Please read these instructions carefully before operating equipment.

Transcription

1 ACCESS WINCH WITH HANDLES 40.2STAACCSH Instruction Manual This product, as supplied by Harken, is considered to be applicable to general lifting operations and is not intended to lift persons. Should this product be incorporated into systems for lifting persons, it becomes partly completed machinery and, when appropriate additional safety devices are added, must be certified for its intended application. Such systems are classified as machinery for lifting persons and would require separate CE marking. Alternatively such systems may be classified as personal protective equipment and would be within the scope of the PPE Directive. i Please read these instructions carefully before operating equipment. Keep these instructions in a safe place for future reference. Harken does not accept any responsibility for damage or harm caused by failure to follow the safety requirements and instructions in this manual. The manufacturer cannot be liable for damage, injury or consequential loss resulting from installation or servicing by unqualified personnel. The manufacturer will also not be liable for damage, injury, or consequential loss resulting from incorrect operation or modification of the equipment.

2 Description A strong, lightweight manual rope-handling winch. Double handles provide maximum ergonomics, for high power and operation speed. Features Maximum Grip The drum s gripping surface is designed specifically to work with the drum diameter and material to maximize gripping power and reduce rope wear. Diagonal ribs stop the rope from rising (keeping rope wraps on part of drum where you have the best control), prevent overrides, and provide a smooth controlled release as rope exits the winch. Spring-loaded, self-tailing jaws adjust under rope pressure to accept a variety of rope diameters. Teeth grip evenly with or without load. Lightweight Aluminium drums and high-strength composite self-tailing jaws and skirt save weight. Powerful Double-handle action allows optimum use of manpower to deliver power and speed. Composite roller bearings reduce friction under load. Low friction and hardness properties make composites ideal for high-efficiency bearing systems. Reliable & Easy to Maintain Composite roller bearings and bushings don t require lubrication and have excellent corrosion resistance. This metal-replacement material is completely nonreactive to saltwater and most chemicals, and has very good wear and abrasion resistance under maximum operating loads. Load-carrying gears and pins are 17-4PH stainless steel for strength and durability. Planetary gears are bronze to avoid stainless-on-stainless galling. Snap-fit design keeps bearings captive in a high-strength Delrin cage when the drum is removed for maintenance. Winches can be disassembled and serviced where mounted. The socket, washer, and screw-top snap-fit together to simplify maintenance and for quick and mistake-free assembly. SELF-TAILING FOR EASY LINE CONTROL Locking jaws hold loaded rope securely during operation and while suspended. The stripper arm is shaped to smoothly feed the rope in and out of the jaws so the operator can use both hands to turn the winch. The stripper arm adjusts to multiple positions after the winch is mounted so rope exit position can be optimized. SPECIFICATIONS Maximum Working Load: Lifting Persons: 280 kg (test coefficient 10:1) See LIMITATIONS Page 3. Lifting Loads: 500 kg (test coefficient 5:1) Break Load: 2800 kg Self-Tailing Jaws Self-Tailing Stripper Arm Composite Bearings Hard Lube-anodized Aluminum Drum and Castle Bronze and Stainless Steel Gears Ø Rope entry Rope Ø Fastener Fasteners Part Drum (D) Base (B) Height (H) Weight height (LE) (Min - Max) circle (HH) Gear ratio Power ratio No. in mm in mm in mm lb kg in mm in mm in mm mm STAACCS 3 1 / / / / /16-1 / / x Access Winch

3 Parts Description / Use 1st Gear Faster = Less Power Handle Self-Tailing Stripper Arm Removable Winch Skirt Winch Base 2nd Gear Slower = More Power Locking Knob Winch Drum Self-Tailing Jaws Part No. 40.2STAACCSH B10ACCS 40.2STAACCS Description Access winch with handles with locking knobs Handle with locking knob Access winch without handles a. Use This winch is designed to be used as a manually powered, rope-handling winch for lifting, lowering, and pulling loads. It is designed to be mounted with the base in a vertical plane so that the double-handle configuration can be used in a pedestal-like action. B. Limitations Do not use: With wire rope With loads in excess of the maximum working load (MWL) of 280 kg for lifting persons. This product, as supplied by Harken, is considered to be applicable to general lifting operations and not intended to lift persons. Should this product be incorporated into systems for lifting persons, it then becomes partly completed machinery and, when appropriate additional safety devices are added, must be certified for its intended application. Such systems would be classified as "machinery for lifting persons" and would require separate CE marking. Alternatively such systems may be classified as personal protective equipment and would be within the scope of the PPE Directive. With loads in excess of the MWL of 500 kg for lifting loads. With more than one person turning the handles at the same time. This can overload the system. WARNING! Subjecting the winch to loads above the maximum working load can cause the winch to fail or pull off the mounting surface suddenly, possibly resulting in severe injury or death Access Winch 3

4 Installation A. PLAN INSTALLATION Mounting Surface Winch must be installed on a flat surface, reinforced if necessary, to withstand a load equal to at least twice maximum working load of winch. It is the installer's responsibility to carry out all structural tests needed to ensure that the mounting surface can withstand the load. Winch Entry Angle of Lifting Rope Winch entry angle must be 8 with a tolerance of ±2 to avoid rope overrides. WARNING! Verify entry angle of rope. It must be 8 with tolerance of ±2, to avoid rope overrides and damaging winch or making winch inoperable, leading to loss of control, possibly resulting in severe injury or death. Mount winch so drive gear (11 Pinion Z13) is positioned where rope enters winch drum. Note: s on winch skirt identifies location of drive gear. Rope Drive Gear 8 WARNING! Mount winch so that drive gear is positioned where rope enters winch drum. Incorrect positioning of drive gear can weaken winch leading to failure, possibly resulting in severe injury or death. Winch Location Winch must be installed in a position to allow sufficient working space around unit, so not to impede operation of handles. Winch must be installed in a position to ensure visibility of the lift trajectory by operator at all times. Harken accepts no responsibility for defective installation or reassembly of its winches. If you have questions or concerns, Harken Tech Service is at your disposal at techservice@harken.it. WARNING! Incorrect installation of winch may cause severe injury or death. Consult equipment supplier if in doubt about correct position of winch. B. YOU MUST PURCHASE SEPARATELY Installation Procedure 1: Five (5) M6 or 1 /4" Socket Head (SH) Bolts (Steel Alloy, 12.9 Class (ISO 898 part 1) Installation Procedure 2: Five (5) M6 Hex Head (HH) Bolts (Steel Alloy, 12.9 Class (ISO 898 part 1). Note: 1/4" Hex Head bolts do not fit in the holes and cannot be used to mount winch. Harken does not supply bolts to install winch since lengths may vary depending on mounting surface. It is installer's responsibility to choose correct bolts, taking into account loads they will have to withstand. Harken assumes no responsibility for incorrect installation of winch or for use of incorrect mounting bolts. WARNING! To install winch, use only steel alloy bolts, 12.9 class (ISO 898 part 1). Bolts made of other materials may not have sufficient strength or may corrode, which can cause winch to pull off mounting surface suddenly during high loads, possibly resulting in severe injury or death. WARNING! Failure to use correct number and type of mounting fasteners or failure to ensure correct mounting surface strength can result in winch pulling off suddenly and unexpectedly during high loads, possibly resulting in severe injury or death. 4 Access Winch

5 Installation Use either Procedure 1 or 2 to install winch. Use Procedure 1 to thread mounting screws into threaded holes in mounting plate. You can also use washers and nuts. Procedure 2 takes less time but can only be used if you can tighten nuts from behind mounting plate. C. PROCEDURE 1 Tools You Will Need One medium flat-blade screwdriver Protective gloves Torque to apply when assembling To install winch you must remove drum. Use five (5) M6 or 1 /4" Socket Head (SH) bolts into tapped mounting plate. You may also use washers and nuts (Steel Alloy, 12.9 Class) (ISO 898 part 1). 1. Remove ring (29). 2. Slide off bushing (30). 3. Slide off central shaft (28). 4. Slide off hub (31) and cover (26). 5. Loosen the three screws (25) (4Nm/35 in-lb) 6. Remove self-tailing arm (26) by rotating and lifting it Access Winch 5

6 Installation PROCEDURE 1 (Continued) 7. Lift off drum (20). Install Socket Head bolts in winch. PROCEDURE 2 Tools You Will Need One medium flat-blade screwdriver Protective gloves Torque to apply when assembling To install winch you must remove skirt as directed below. Use five (5) M6 Hex Head (HH) bolts, washers and nuts (Steel Alloy, 12.9 Class) (ISO 898 part 1). Note: 1/4" Hex Head bolts will not work for this procedure. 1. Carefully pry off skirt (2) using screwdriver placed as shown. 2. Take off skirt (2). 3. Position 5 Hex Head (HH) bolts in holes. 4. Correctly positioned bolts. 6 Access Winch

7 Installation PROCEDURE 2 (Continued) 5. Reposition skirt No. 2 in housing. 6. Press down skirt (2) to position correctly. Note: Make sure skirt is correctly clipped on to base of winch. final installation 1. Carry out Procedure 1 or Procedure 2, then install winch on a flat surface in selected position. 2. Position base of winch in selected area and mark holes or use drilling template. Drilling template is available on Harken website, Note: Templates are available in DXF and DWG formats only. Printing must be strictly controlled to insure that templates are printed full size. A reference dimension provided on the template must be carefully checked after printing. Note: When downloading winch templates make sure you have correct size paper and that printer will output at 100%. Before drilling holes verify that template is correct in every detail. Harken cannot be responsible for incorrectly drilled holes because of a faulty template. 3. Remove winch and drill five (5) 6.2 mm diameter clearance holes. If drilling and tapping consult industry standards for drill/tap size. Important: Do not countersink bolts. 4. Bolt base of winch to support plate. Use bolts that are the correct length for thickness and type of support plate. Consult equipment supplier if in doubt. Procedure 1: Use five (5) M6 or 1 /4" Socket Head (SH) bolts, washers, and nuts. If using threaded holes in mounting plate consult industry standards for minimum thread engagement for drilling and tapping. See Page 5. Procedure 2: Use five (5) M6 Hex Head (HH) bolts, washers, and nuts. Note: 1/4" Hex Head bolts do not fit in the holes and cannot be used to mount winch. See Page To obtain correct Maximum Working Load (MWL) all five bolts, nuts, and washers must be securely tightened and there must be at least 2 1 /2 threads showing below all five nuts. WARNING! Failure to use correct number and length of mounting fasteners and/or failure to tighten them correctly so that at least 2 1 /2 threads show below all nuts can result in winch pulling off suddenly and unexpectedly during high loads which may cause load to drop, possibly resulting in severe injury or death Access Winch 7

8 Installation final installation (continued) Radial Winch 40 Drive Gear (11 Pinion Z13) Reduced-size drilling template. See Page 7 for important information about template. REASSEMBLE WINCH 1. Reassemble winch following either Procedure 1 or 2 in reverse order and apply products indicated in Maintenance section. 2. Position self-tailing arm so rope leaving winch leads to correct position usually 4 or 5 o clock. POSITION HANDLES 1. Insert handle socket on central shaft. 2. Thread locking knob on central shaft to secure handle and tighten. 3. Position handles at 180 to one another as shown in photo. 8 Access Winch

9 Operation PERSONAL PROTECTIVE EQUIPMENT Rope Ø Min. Rope Turns Max. Rope Turns Wear gloves to protect against rope abrasion or chafe when rotating handles. 8 mm mm 4 5 LIFTING LOAD 12 mm 4 4 important! Keep fingers, loose clothing, hair, etc. away from winch. Area around winch handles should be kept clear of people and objects at all times. Be sure to keep loose rope near winch to prevent tripping. A. Start at base and wind rope onto drum in a clockwise direction. Use at least four (4) complete turns, but no more than six (6), depending on rope diameter. Excess turns may cause rope to override (overlap) or may cause excessive friction. DANGER! Winch must not be used to lift people unless combined with suitable additional safety devices. WARNING! Always put a minimum of four (4) turns on winch drum. Fewer turns can severely decrease holding power which may result in rope slippage or failure to hold load. Rope slippage or failure to hold load may cause lifted load to fall, possibly resulting in severe injury or death. B. Ensure that the rope does not override (overlap) on winch. WARNING! Never allow rope to (override) overlap on winch drum. This can cause rope to jam and can prevent load from being lifted/lowered. Tension on rope to load must be relieved to clear override (overlap). This procedure carries a risk of serious injury or death if load drops or becomes uncontrollable. C. Pull rope through to take up any slack, then load into spring-loaded, self-tailing jaws by winding rope clockwise and pulling tight to engage. Self-tailing jaws act as locking mechanism so operator does not have to pull rope in or let it out while rotating handles. WARNING! Rope must be securely pulled into self-tailing jaws. Do not rely solely on rope turns to hold load. Stripper arm must be positioned correctly so line is not forced out of self-tailing jaws while rotating handles. Check that rope remains secured in self-tailing jaws while cranking. Failure to securely pull rope into self-tailing jaws may cause rope slippage which can cause lifted load to fall, possibly resulting in severe injury or death. CORRECT INCORRECT Self-Tailing Jaws Access Winch 9

10 Operation D. Begin turning handles counterclockwise. Gears engage automatically depending on direction handles are rotated. 1st gear: rotate handles counterclockwise. 2nd gear: rotate handles clockwise. E. When handles become difficult to rotate in 1st gear, reverse direction to access 2nd. A higher power ratio makes a heavier load easier to lift with the same effort. Double handles optimize power applied. LOWERING LOAD 1st Gear Faster = Less Power 2nd Gear Slower = More Power WARNING! Do not operate with more than one person turning the handles at the same time. This can overload the system, causing the winch or components to fail causing a fall resulting in severe injury or death. We recommend using a safety device in the final operating system, such as a grab-rope mechanism (e.g. Prussic knot, rope-grab clutch). Engage grab rope mechanism or clamp rope turns on drum with your hand. Carefully unwind rope from self-tailing jaws only, while maintaining even tension on rope. Operator must hold rope, maintaining tension at all times unless it is securely fastened in self-tailing jaws. CORRECT INCORRECT WARNING! Use caution when lowering load using winch. Carefully hold rope when it is out of self-tailing jaws. Rope tail must not be released. Releasing rope tail will result in rope slippage. When lowering is completed, place line securely in self-tailing jaws. Rope turns alone may hold for a short time but will slip. Failure to hold load will cause it to fall, possibly resulting in severe injury or death. WARNING! Do not take rope turns off winch drum until rope is completely unloaded. Taking turns off winch drum will result in rapid rope slippage and failure to hold load. Failure to hold load will cause it to fall, possibly resulting in severe injury or death. 10 Access Winch

11 Inspection INSPECT BEFORE EACH USE A formal inspection of the winch and its connection to the structure must be performed at least annually by a knowledgeable person other than the user. The inspection should be recorded in an inspection and maintenance log. BEFORE EACH USE Inspect winch and self-tailing jaws for degradation, cracks, or wear that may affect locking strength and operation. Check lifting rope to make sure that it is free from wear. If in doubt, replace with a suitably strong rope. HEAVY USE/HARSH ENVIRONMENT In addition to inspection before each use, a detailed monthly inspection of the unit is recommended. If unit is under heavy use and/or in a harsh environment inspect and lubricate frequently. 6) Maintenance WASH Wash winch frequently with fresh water. Do not allow cleaning products or other caustic solutions to come into contact with winch, especially anodized, chrome-plated, or plastic parts. Do not use solvents, polishes, or abrasive pastes on logos or winch stickers. MAINTENANCE SCHEDULE Winch must be completely overhauled, cleaned, and lubricated at least every 12 months. Harsh environment and/ or heavy use may require more frequent maintenance. After inspection, replace worn or damaged components with genuine Harken parts. Do not replace or modify winch with a part that was not designed for it. CAUTION! Periodic maintenance must be carried out regularly. Lack of adequate maintenance shortens the life of the winch, can cause serious injury and also invalidate the winch warranty. Installation and maintenance of winches must be carried out exclusively by trained personnel. disassembly Tools You Will Need Medium flat-blade screwdriver Small flat-blade screwdriver #5 Allen wrench Protective gloves Carry out Procedure 1 as shown in Installation through step 5 and then do following: Torque to apply when assembling 1. Completely unscrew three screws (25). 2. Remove stripper arm support (19) Access Winch 11

12 Maintenance (Disassembly) 3. Unscrew six (6) Socket Head Cap Screws (15) (8Nm/71 in-lb). 4. Remove Assy Housing (14). Important: Washer (12) may remain inside drum support. 5. Remove washer (12). 6. Remove gear (7) and remove pawls (5). To facilitate operation, press spring against pawl with a blade. 7. Slide off gear (3). 8. Slide off gear (27). 12 Access Winch

13 Maintenance (Disassembly) 9. Slide off gear (10) 10. Remove pawls (5). To facilitate operation, press spring against the pawl with a blade. 11. Remove washer (9). REPLACING SELF-TAILING JAWS Tools You Will Need Medium flat-blade screwdriver If it is necessary to replace winch jaws, proceed as follows: Torque to apply when assembling 1. Unscrew four (4) screws (23) (4Nm/35 in-lb) 2. Remove jaws (22) Access Winch 13

14 Maintenance Tools You Will Need Brush clean 1. Use degreaser to soak metal components. Rinse plastic parts in fresh water. 2. Dry parts with rags that do not leave residue. 3. Inspect gears, bearings, pins, and pawls for any signs of wear or corrosion. 4. Carefully check teeth of gears and ring gears to make sure there are no traces of wear. 5. Check roller bearings to ensure there are no breaks in bearing cages. 6. Replace worn or damaged components. See Page 14 and Parts on Pages LUBRICATE BK Carry out maintenance on components using products listed and shown below on exploded view. BK Use brush to lightly lubricate all gears, gear pins, teeth, and all moving parts with Harken Grease. 3. Lightly lubricate pawls and springs with Harken Pawl Oil. Do not use grease on pawls! Location Harken Part No. Product G BK4513 Harken Grease L Loctite 243 O BK4521 Harken Pawl Oil 2 Apply Harken grease on drum gear G G G 2 L G O G G G L L 14 Access Winch

15 Maintenance SPARE PARTS Spare parts can be ordered from Harken as described in the Harken Worldwide Limited Warranty using the part number in the Parts List and the serial number of the winch, which is printed on a plate on the drum support and also on the skirt. W XXXXX XXXXXXXXX Last two numbers of the year of production, i.e. 10 for ) Assembly Assemble winch in reverse order of sequence in the Disassembly section. To tighten bolts, use torque indicated in disassembly procedure. When positioning stripper arm, align peeler with it. If jaws have been disassembled, insert peeler between two jaws, taking care that letters "TOP" on peeler are facing upwards. ASSEMBLE PAWLS Correctly position spring in housing as shown at left. Hold spring closed and slide pawl into housing. Once in position, check that pawls can be easily opened and closed with a finger. If you have questions concerning the assembly procedure contact Harken Tech Service: techservice@harken.it. OIL 8) Handling Protect against extreme temperatures: -10 C to +40 C Extreme heat may distort composite parts. Extreme cold can cause the material to become brittle and cause the lubrication to congeal. 9) Storage Store in clean/dry place Avoid impact damage which could damage jaws and skirt; ensure good packaging when shipping Access Winch 15

16 Declaration of Conformity Manufacturer Harken Italy S. p. A. Via Marco Biagi, 14, Limido Comasco (CO) Italy Telephone: Web: EC Declaration of Conformity Harken Italy S.p.A. declares that the product described hereafter: Access Winch 40.2STAACCSH complies with the essential requirements of the Machinery Directive 2006/42/EC and carries the appropriate CE marking. Compliance has been demonstrated with reference to the harmonized standard; BS EN 13157:2004 Cranes Safety - Hand powered lifting equipment A technical file is retained for this equipment by the authorized manufacturer. Done at: Harken Italy S.p.A. 28th April 2010 On: Signature Andrea Merello Harken Italy S. p. A. Via Marco Biagi 220 Limido Comasco (CO) Italy 12) Explanation of Label Access WincH (+39) EN Minumum 4 turns clockwise, rope Ø 8-12 mm Break Load 2800 kg Italy SpA i Max Working Load Lifting Loads= 500kg (coefficient 5:1) Lifting persons= 280kg (coefficient 10:1) 40.2STAACCSH Serial No. W XXXXX XXXXXXXXX Manufacturer s name 2. Product name and code 3. Manufacturer's address 4. Pictogram instruction to read the manual 5. CE marked and tested to EN standard 6. Safety instruction to put a minimum of 4 rope wraps clockwise around drum; minimum rope diameter is 8 mm, maximum rope diameter is 12 mm 7. Serial number in format: W XXXXX last two numbers of the year of production XXXXXXXXX (i.e. 10 = year 2010) 8. Warning! Maximum lifting load (maximum load for lifting persons) 16 Access Winch

17 Parts Access Winch 17

18 Parts Pos. Q.ty Code Description 1 1 A Assy Base Winch 40 EL/HY Winch Serial Number Sticker 2 1 A Assembly Skirt Winch 40** 3 1 S Gear Z S Pawls Carrier Ø8xN2* 5 4 S Pawl Ø8* 6 4 S Pawl Spring dia S Gear Z S Pin ø9x S Washer 36x9,5x1* 10 1 S Gear Z S Pinion Z S Washer Ø22.5xØ45x1* 13 1 S Pin ø9-ø12x A Assy Housing Winch M Socket head screw M6x16 UNI 5931* 16 1 S Washer Ø62xØ80x1.5* 17 2 A Bearing Ø56xØ68x24* 18 1 S Winch Serial Number Sticker 19 1 S A0 Stripper arm support 20 1 S Drum A W S Red line 22 1 A Assy Winch 40 Jaws Lower Jaw W35/40 Upper Jaw w35/40 Peeler W20-40 Spring 23 4 M Screw UNI EN ISO 1207: M6x35 - A4* 24 1 S Stripper Arm W35/ M Screw M6x50 UNI6107* 26 1 S A5 Cover 2 speed W A Assy Gear Z A Assy central shaft 29 1 M Smalley ES S Bushing Ø21.5xØ19x S Bushing central shaft 18 Access Winch

19 Parts ,20 2 Part No. 40.2STAACCSH B10ACCS 40.2STAACCS Description Access winch with handles with locking knobs Handle with locking knob Access winch without handles Access Winch 19

20 Manufacturer Harken Italy SpA. Via Marco Biagi 14, Limido Comasco (CO), Italy Tel ; Fax Web: EU Representative Harken UK Ltd Bearing House, Ampress Lane Lymington, Hampshire S041 8LW, England Telephone: (44) Fax: (44) Web: Worldwide Limited Warranty Refer to the Harken Worldwide Limited Warranty on the website at