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OWNER'S MANUAL

Specifications, installation, hose and wiring selection, start-up, maintenance and troubleshooting for the Harken Hydro 4, 6 and 8 hydraulic power units that drive hydraulic winches, furlers and cylinders.

DocumentHarken 4/6/8 Hydraulic Power Units Instruction Manual
FormatPDF · 25 pages · 3.8 MB
LanguageEnglish
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Harken 4/6/8 Hydraulic Power Units — Instruction Manual

Technical Information

Model Functions* Motor Max current drain (amps) Tank l (gal) Max pressure bar (PSI) Flow @ 100 bar / 1430 PSI l/min (gal/min) Weight lb (kg) Use with winches Fasteners in (mm)
Hydro 4 6 1 × 3000 watts 160 10 (2.6) 140 (2030) 9 (2.4) 132.3 (60) 44 - 74 3/8 (10)
Hydro 6 9 2 × 3000 watts 2 × 160 25 (6.6) 140 (2030) 24 (6.3) 198.5 (90) 44 - 980 3/8 (10)
Hydro 8 12 2 × 3000 watts 2 × 160 50 (13.2) 140 (2030) 36 (9.5) 264.6 (120) 44 - 1150 3/8 (10)
Version 4.3 4.6 6.6 6.9 8.9 8.12
Hydraulic functions 3 6 6 9 9 12
Electric motors 1 1 2 2 2 2
  • *Every hydraulic winch or furling unit counts as a function. Values are based on 24 volts and differ on a 12-volt system.
  • All standard units use 3000-watt 24-volt motors; the Hydro 4 can be ordered with a 12-volt motor. Every unit is supplied with an electric control box.
  • Quick-release hose couplings are optional. Deck push-buttons are optional: two BRS102/P switches are suggested for each winch.

Power Unit, Control Box and Switches

Model A in (mm) B in (mm) C in (mm) D in (mm) E in (mm)
Hydro 4 25 (635) 16 17/32 (420) 9 7/16 (240) 9 13/16 (250) 6 11/16 (170)
Hydro 6 27 9/16 (700) 23 5/8 (600) 16 17/32 (420) 12 13/16 (326) 6 15/16 (176)
Hydro 8 29 15/16 (760) 31 1/2 (800) 18 11/16 (475) 15 9/16 (395) 10 13/16 (275)
  • Clearance required for installation (as drawn): 2" (50 mm), 7 7/8" (200 mm) and 3 15/16" (100 mm) around the unit.
  • Control box (Hydro 4/6/8): height 5 1/8" (130 mm), width 15 9/16" (395 mm), depth 12 13/32" (315 mm).
Part no. Description Ø in (mm) Height in (mm) Weight oz (g)
BRS102/P Remote switch w/guard 2 11/16 (68) 13/16 (21) 4.5 (128) View switch →
BRS104/P Remote switch w/guard 3 (76) 3/4 (19) 3.4 (95) View switch →

Mounting

  • Choose a dry, well-ventilated area as close as possible to the centre of the system and to the batteries, with room around the oil fill lid and drain plug.
  • Fasten the unit with 4 M10 bolts in the four threaded holes under the reservoir. Make sure the bolts are not so long that they pass through the reservoir.
  • Mount the control box close to the power pack, with easy access for maintenance and fuse checks.
  • Use only Exxon Nuto H46 or equivalent hydraulic oil. Never run the pack without oil. Leave the maximum pressure valve (near the base of the motor pump) as set by Harken.

How It Works

  • Each function normally has two deck push-buttons: one for 1st gear, one for 2nd. On a 3-speed winch one button gives 1st and 3rd, the other 2nd. The 1140 winch with hydraulic backwind has a third button for the backwind.
  • Pressing a button starts the motor(s) and opens the valve for that function; each hydraulic motor is fed by two hoses, which swap inlet and outlet to reverse rotation in 2nd gear.

Hoses and Fittings

Hose type Diameter in Max length m (ft) Max working pressure bar (PSI) Min bend radius mm (in)
SAE 100 R2 1/4 Only for hydraulic rams 400 (5800) 100 (4)
SAE 100 R2 3/8 10 (33) 330 (4800) 130 (5)
SAE 100 R2 1/2 15 (49) 275 (4000) 180 (7)
SAE 100 R2 5/8 15 (49) 250 (3600) 200 (8)
SAE 100 R2 3/4 15 (49) 215 (3100) 240 (9)
SAE 100 R8 1/4 Only for hydraulic rams 345 (5000) 35 (1.37)
SAE 100 R8 3/8 10 (33) 275 (4000) 65 (2.5)
SAE 100 R8 1/2 15 (49) 285 (4100) 75 (3)
SAE 100 R8 5/8 15 (49) 285 (4100) 205 (6)
  • Use SAE 100 R2 hose (double metallic braid) or SAE 100 R8 tube (Kevlar braid). Galvanised fittings rust in salt water; hoses and fittings must be made up by qualified personnel.
  • Terminals: JIC (UNF thread, 37° flare) or BSPP (cylindrical, 60° flare – matches the power pack and Harken winch motors). Use one flare type throughout. BSPP and JIC need no Teflon or other seal.
  • Run hoses by the shortest, straightest route, respecting the bend radius, supported with hose clamps (bought separately). A hose under pressure changes length by +2% to -4%. Avoid 90° connections; if needed use smooth-angle 90° terminals.
  • Flush hoses with clean, filtered oil from an external pump if not free of debris. Keep unused ports closed.
  • Harken hydraulic winches and furlers must have a case drain hose: Rilsan-type 6 × 8mm hose with 1/4 connections, each connected directly to its own port under the oil fill lid.
  • The manual's reference pages tabulate the valve, nipple, hose and terminal threads for each valve station (ev1.1 to ev6.2) and give a blank table to record your connections.

Electrical Connections

Battery to control box Hydro 4 Hydro 6/8
0 - 5 m (0 - 16 ft) 25 mm² (3 AWG) 70 mm² (00 AWG)
5 - 10 m (16 - 33 ft) 35 mm² (1 AWG) 95 mm² (000 AWG)
10 - 15 m (33 - 49 ft) 50 mm² (0 AWG) 125 mm² (0000 AWG)
  • Lead cables into the control box through IP68 waterproof fairleads. Run push-button cables without junctions and mark them: push button p1.1 must activate coil e1.1 of valve e1, and so on.
  • Lay 2 × 1 mm² cables from the box to the valves; motor supply cables 45mm² with a 9mm hole terminal (polarity not important). Do not connect the motor until final start-up and keep terminals apart.
  • Check the controls before connecting the motor: with the motor isolated, press each button while a second person checks with a tester that the valve of that function is powered; you should hear the remote switch click.
  • Wiring schematics for Hydro 4 and Hydro 6/8 are in the PDF.

Starting

  • Fill the reservoir through the fill lid up to the maximum mark on the level/temperature gauge.
  • Check all connections are tight; run one function at a time, starting with an unloaded winch, and watch for leaks. The level drops as hoses fill: keep it above minimum.
  • Bleed air by running each function in one gear for about 20 seconds, watching oil level and temperature. Single- and double-effect cylinders need their maker's bleed procedure.
  • Pressure check: open the gauge on the pack (counterclockwise) and verify system pressure – usually a maximum of 140 bar (2000 psi). Keep the gauge closed (clockwise) in normal use.

Maintenance

Interval Task
Weekly / monthly Check oil level; check for oil leaks
Yearly Check and clean motor brushes; check fluid connections; check hoses for wear; change filters; change oil
Every two years Change brushes

Never run the system on low-power batteries: low voltage increases current and overheats cables and motor. A voltage drop in operation is normal.

Troubleshooting

Problem Check
Functions are not working Battery switch ON; fuse inside the electric box.
One push-button not working Check it switches on and off (replace if not); check its wires.
Motor runs but several functions do not work, or work stop-and-go Oil level (fill to upper line); bleed the system.
Motor runs but the needed function does not Valve coil powered when the button is pushed? If not, check valve wiring; if wiring is fine, check pressure; if fine, change the valve.
System is weak: winches can be stopped by hand Battery must not drop below 24 volts during use; gauge must reach 2000 psi/40 bar (as printed) – if not, clean or change the max pressure valve; check for leaks.
Functions turn slowly Clean the suction and return filters.

Warranty: two years from final installation in the yacht, excluding improper installation, maintenance or use (e.g. running without or low on oil, changing the max pressure valve setting, not cleaning hoses, low-power batteries). Flow and current charts for each unit are in the PDF.

Need a part that isn't listed? Ask us to source it and quote the part number from the PDF.

Products in this Manual