1. Using the spanner wrench (supplied), turn the retaining nut counter-clockwise to remove.
2. Slide the winch drum up and off the bearing spindle. Watch for the needle bearing cages as they may come off with the drum. Also be careful where you set down the drum, as it may have winch lube on the bottom ring gear.
3.Now is a good time to clean and service your winch. Check these websites for how to’s and schematics:
4.Inspect the threads of the center stem and make sure that the bearings are below the bottom thread. If not, and you have a fiber or plastic spacer, you may have to sand or grind it down to reduce its overall height. With your hand, thread the spindle extension onto the spindle in a clockwise rotation.
5.Take a ½” o.d. (max) rod or large screwdriver and pass it through the holes in the middle of the extension. Continue tightening until it stops.
Check to make sure it does not bear down or compress the bearing cages. If so, remove more of the spacer until there is at least 1/16” clearance between bottom of spindle extension and bearing. (You may choose to remove spacer entirely; or, if you have plastic bearing cages, use a random orbital or sandpaper to remove .010 top and bottom of each bearing until clearance is met.) In some situations where there is no spacer, removal of material from the bottom of the spindle extension may be necessary. Contact us for info or replacement. Tighten the single set screw in side of extension.
6.Slide drum down on spindle and check for clearance. Turn drum by hand and check for any friction or rubbing. If clear, use the 5/64 hex wrench (inc) to tighten set screw in
side of spindle extension.
7. If, in the future you find that the line lifter/stripper arm has moved or seems to have unusual play, repeat the above process with the spindle extension. Dimple with punch where set screw makes contact with spindle.
8. Next, place the white Delrin spindle bearing (black shown) over the extension.
(This bearing does NOT require lubricant).
9. With the Winchmate face down in your lap, place the drum upside down into bottom of spool section. (See photo below)
10. Take the two-piece retaining ring and place the two halves together around drum (textured side down). The pins will align the two halves for proper threading. Let the retaining ring rest in the starting position of threading.
11. Start the threads in a COUNTER CLOCKWISE ROTATION (NOTE:
THESE ARE REVERSE THEADS!) Using both hands press inward and downward toward the center, gently feel the threads while turning slowly. They should start smoothly. DO NOT CROSS-THREAD. If they do not start easily or bind, loosen and restart.
12. Hand-tighten retaining ring until it appears snug against drum crown. There should be minor play of the spool section so that it can be aligned on the spindle when installing. The spool section will be fully tightened after the drum has been replaced on the center stem.
13. Carefully slide drum down over bearing spindle/center stem. Rotate drum slightly making sure it is seated properly and is not resting on gears.
14. With one hand, grasp and turn the top spool section counter clockwise while at the same time, holding the retaining ring stationary. (This can be done by inserting the spanner wrench into the spanner holes of the retaining ring). When you can no longer turn the spool by hand, the Winchmate is secure. The spool section will continue to achieve maximum tightening under sheet load.
15. Place the 2 7/8” OD black ABS spacer over the spindle extension and into the top recess of spool section. (This spacer is mandatory).
16. Next, place the line-lifter/stripper arm onto the spindle extension in the desired position. This is where you want the sheet to exit the drum. If you are having difficulty aligning/installing the stripper arm, lift drum slightly so that line-lifter/stripper arm clears the top of the spindle extension and then lower back down into position. Loosening of the hex-cap screw that holds the rope blocker may help as well.
The cap screw should not be tightened completely as the rope blocker should “float” in the jaws. There may be some contact with line jaw “ribs” that can easily be removed with a file and or sandpaper.
17. Install the drum nut and tighten down with supplied spanner wrench. Check for clearance between heads of cap screws and bottom of stripper arm then remove.
18. Place the stainless steel winch handle extension into winch handle receiver of spindle extension. If it does not drop straight in, turn it slightly (45 deg.) or until it does. DO NOT force it down, as it will become difficult to remove. Some existing receivers are deformed or damaged. If this is the case, you may have to grind or file down the male (square) portion of the extension until it “drops in” freely.
19. Install and tighten the chrome “Winchmate” drum nut using spanner wrench. Again, turn the winch by hand and check for clearances and or binding. Determine the cause (if any) and make adjustments.
MAKE SURE DRUM NUT IS TIGHTENED PROPERLY.
20. Insert your index finger into the extension/receiver and pull upward. If there appears to be excessive or no play, remove the nut and install/remove the spacer (supplied). Reinstall the nut (use spanner wrench to retighten).
CHECK FOR THE FOLLOWING TOLERANCES:
Rotate drum by hand and “feel” for friction. If drum seems to “rub” at a particular place of rotation, it indicates that the spool section might be slightly off center. Loosen the retaining rings and retighten. If friction remains, pull drum to determine cause. Remember, that during initial use and break in, this may disappear. However, if friction is persistent, contact us for support.
Wrap a jib sheet around drum.
ALWAYS USE A MINIMUM OF THREE (3) WRAPS ON DRUM! Pass sheet over line-lifter and into line jaws. Make sure sheet exits cleanly. Cleat off the clew end of sheet and put tension on Winchmate (as if under operating conditions). Retighten with large spanner wrench and check for slippage of Winchmate on drum. Check various line sizes you will be using in the jaw prior to leaving the dock. If you purchased a fixed jaw model, pull the sheet out by hand to check tension or “bite”. If the sheet feels pinched, remove the 6 cap screws and add a spacer (or 2) with the 6 holes between top and bottom spool. The jaw should hold firmly but not be difficult to remove from jaw.
Annual maintenance should include waxing or sealing of the anodized aluminum as well as cleaning and lubricating (winch grease) the winch handle extension and springs and internal maintainence. Winch covers are recommended for ultimate protection.