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Harken Air 900 User And Maintenance Manual

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Rev.0 – 30/03/2021
Winch Air 900
USER AND MAINTENANCE MANUAL
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Summary of Contents for Harken Air 900

  • Page 1 Rev.0 – 30/03/2021 Winch Air 900 USER AND MAINTENANCE MANUAL...

  • Page 2: Table Of Contents

    Glossary ............................4 Symbols ............................4 Safety information ........................5 General advice ..........................6 ® Harken limited worldwide warranty ..................6 Product information ........................7 Product identification ........................7 7.1 Speeds ............................7 7.2 Maximum Working Load (MWL) ....................8 7.3 Materials ............................
  • Page 3 Rev.0 – 30/03/2021 12.2.4.1 Hydraulic system diagrams .................... 26 13. Cleaning and maintenance ......................27 13.1 Internal maintenance procedure ....................28 13.1.1 Maintenance product ......................28 13.1.2 Tools ..........................29 13.1.3 Disassemble procedure ......................30 14. Assembling ..........................38 15. Troubleshooting ........................39 15.1 All versions ..........................

  • Page 4: Glossary

    Rev.0 – 30/03/2021 Glossary Intended use: specific and proper use of the winch for which it is designed Improper use: use of the device in a different way from that indicated in the instructions for use specified in this manual Qualified operator: person who has attended specialisation and training about the use of the winch User: person who uses the winch regularly...

  • Page 5: Safety Information

    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. Harken cannot be responsible for damage or injury resulting from unsafe product use, lack of maintenance or incorrect product and /or system installation or operation.

  • Page 6: General Advice

    Rev.0 – 30/03/2021 General advice Intended use The Harken devices are designed and manufactured for a use on sailing boats to control ropes, halyards and related sail and rig systems. For any other usage, contact the Harken Italy Technical Service by e-mail: techservice@harken.it...

  • Page 7: Product Information

    Rev.0 – 30/03/2021 Product information Winch Air 900 is designed with a special care to the racers’ needs, but it may be effectively employed on cruiser yachts and used to trim and hoist sails. Winch Air 900 is produced in the Self-Tailing version (ST).

  • Page 8: Maximum Working Load (Mwl)

    Rev.0 – 30/03/2021 Maximum Working Load (MWL) Winch Air 900 is designed to put a maximum working load (MWL) of 9000Kg. WARNING! 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.

  • Page 9: Handling Rotation

    Rev.0 – 30/03/2021 Handling rotation Winch Air 900 is available in the right-hand version and in the left-hand version. Viewing the winch from above, in the right-hand version drum rotates clockwise; in the left-hand version drum rotates counter-clockwise. Right-hand Left-hand...

  • Page 10: Product Composition

    Rev.0 – 30/03/2021 Product composition Winch Air 900 is composed by the following groups: Technical characteristics Gear ratios and power ratios Gear Gear ratio Power ratio reduced 3.12 4.35 13.11 18.25 67.17 93.48 NOTE! The theoretical power ratio is calculated without taking account of any friction.

  • Page 11: Rope Diameter

    Rev.0 – 30/03/2021 Rope diameter In the Self Tailing top, Winch Air 900 is equipped with jaws that adapt automatically to the following rope diameters range: Ø10-Ø24mm. For the rope usage, see the ‘Rope use’ chapter of this manual. WARNING! For safety and correct performances, use ropes of the diameters indicated below.
  • Page 12 Rev.0 – 30/03/2021 Oil bath is not equipped with the assembled winch, shipped to the customer with greased gears. If customer desires to use the oil bath gears, the disassemble procedure explained in this manual (refer to the ‘Disassemble procedure’ chapter) is to be respected till step #XX and then proceed as follows: - clean the parts with a degreasing that does not leave residues, proper to clean metal components.

  • Page 13: Installation Procedure

    Rev.0 – 30/03/2021 10. Installation procedure To install the winch, please follow the steps shown below of the installation procedure, taking into account the outline, the mounting template and the several technical info needed. 10.1 Outline NOTE! The following dimensions refer to the winch without motorization. All dimensions are in [mm].

  • Page 14: Entry Line

    Rev.0 – 30/03/2021 10.2 Entry line WARNING! Before installing, ensure the following requirement is respected: in deciding where to install the winch make sure that the rope is not parallel to the base of the winch to avoid line overrides around the drum, which could seriously damage the winch and/or put the crew in danger.

  • Page 15: Installation - Technical Information

    Rev.0 – 30/03/2021 WARNING! Situation to avoid: incorrect entry angle with the rope parallel to the base of the winch. Beware of possible overrides around the drum. INCORRECT! 10.3 Installation - Technical information WARNING! - The mounting surface requires a flat area of 0.5mm tolerance under the Winch base plate.

  • Page 16: Installation - Fasteners

    Harken assumes no responsibility for incorrect installation of its devices or for an incorrect choice of mounting fasteners. WARNING! - Use only the bolt size and number specified in the outline drawings.

  • Page 17: Winch Mounting Template

    A. Place the drilling cut-out template over the point chosen for installation. Harken provides drilling cut-out template to the customer, composed by handling tools and an aluminum base that allows to drill the deck respecting the correct positioning of the cut-out...
  • Page 18 Rev.0 – 30/03/2021 The template in DWG format and 1:1 scaled is available on request from the Harken Italy Tech Service at techservice@harken.it. Small-scaled mounting template is shown below. B. Mark the position of the holes to be drilled in the deck.
  • Page 19 Rev.0 – 30/03/2021 D. Seal the external part of the main holes and all the fixing holes with a suitable marine adhesive sealant as shown in the following image (green lines). To apply the adhesive sealant: clean and remove all grease from winch bottom surface and apply the sealant.

  • Page 20: Self-Tailing Drilling Procedure

    Rev.0 – 30/03/2021 10.6 Self-Tailing drilling procedure Once installation is completed, proceed with the drilling operation of the Self-Tailing. In order to have the most comfortable position of the peeler relative to the usage of the rope, user must drill two Ø5.5mm holes radially in the top of the winch: the position of the two holes determines the rope usage.
  • Page 21 Rev.0 – 30/03/2021 2. Step #2: place the stripper arm on the upper jaw, choosing the position: 3. Step #3: once the position is chosen, proceed with the drilling of the carbon top to place the stripper arm assembly on the top. NOTE! Use a 5.5mm-diameter drill.

  • Page 22: Rope Use

    Rev.0 – 30/03/2021 Rope use NOTE! The following instructions are available for right-hand winches; for left-hand versions all the rotations are opposite. Before use, verify that: - The correct rope diameter is used, as indicated in the ‘Rope diameter’ chapter of this manual. - The most comfortable position of the peeler relative to the user of the winch is chosen.

  • Page 23: Winch Use

    Rev.0 – 30/03/2021 12. Winch use 12.1 Manual use After winch is assembled and after wrapping the rope around the drum, test the winch functioning before sailing: - Press the central button (Fig.1) - Move counterclockwise the lock of the Winch handle (Fig.2) - Insert the lock-in winch handle in the handle socket (Fig.3) - To operate the 1 speed, turn the handle clockwise (for a right-hand winch) (Fig.3)

  • Page 24: Powered Use

    Rev.0 – 30/03/2021 12.2 Powered use If the Winch Air is powered by a motor, it needs two commands. 12.2.1 Operating first speed on a powered winch To operate first speed: • Press the central button of the winch. If the button does not engage, turn the winch briefly to allow the mechanism to engage.

  • Page 25: Operating Third Speed On A Powered Winch

    12.2.4 Motorization equipment Winch Air 900 powered is equipped with a 100cc hydraulic motor. Hydraulically operated winch has a pull capacity proportional to the working pressure of the system, while the recovery speed of the winch is proportional to the oil flow.

  • Page 26: Hydraulic System Diagrams

    Rev.0 – 30/03/2021 12.2.4.1 Hydraulic system diagrams The main motor can use both a closed centre valve, which is generally preferable, or an open centre one.

  • Page 27: Cleaning And Maintenance

    Rev.0 – 30/03/2021 Cleaning and maintenance The more the Winch is used, the more frequent it will be its maintenance and cleaning: environmental conditions and use influence the usury of the components and directly the maintenance and cleaning frequency by the user. Complete maintenance, cleaning and lubrication must be performed every 12 months.

  • Page 28: Internal Maintenance Procedure

    Generally, for use on all screws, requires no heating before removal. Synthetic GREASE Harken - BK4513 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.

  • Page 29: Tools

    Rev.0 – 30/03/2021 ® Anti-seizing (i.e. SAF-T-EZE or similar) 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.

  • Page 30: Disassemble Procedure

    Rev.0 – 30/03/2021 13.1.3 Disassemble procedure Step #1.1 – For motorized versions only Step #1 Step #2 Step #1.2 – For motorized versions only...
  • Page 31 Rev.0 – 30/03/2021 Step #3 Step #4 Step #5...
  • Page 32 Rev.0 – 30/03/2021 Step #7 Step #6 Step #8...
  • Page 33 Rev.0 – 30/03/2021 Step #10 Step #9 Step #11 Step #12...
  • Page 34 Rev.0 – 30/03/2021 Step #13 Step #14 Step #16 Step #15...
  • Page 35 Rev.0 – 30/03/2021 Step #17 Step #18...
  • Page 36 Rev.0 – 30/03/2021 Step #19 Step #20...
  • Page 37 Rev.0 – 30/03/2021 Step #21 Step #22...

  • Page 38: Assembling

    Rev.0 – 30/03/2021 Assembling Once maintenance is finished, reassemble the winch in reverse order with respect to the sequence described above and use the maintenance products. WARNING! In the assembling phase: position the 1 speed spring correctly in the housing, as shown in step #11 of the disassembly procedure (shown above) position the pin of the spring correctly, as shown below.

  • Page 39: Troubleshooting

    Rev.0 – 30/03/2021 Troubleshooting 15.1 All versions To identify the various components, refer to figures of the disassemble procedure for the Winch maintenance. PROBLEMS POSSIBLE CAUSES POSSIBLE SOLUTIONS ● The winch does The first speed button does not - check that the pin of the springs is not disengage broken.

  • Page 40: Ordering Spare Parts

    Rev.0 – 30/03/2021 Ordering spare parts ® ® Spare parts can be requested from Harken as described in the Harken Limited Worldwide Warranty available on the web site http://www.harken.com/ Contact us Manufacturer ® Harken Italy S.p.A. Via Marco Biagi, 14 22070 Limido Comasco (CO) Italy Tel.: (+39) 031.3523511...

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