the date of purchase, including but not limited to the America s Cup, some ocean and round the world races. America s Cup products are subject to specific agreements. Finishes in carbon are excluded from warranty for damage caused by wear and by ultraviolet radiation due to long exposure to sunlight. Contact Harken for information on what materials to use to renew the damaged finish. For the classification of events and for more details on the custom products and high performance installation warranty, contact Harken Italy. The Harken warranty covers material and manufacturing defects. When each specific warranty period ends, Harken will not recognise any implicit or explicit warranty on its products. Warranty service: Harken provides by fax, , letter or telephone the technical support needed for diagnosing any specific problem and will, at its discretion, repair or replace defective products. Such products must be returned to Harken Italy within the warranty period and must be accompanied by a receipt or invoice specifying the date of purchase. Warranty exclusions: The Harken warranty does not cover any product against defects arising from corrosion, ultraviolet radiation and normal wear and tear. Nor does it cover incorrectly installed products, products that have not been adequately checked after installation, improperly cared for products, or products that have lost colour after the use of teak or other unspecified cleaners or of caustic solutions. Also not covered are products used outside normal marine applications or for applications for which they were not designed and manufactured; those used in excessive conditions or outside the recommendations or the working load specified in this manual; those subject to improper use, negligence, incidents or those that have undergone unauthorised modification or repair. Also excluded are normal wear on the drums and pawls of the winches, and wear due to metal wires on any part of the equipment. Also excluded are electric motors and their accessories and switches that have been dismantled or wired outside the normal requirements of installation or in an improper manner. Different warranty agreements may be stipulated on some of the products mentioned above. Contact Harken Italy for information on such agreements. Obtaining assistance: Any defective product must be sent to Harken Italy (Via della Cerca 12/ Lurago Marinone (CO) - Italy) accompanied by a copy of the document (receipt or invoice) specifying its date of purchase and a letter including the customer s name and telephone number, the type of boat on which the product was mounted and the use made of it, together with a description of the defect or fault and the conditions of use of the product. Before sending any defective product contact info@harken.it to obtain authorisation. For details of the returned product acceptance document and means of shipping, contact Harken Italy Customer Service. REVISION INDEX: 1 B1140 Winch 48

49 APPENDIX A Base Sheave B1140 Winch 49

50 Introduction The following paragraphs describe the technical characteristics of the 1140 Winch Base Sheave. Technical information and characteristics Exploded view and parts list BASE SHEAVE KIT FOR WINCH B 1140 Fig. 1 POS. Q.TY CODE DESCRIPTION MATERIAL 1 1 A Base of base sheave assembly 2 1 S Base sheave cover Al UNI T6 3 1 A Base sheave assembly 4 1 S Toothed ring for base sheave 17-4 PH 5 7 S Stud screw M8x44 AISI M Nut M8 UNI 5588 A4 AISI M Washer D.8 ISO 7089 AISI A Bearing 510x525x40 B1140 Winch 50

51 Technical information and characteristics Exploded view and parts list DETAIL OF THE ASSEMBLY OF THE WINCH B 1140 BASE SHEAVE Fig. 2 POS. Q.TY CODE DESCRIPTION MATERIAL 1 1 S Ratchet base pulley Al UNI T M Heli-coil M5x7,5 AISI S Pawls carrier for base pulley 17-4 PH 4 10 S mm Pawl 17-4 PH 5 20 M Screw M5x20 UNI 5931 AISI M Plug-pawl retainer PLASTICA GENERICA M Ball Ø 9.52mm DELRIN 8 10 S Pawl spring AISI 302 B1140 Winch 51

52 Dimensions Drawing showing overall dimensions of hydraulically powered winch 1140 with base sheave: Fig. 3 Installation To install the winch 1140 with base sheave follow the indications in the chapter on installation in the winch 1140 Manual. In case of doubt, contact the Harken Italy Tech Service (techservice@harken.it).! WARNING!: The drilling cut-out template of the right-hand winch 1140 with base sheave differs from that of the winch 1140 without base sheave in the winch manual. Below is a reduced scale drawing of the drilling cutout template the right-hand winch 1140 with base sheave. B1140 Winch 52

53 Installation Fig. 4 Drilling cut-out template of the right-hand winch 1140 with base sheave. B1140 Winch 53

54 Maintenance Disassembling procedure: To identify the various components refer to the exploded view in figs. 1 and 2 of this appendix A. 1 2 Unscrew the 7 n 6 nuts. Lightly tap with a plastic headed hammer to break the Duralac film and then slide off the base sheave cover (n 2). 3 4 Slide off the toothed ring (n 4). Slide off the base sheave (n 3). At this point, inspect the pawls, the balls and the bearing. The bearing has a vertical slot to aid positioning.. B1140 Winch 54

55 Maintenance Esploded view Showing the products to use for correct maintenance of the base sheave: Symbols: O= oil A= anti seize G= grease D= anti corrosive lubricant V= strong threadlocker B = medium threadlocker Fig. 5 Note: Oil all the pawls in position n 4 of fig.2 of this Appendix and apply medium threadlocker on all the screws in position n 5. Apply the anti corrosive lubricant on the external contact surfaces of all the pawl carriers in position n 3. B1140 Winch 55

56 Maintenance Esploded view Fig. 6 Note 1: Apply the anti corrosive lubricant on the upper and lower surfaces of toothed ring n 4 in fig.1 of this Appendix. B1140 Winch 56