1. Make sure you have a retaining nut. These nuts will also have spanner holes rather than a retaining clip or cap screw as used on the #26 and smaller winches.
2. Using the spanner wrench (supplied), turn the retaining nut counter-clockwise to remove.
3. 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.
4. Now is a good time to clean and service your winch. Check these websites for how-to’s and schematics:

   http://www.arco-winches.com/barient.html
   http://www.cncphotoalbum.com/winches/barientndx.htm
   http://cncphotoalbum.com/indexes/winches.htm
   http://sailnet.com/collections/articles/index.cfm?articleid=woodto027

5. 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. Take a ½” o.d. (max) rod or large Phillips 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 is necessary. Contact us for info or replacement.
6. Slide drum down on spindle and check for clearance. If drum rubs on spindle extension, this indicates extension has flared due to inadequate thread length and needs to be sanded with emery (best to remove first).
   If clear, tighten the setscrew (1 ea) with at the side of the spindle extension (5/64 hex wrench provided).
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 screws make contact with spindle.
8. Next, place the white (black shown) Delrin spindle bearing over the extension. This bearing does NOT require lubricant.
9. Next, place 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, loosen and restart.
12. Hand-tighten retaining ring until it appears snug against drum crown. There should be some 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 with the retaining ring stationary. (This can be done by inserting the large spanner wrench into the spanner holes in 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 spindle extension and into the top recess of spool section.
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). First loosen rope blocker cap screw and place the two spacers with 6 holes and solid spacer under line lifter. 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. Determine proper 3 7/8 spacer required between spool and line lifter. (Partially retighten rope blocker cap screw after installation of drum nut.) Rope blocker can “float” in jaws.
17. Place the stainless steel winch handle extension into winch handle receiver of spindle. If it does not drop straight in, turn it at 90 deg. intervals 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 grind or file down the male portion of the extension until it “drops in” freely.
18. 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 and install/remove appropriate spacers (save spacers). MAKE SURE NUT IS TIGHTENED PROPERLY.
19. 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 O-ring (supplied). Reinstall the drum nut (use spanner wrench to tighten).

CHECK FOR THE FOLLOWING TOLERANCES:

Rotate drum by hand and “feel” for friction. If winch 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.

The Winchmate will handle lines of l/2” dia. as shipped (spring jaw: 7/16-5/8”). The sheet should not be overly “pinched” by the line jaw (fixed jaw) or it will not want to “off-feed”. For larger sheet diameters, install the ABS spacer(s) (fixed jaw) with the 6 holes as necessary. Remove spacer with six holes from under stripper arm and place one or more between spool sections. Remove the 6 stainless hex-cap screws (fixed jaw) on the spool section, install the spacer(s). Staggering “ribs” will provide less “grip” (fixed and spring). Replace the screws using thread bond (Locktight/Neverseize or other). If you determine later that the spacer needs to be removed, this can be done with spool section remaining on the drum. Always replace spacers under stripper arm (fixed jaw) if not used between spool sections.

Wrap jib sheet around drum and onto cleat. ALWAYS USE A MINIMUM OF THREE (3) WRAPS ON DRUM! Pass sheet over line-lifter and into line jaws. Make sure sheet exits cleanly and does not bind on rope blocker. If so, check for clearance and adjust. Apply tension with winch handle. If sheet is pinched and difficult to remove from jaw, install spacer(s) (with 6 holes) into spool section to allow for less tension or stagger ribs. SHEET DOES NOT REQUIRE MAJOR TENSION IN LINE JAW. Too much tension will result in sheet binding at rope blocker. While the winch is in tension, re-tighten the retaining ring (fixed and spring jaw) with the large spanner wrench. Make sure the Winchmate is functioning properly before leaving dock.

CONCTACT US FOR SUPPORT

info@winchmate.com
415 460-5151