OPERATING INSTRUCTIONS
Contents
1. Not approved for use as a retractable transportation device for per sonnel BGR 159 Not approved for use in explosive areas environments Not suitable for aggressive environments Not suitable for lifting hazardous loads Organisational measures Ensure that these operating instructions are always at hand Ensure that only trained personnel work with the equipment Check at regular intervals whether it is being used in a safety and hazard conscious manner Installation service and repair Only by specialist personnel Only use original spare parts for repairs Do not modify or alter safety relevant parts Additional attachments must not impact safety Further regulations to be observed are German Industrial Health and Safety Ordinance BetrSichV Country specific regulations German Accident prevention regulations BGV D8 Load Do not leave suspended without supervision Do not allow to swing Do allow to fall in the rope Rope Compliant with EN 12385 1 and EN 12385 4 and the technical data Maintain rope deviation angle non rotating rope lt 3 standard rotation resistant rope lt 1 5 Use arotation resistant rope for unguided loads This can reduce the resting period of the rope drive mechanism group Wind up the wire rope under pretension e g fully wind up the rope and adjust the rope length to the lift 094297 e gb hse2. 77100 mit anaerobem Kleber hochfest gesichert WN 77100 Lagerstellen mit Gleitmo 805 fetten Oberfl che Altgemeintoleranz Maflstab FERTIGUNGSZEICHNUNG eh ISO 2768 c g Rohteil Nr hE len beachten r J j Per ferien Konsolenseilwinde KWE250 Bearb a T Ta ee ore een mont ee 0 0 haqcon hebetechnik gmbh Klassifizierungs Nr Zeichnungs Nr Blatt EE j mr 4 x Joset Haanam Stra e 6 1 x Raion D 37856 Freuienberg Hain 66423 215703 Bust Anderung Datum Name _ ursprung _ 215302 Ersatz f r 215302 haacon hebetechnik gmbh Phone 49 0 9375 84 0 Fax 49 0 9375 8466 4 133096 112982 100636 S235RG2 4432 0 5 2 402 ISO 10642 M6x16 8 8 A2K 140099 133674 ISO 7380 M8x16 A2 133852 133 851 S235JRGZ 235JRG2 115199 4483 0 65 0 411 EN 120177 029 5x023x2 133169 100103 ISO 8752 4x26 A 128266 3235JRG2 C N as Hi 100507 1964 24 0 863 401137 120177 1624 3 0 32 029 5x023x2 alternativ EDV 100419 115082 s 11 5 0 406 DEZENT S 4 N N WA a E MM aaa 133663 16MnCr5 SH 106497 DIN 471 22x1 2 A2 oh MER LLL NLL s 115049 101266 4483 0 65 0 404 ISO 10642 M8x16 8 8 A2K 120133 Schnitt A A 100500 een Sch tzvermerk rn FERTIGUNGSZEICHNUNG ISO 16016 Werkstoff ae en Tas rn K ilwinde KWV650 Bearb PoP Gers qf Fisch an in PT Torment Fritsch Mont a S Pf ff agacon hebetechnik gmbh Kigssifizierung
3. A3P 140135 ISO 10642 M8x60 A2 133940 Schnitt C C Mafstab 1 1 133945 Lagerstellen mit Gleitmo 805 einfetten Scnuzvemem En Pers ta FERTIGINGSZEICNING ISO 2768 c 1 2 ISO 16016 gt Werksialf Hatbzeug beachten Status freigegeben Rohteil Nr I 1 ttt psum nm 1 ae SS ee P 2 327__ 310512_ Fitsch __ haacan D 37856 Freudenerg main hoacon hebetechnik gmbh Klassifizierungs Nr Zeichnungs Nr Blatt Josef Hanmenn Strafle 6 62010 215702 pust Anderung Datum Name Ursprung 215355 Ersatz f r 215355 133965 140095 DIN 471 14x1 CuSn8 133693 1 4301 140138 1 4301 Schnitt B B 140099 ISO 7380 M8x16 A2 133973 133696 CuZn39Pb3 140139 1 4301 en 2 E 2 I NM 133962 100425 ISO 7089 8 200HV A2 100359 ISO 4032 M8 A2 70 140135 ISO 10642 M8x60 A2 x Schnitt C C Ma stab 1 1 MZ AL Nl TA N SEES 133967 133968 14122 14462 Lagerstellen mit Gleitmo 805 einfetten berf che Allgeneifoleranz Mafislab FERTIGUNGSZEICHNUNG Schutzvermerk D sO ta Ee See ua ISO 16016 ro o ISO 2768 e 12 Halbzeug Beachten mia T C ss2 paum Name ae E gt gt konsoiensetunte non Sep MAN Nora WAN KWE1000 SchwFr hoacen hebelechnk gmbh Klassifizierungs Nr Zeichnungs Nr Blatt Jogef Hanmann Sirofie 6 4 2 3397 310512 Frisch haacon D 97896 Freutenberginan 66423 2
4. 1250 KWV650 KWV 300 KWE1000 215705 KWE650 215704 KWE250 215703 133703 KWE 215545 134757 EL EO BL PUBIS po you 1ll si oop Bunsepyenequie 1Z000 ee NWUOs Wa sKsjusWwebeueW sqq H ELOZ ZONE 40 6 0260 EL 20 S UOHIPS ELoZ 20 0 Blsquapnauy Aq pau is UONONJSUOD uoneju uinoop y 104 ajqisuodsay D IduuoO BJOM g Ned IIA X pusddy ul p uil no se UOI E USLUNDON JEdIUYDS olJio9ds OY paysenbe os J Ajjed1u0s 09 8 SUONNNISUI 9 e S enpiAIpui o Jonpo d siy o Bululewed uogezuawnoop aoads au 1Yluuqns o s pe Jeinpejnuew Seu L ni e npejnuew ay Aq p Je o p AjWOJUOD SIU ASO M y 93 77 9002 SAOsJIpP SUulyOew QU uA SLUJOJUOD pajjejsui q o SI YOIYM u sulyoew y zey PSUILWSJAp SI 1 JUN uonei do ozu u xe q jou Jsnw Jonpoud sy HI Zr 9002 SANOGUIP SulyoeW Jad se sulypew a a dwoou ue s onpoid Sy L suonon4sul Buelsdo SpeO 4 0 SSUIYSEYN spJiezey jediueyoow Jsule e seinesw dAl 09 0jd LONEWUOJU S JUSLUSAOLU P9IJOJJUOOUN JO YSIy sued BulAoui Aq pasneo sysiy s1 u109 pue s Bp soeyins Aq sysiy uone4sdo Bulnp ebeyeeg Jo YS y Buljpuey s Buipie6 i asuiyoew y Jo uononi suoo s onpoid pue sjengen Ajyayes Jo uonei6B6 lui y 104 53iseg p ye xipueddy HI ZPI900Z SOUIYSEI SA O9IIP BU JO syLuawau nba DISeq y Y IM sullojuoo 1 S0 0 abue Aysedes peo VA ouel 3MM AMA 087602 z98r r8r L zer LSZH S8Sr k6rr 8rr ZLvv LL
5. 15705 Pust nderung Datum Nome Ursprung _ 215358 094297 e gb hseilw_s haacon hebetechnik gmbh Phone 49 0 9375 84 0 Fax 49 0 9375 8466
6. OPERATING INSTRUCTIONS Translation Rope winch Type KWE 250 KWV 300 KWE 650 KWV 650 KWE 1000 KWV 1250 1 USER GROUPS Duties Qualifications visual inspection instructions Authorised person 1 repair maintenance Technical expert 2 SAFETY INSTRUCTIONS Appropriate use Operate the equipment in accordance with the information in these operating instructions Only use to lift lower and pull freely movable loads Only use when in perfect working order Only allow to be operated by personnel instructed on how to do so Special ist per sonnel 50 C 20 C OHP Safety conscious work First read the operating instructions Always be conscious of safety and hazards when working Observe lifting device and load during all movements Immediately report any damage or defects to the person in charge gt N A Repair equipment first before continuing work Do not leave the load suspended without supervision Transport device protected against impacts and shocks falling over or toppling IE Om The following are not allowed Overload gt technical data type plate payload plate Mechanical propulsion Impacts blows Use exclusions Not suitable for permanent operation and vibration stress Not approved for use as builders hoist BGV D7 Not approved for use on stages or in studios BGV C1
7. ccurs during lowering pour a few drops of oil into the gap in the crank cam Safety cranks with a gap aperture gt 30 should be replaced Repair must be carried Out by only by the manufacturer CAUTION Only disassemble the crank ratchet brace and locking pawl when the equipment is not under load Do not oil or grease the brake pads 10 OPERATION FAILURES AND THEIR CAUSES Dirt or something similar has accumu lated in the bearing Winch was distorted during mounting Wrong coiling of the rope winding direction for lifting was not correct The brake is worn out Too light load Brake discs or brake mechanism is only be lowered with distorted high expenditure of force 11 SPARE PARTS Check the fixing Is the mounting surface even are the screws tightened correctly Lay the rope correctly Check brake parts and replace worn out parts The load has to be at least ca 20 kg resp 50 kg Release the brake by slightly striking against the crank arm with the flat of the hand in lowering direction When ordering spare parts itis essential to quote The type and serial number of the equipment item and part number 12 DISASSEMBLY DISPOSAL Make sure to observe the safety instructions Dispose of the equipment and the substances within it in an environ mentally responsible manner haacon hebetechnik gmbh Phone 49 0 9375 84 0 Fax 49 0 9375 8466 KWV
8. f the coupling disc Unloaded rope can be pulled off Clutch in Pull and turn crank until the coupling pins engage into the coupling disc Version with adjustable crank arm option Loosen wing screw adjust crank radius tighten wing screw Version with detachable crank option 8 INSPECTION The equipment must be inspected in accordance with the conditions of use and the operating conditions at least once per year by an authorised person 2 per TRBS 1203 Technical expert testing per BetrSichV 10 sect 2 represents implementation of EC Directives 89 391 EEC and 95 63 EC and the annual occupational safety inspection per BGV D8 23 sect 2 and BGG956 These inspections must be documented Before commissioning After significant alterations before recommissioning Atleast once per year In the event of unusual occurrences arising that could have detrimen tal effects on the safety of the winch extraordinary tests e g after a long period of inactivity accidents natural events After repair works that could have an influence on the safety of the winch Technical experts AP2 are persons who have sufficient knowledge based on their specialist training and experience in the areas of winches lift and pull systems and the relevant official occupational health and safety rules accident prevention regulations guidelines and generally accepted engineering rules e g EN standards to evalua
9. ilw_s The length of the rope is correct if gt 1 5 x rope Lifting equipment Ensure sufficient load bearing capacity Only use load hooks with a safety flap Use the approved load hooks with rope thimbles and rope clip Attach the load properly Do not use the winch rope to secure the load 3 TECHNICAL DATA ololelzfefo Room 4 4 7 6 sj FEM Rating iEm iEm iEm iEm iEm Em Breaking load kN 7 4 8 9 19 2 19 2 29 5 36 8 Crank force N 220 270 250 240 200 240 1 FEM Rating according to DIN 15020 resp FEM 9 511 for ordinary rope 4 GENERAL The hand winches are drum type winches They are driven by a single reduction pair of straight cut internal sour gear or direct The load is safely supported in any position by means of an automatic mechanical brake 5 MOUNTING the mounting structure must be designed to sustain the max forces imposed by the winch pay careful attention that the mounting surface is flat and true use always 4 screws size M10 min quality 8 8 tighten the screws evenly and secure screws ensure that the crank is free running crank clearance 6 ROPE MOUNTING With wrong rope coiling the brake is not effective 1st Layer max no of layers Last layer 250 300 kg Wire rope fixing 1000 1250 kg Grease slightly the drum before fixing the wire rope Recommended ropes Ordina
10. oy LZev r8zr gezr gLzr 0Lzr z0Zr S8Lr 0907 89r z9r LZY LYZ 022 odAL s y u m do1 pueH 9WweU JONPOId jonpoud y uiew 6i qu pn ij 96826 A 9 9SSENS UUEWEEH J9SOf uqui6 yiuyos jeqey uoseey 9978 SLE6 0 6r XE4 0 78 S 6 0 67 uoud Joinjoejnueyy ulew 61 qu pn id 96816 A 9 asseuls uueweeH josor uqui6 Y uyosjoqay uooeey dacb s uooppu uUONNEJEIIOAG UONJEIJEJSUI NF haacon hebetechnik gmbh Phone 49 0 9375 84 0 Fax 49 0 9375 8466 _e gb_hseilw_s 094297_e 094297 e gb hseilw_s 140 ISO 7380 M8x16 A2 100722 DIN 471 14x1 A2 115082 11 5 0 406 133884 mit Geh useseite vernietet 115081 11 5 0 405 101137 1624 3 0 32 Lagerstellen mit Gleitmo 805 fetten 133697 1 4301 140099 ISO 7380 M8x16 A2 100721 DIN 471 14x1 133878 CuZn39Pb3 100005 ISO 4762 M5x12 8 8 A2K 133693 14301 133814 1 4301 mit Geh useseite 133697 vernietet 099 133661 133664 133878 235JRG2 CuZn39Pb3 133810 14 235 JRG2 ISO 4762 M5x12 A2 70 mit anaerobem Kleber hochfest gesichert WN 77100 Ob che Altgemeintoleranz Maflstab FERTIGUNGSZEICHNUNG en ISO 2768 c era ISO ISO 16016 Werkstoff Halb 7 a hua b a I ss sa lwi J Tann a Konsolenseilwinde KWV300 T J fen mont m F IL Josef Haamann Sira e 6 haacon D 97896 Freudenberg Main 6 6 4 2 3 21 3 7 0 0 133704 mittelfest gesichert u WN
11. ry ropes zinc plated EN 12385 Tab 12 6x19 WC 1770 B sZ former DIN 3060 SE znk 1770 sZ Ordinary ropes stainless steel similar to EN 12385 7 x 19 former DIN 3060 SE bk 1570 sZ 1 4401 Rope diameter and breaking load see point 3 It is not allowed to use plastic coated ropes haacon hebetechnik gmbh Phone 49 0 9375 84 0 Fax 49 0 9375 8466 1 Hard solder the rope end clamp to the rope drum with a hexagonal wrench SW 4 with 6 Nm SW 5 with 5 Nm fig 1and fig 2 After rotating the crank in clockwise direction the rope must reel up on the drum as illustrated in fig 3 fig 3 fig 1 A functional test must always be accomplished before begin ning work 7 OPERATION Lift the load Turn crank clockwise Lower the load Turn crank anti clockwise If the crank is not turned the load is suspended safely When lifting a load do not wind rope beyond the point where at least 1 5 x rope dia meter is left free on drum flanges above outermost layer When loaded at least 2 turns of the rope must remain on the drum The capacity of the first layer corresponds to the nominal ca pacity of the winch This means that the capacity decreases with every further layer refer to type Capacity number plate for capacity of first and last layer Version with crank to declutch rope drum option Only for unloaded rope Declutchable rope drum Push crank arm towards the rope winch The coupling pins move out o
12. s Nr Zeichnungs Nr Blatt BEE GE ee Josef Haanann Sirafie 6 1 I ee C haacon D 97896 Freudenberg Main 620 10 215 7 01 Bust Anderung Datum Name Ursprung _ 215300 Ersatz f r 215300 140103 140099 133928 133682 140102 133696 1 4301 ISO 7380 M8x16 A2 1 4301 1 4301 CuZn39Pb3 mit anaerobem Kleber hochfest gesichert WN 77100 100103 ISO 8752 4x26 A 100430 ISD 7092 14 200HV A2 133938 133693 1 4301 pi fi x xe 133937 1 4462 x 100500 120133 100 220 0010104 ISO 10642 MBx16 A2 70 SM 22 26 Oberfl che Allgemeintoleranz Mofistob FERTIGUNGSZEICHNUNG r e ISO 2768 c ISO 16016 Werksialf Hatbzeug beachten Status freigegeben Rohteil Nr I 1 penn om sm 3 1 Alle Lagerstellen mit Nom WALI KWE650 See Gleitmo 805 fetten Klassifizierungs N Zeichnungs Nr Josef Haomann Strofie 6 62010 215704 ACON D 97896 Freudenberg Miln I Pust Anderung Datum Name _ trsprung 215301 DO TEE VE o 094297 e gb hseilw_s haacon hebetechnik gmbh Phone 49 0 9375 84 0 Fax 49 0 9375 8466 5 101137 1624 3 0 32 133961 100722 DIN 471 14x1 A2 104871 220 0 75 0 407 104872 220 0 75 0 406 133944 235JRG2 133950 133096 S235JRG2 Schnitt B B ISO 7380 M8x16 A2 133943 235JRG2 133696 CuZn39Pb3 133963 133962 133939 100425 ISO 7089 8 200HV A2 100356 ISO 4032 M8 8
13. te the operational safety of winches and lift and pull systems Technical experts AP2 are to be nominated by the operator of the equipment Performance of the annual occupational safety inspection as well as the training required to obtain the aforementioned knowledge and skills can be provided by haacon hebetechnik 094297 e gb hseilw_s 9 MAINTENANCE RECOMMENDATION The operator determines the intervals themselves based on frequency of use and the operating conditions Regular cleaning no steam jets Carry out visual check on inaccessible brakes locks every 5 years at the latest replace brake pads as required General overhaul by the manufacturer after 10 years at the latest CAUTION N Only perform inspection maintenance and repair work on an unloaded hoist Only allow work on brakes and locks to be per formed by qualified specialist personnel Maintenance and inspection work _ Intorvas ier Grease bearing of drive pinion Check rope for wear acc to DIN ISO 4309 and service s Check fastening bolts for secure seating Check all parts of the winch and crank for wear if ap plicable replace defective parts and lubricate Check type plate for legibility Have an inspection performed by an expert Annually Lubricant recommendations Multi purpose grease per DIN 51502 K3K 20 Safety crank Load is not held Brake does not release load may If sluggishness o
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