Harken Industrial 500 User manual

Please read these instructions carefully before installing, servicing, or operating the equipment.
This manual may be modified without notice. In the event of this manual being translated, the English version is definitive. For latest
manual revision go to www.harkenindustrial.com/manuals
PLEASE SAVE THESE INSTRUCTIONS
RIGGERS WINCH 500
Installation Manual – Intended for specialized personnel or expert users
INRW500_A 03/19
Introduction
Safety Precautions 3
Applications/Limitations 4
Specification 5
Installation
Plan Installation 6
Pre-Use Checks 7
Operation
Lifting Loads 8
Lowering Loads 9
Maintenance
Inspection 10
Maintenance 10
Disassembly 11-13
Cleaning 14
Assembly 15-17
Declaration of Conformity 18
Parts
Exploded View 19-20
Parts List 21-22

2 Riggers Winch 500 01/03/19

3 Riggers Winch 500 01/03/19
Safety Precautions
Please read these instructions carefully before operating equipment.
Keep these instructions in a safe place for future reference.
i
This product, as supplied by Harken®, is considered to be applicable to general lifting operations.
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.
Service Manual
You can download the Service Manual from www.harkenindustrial.com/manuals. This manual is for use only by
specialized personnel. Installation, disassembling and reassembling by personnel who are not experts may cause serious
damage to property or injury to users and those in the vicinity of the product. Harken®accepts no responsibility for
damage or harm caused by not observing the safety requirements and instructions in the service manual. See limited
warranty, general warnings, and instructions at www.harkenindustrial.com/manuals.
Introduction
This manual gives technical information on installation and service. If you do not understand an instruction, contact
Harken®.
WARNING! Strictly follow all instructions to avoid potential hazards that may kill or hurt you and others.
See www.harkenindustrial.com/manuals for general warnings and instructions.
DANGER! This indication alerts you to imminent hazards that will kill or seriously injure you and others
if you don't follow instructions. The message will tell you how to reduce the chance of injury.
WARNING! This indication alerts you to potential hazards that may kill or seriously injure you and others
if you don't follow instructions. The message will tell you how to reduce the chance of injury.
CAUTION! This indication alerts you to potential hazards that may hurt you and others if you do not fol-
low instructions. The message will tell you how to reduce the chance of injury.

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Applications/Limitations
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.
B. LIMITATIONS
DO NOT USE:
• With wire rope
• With loads in excess of the maximum working load of 500kg for lifting loads.
Self-Tailing
Stripper Arm
Handle
Winch
Drum
Self-Tailing
Jaws
Winch
Plate
Pigtail
A. USE
Harken®Riggers Winch 500 is designed to be used as a manually powered, rope-handling winch secured on a
universal mounting plate, for lifting, lowering and pulling loads.
C. TRAINING
This equipment must be installed and used by persons trained in its correct application and use.
D. STANDARDS
This product/system has been certified to EN13157 standards.
E. TESTING
Maximum working loads are 4:1 coefficient ratio of the breaking load.
Part No. Description Quantity
A96889400 Harken Radial Winch 1
F83256700 B10AL Harken Winch Handle (lock-in) 1
A96885400 Plate 1
WARNING! As reported in the Directive 2009/104/EC "Persons may be lifted only by means of work equipement and
accessories provided for that purpose. Without prejudice to Article 5 of Directive 89/391/EC, exceptionally, work equipment
which is not specifically designed for the purpose of lifting persons may be used for that purpose, provided appropriate
action has been taken to ensure safety in accordance with national legislation and/or practice providing for appropriate
supervision" .
CONTENTS SUPPLIED

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Self-Tailing
Stripper Arm
Hardcoat, PTFE-
Impregnated
Aluminum Drum
and Castle
Bronze and Stainless
Steel Gears
Composite
Bearings
Self-Tailing
Jaws
Part
No.
Ø
Height (H) Weight
Rope entry
height (LE)
Rope Ø
(Min - Max)
Fastener
circle
Fasteners
(HH) Gear ratio Power ratioDrum (D) Base (B)
in mm in mm in mm lb kg in mm in mm in mm mm 1 2 3 1 2 3
INRW500 3
1
/ 8 80 6
3
/ 16 157 6
7
/ 8 175 8.4 3.8 3
1
/ 4 82
5
/ 16 -
1
/ 2 8- 12 4
7
/ 8 123 5 x 6 2.13 6.28 —13.50 39.90 —
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 – overall weight only 7kg
Powerful – 2-speed gearing allows optimum use of
manpower to deliver power and speed.
Reliable & Easy to Maintain – Composite roller
bearings and bushings don’t require lubrication and have excellent corrosion resistance. This ‘metal-
replacement’ material is completely non-reactive 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.
Winches can be disassembled and serviced where mounted.
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:
Winch: 500 kg
Break Load: 2800 kg
DESCRIPTION
Lightweight CE certified portable winch, mounted on an adaptor place.
The winch can be utilized in many applications; from utility masts, telecoms, marine, wind-turbine transition piece,
davits, stage and theatre rigging.
The adaptor plate can be affixed in a number of ways, dependant on the environment and industry; from ratchet
straps, M10 bolts, karabiners, to scaffold clamps. This makes for a truly universal and adaptable lifting solution.
Specifications
WARNING! Subjecting the winch to loads above the maximum working load can cause the winch to
fail or pull off the mounting plate suddenly, possibly resulting in severe injury or death.

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Installation
A. PLAN INSTALLATION
The adapter plate can be affixed in a number of ways dependant on the environment and industry; from
ratchet straps, M10 bolts, karabiners, to scaffold clamps, making for a truly universal and adaptable lifting
solution.
It is the installer’s responsibility to carry out all structural tests needed to ensure that the mounting surface
can withstand the load.
Lifting Rope - Entry Angle
The winch plate must be installed so that the line can be led through the pigtail to the winch drum, with no
more than 30oof line deflection in any plane. The installation should use pulley deflectors if necessary to
ensure a fair lead to the winch. The pigtail should not take any angle load. (See diagram)
Mounting Plate - Attachment
Ensure the plate is securely attached to the mounting surface, so that it can operate under load without
significant movement.
The following illustrate some possible ways that the plate can be mounted.
Riggers Winch 500 - Location
The Winch kit must be installed in a position to allow sufficient working space around the unit, so not to
impede operation of the handle.
The stripper arm must be in a 4 o’clock position once the plate is mounted.
The Winch kit must be installed in a position to ensure visibility of the lift trajectory by the operator at all times.
The following illustrate some possible ways that the plate can be mounted.
WARNING! Leading the rope directly on to the drum can cause overrides and damage winch or make winch
inoperable, leading to loss of control, possibly resulting in severe injury or death. Always lead the rope
through the pigtail.
30o
30o
max. deflection
max. deflection

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Installation
1) Check plate for damage (excessive wear, cracks, deformation)
2) Check underside of plate;
a)5 fasteners around central hole, recessed 1 mm approx.
b)Pigtail end recessed 1 mm approx.
3) Winch base securely fastened to plate (small amount of play between winch drum and base is normal)
4) Pigtail is pointing towards drum (as per diagram)
5) Stripper arm is positioned correctly depending on orientation of plate
a) Wedge is correctly positioned behind stripper arm (see diagram)
6) Winch drum can be turned by hand clockwise
7) Winch drum cannot be turned by hand counter-clockwise
8) Handle can be inserted in winch and lock-in mechanism prevents accidental removal
9) Handle can be rotated in both directions, resulting in the winch drum rotating
WARNING! Incorrect installation of winch may cause severe injury or death. Consult equipment supplier
if in doubt about correct position of winch.
Pre-Use Checks

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Operation
PERSONAL PROTECTIVE EQUIPMENT
Wear gloves to protect against rope abrasion or chafe when operating winch.
LIFTING LOAD
1. Feed the rope through the pigtail and, starting at the base of the winch, wind rope onto drum in a clockwise
direction. Use at least four complete turns, but no more than six, depending on rope diameter. Excess turns
may cause rope to override or may cause excessive friction. (See images).
WARNING! Always put a minimum of 4 turns on winch drum. Fewer turns can severely decrease holding
power which may result in rope slippage or failure to hold load, causing lifted load to fall, possibly resulting
in severe injury or death.
IMPORTANT! Keep fingers, loose clothing, hair etc away from winch. Area around winch handle should
be kept clear of people and objects at all times. Be sure to keep loose rope near winch to prevent
tripping.
Excessive turns at base of winch Rope override
WARNING! Never allow rope to override on winch drum. This can cause rope to jam and can prevent load
from being lifted/lowered. Tension on loaded rope must be relieved to clear override. This procedure car-
ries a risk of serious injury or death if load drops or becomes uncontrollable.
2.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 the handle.
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 that the weight of rope or any other force does not
cause the rope to be pulled out of the jaws (see images overleaf). Check that rope remains secured in self-
tailing jaws while cranking.
Failure to secure rope in jaws may cause rope slippage which can cause lifted load to fall, possibly resulting
in severe injury or death.

9 Riggers Winch 500 01/03/19
3.Begin turning handle counter-clockwise. Gears engage automatically depending on
direction handle is rotated.
1st gear: rotate handle counter-clockwise
2nd gear: rotate handle clockwise
When handle becomes 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.
1st Gear
Faster = Less Power
2nd Gear
Slower = More Power
direction
of load
direction
of load
direction
of load
direction
of load
LOWERING LOAD
We recommend using a safety device, such as a grab-rope mechanism (eg. Prussic knot, rope-grab clutch).
1. Engage grab rope mechanism or clamp rope turns on drum with your hand.
2. Carefully unwind rope from self-tailing jaws only, while maintaining even tension on rope.
3. Do not take rope turns off winch drum until rope is completely unloaded.
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, causing the load to
fall, possibly resulting in severe injury or death.

10 Riggers Winch 500 01/03/19
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.
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 a
Harken®Riggers Winch 500 with a part that was not designed for it.
CAUTION! Periodic service must be carried out regularly. Lack of adequate maintenance shortens the life
of the Harken®Riggers Winch 500, can cause serious injury and also invalidate the warranty. Installation
and maintenance of Harken®Riggers Winch 500 must be carried out exclusively by trained personnel.

11 Riggers Winch 500 01/03/19
Disassembly
6. Completely unscrew three screws n°27
DISASSEMBLY
Tools You Will Need
Medium flat-blade screwdriver
Small flat-blade screwdriver
#5 Allen wrench
Protective gloves
To inspect the winch you must remove the drum.
1. Unscrew the central screw (2 Nm/18 in-lb) 2. Slide off the hub n°28 and the cover n°29 3. Unscrew the three screws n°27
(4 Nm/35 in-lb)
4. Remove the self-tailing arm n°26 by
rotating and lifting it.
5. Lift off the drum n°22
7. Remove the self-tailing arm support n°21 8. Slide out the central shaft n°19 9. Unscrew the 6 stainless hex screws n°16
(8 Nm/71 in-lb) NOTE not those painted red

12 Riggers Winch 500 01/03/19
Disassembly
11. Remove the drum support n°15
Important: washer n°12 may remain
inside the drum support!
12. Remove the washer n°12 13. Remove the gear n°7 and remove the
pawls n°5. To facilitate the operation press
the spring against the pawl with a blade.
14. Slide off gear n°3 15. Slide off gear n°14 16. Slide off gear n°10
17. Remove the pawls n°5. To facilitate the
operation press the spring against the
pawl with a blade.
18. Remove washer n°9

13 Riggers Winch 500 01/03/19
Disassembly
2. Remove jaws (22).1. Unscrew four (4) screws (23)
( 4 Nm/35 in-lb)
If it is necessary to replace winch jaws, proceed
as follows:
Torque to apply when assembling
Tools You Will Need
Medium flat-blade screw-
driver
REPLACING SELF-TAILING JAWS

14 Riggers Winch 500 01/03/19
Harken®Grease
G
Harken®Pawl Oil
O
Loctite®270
L
Anti-seize
A
G
G
A
A
G
A
G
G
G
G
G
G
O
O
G
G
A
Cleaning
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 16 - 17.
LUBRICATE
1. Carry out maintenance on components using products listed and
shown below on exploded view.
2. 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!
Tools You Will Need
Brush
BK4513
BK4521

15 Riggers Winch 500 01/03/19
Cleaning
Make sure that the holes and drainage channels in the base of the winch are not obstructed. Assemble winch in
reverse order of sequence in the Disassembly section.
To tighten bolts, use torque indicated in disassembly procedure.
If jaws have been disassembled, insert peeler
between two jaws, taking care that letters
"TOP" on peeler are facing upwards.
When positioning stripper arm, align peeler
with it.
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: [e-mail].
OIL
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 label on the drum support
and on the skirt.
W XXXXX
XXXXXXXXX
Assembly
Last two numbers of the year of
production, i.e. 10 for 2010.
LL

16 Riggers Winch 500 01/03/19
Tools You Will Need
Medium flat-blade screwdriver
Protective gloves
ASSEMBLY PLATE PROCEDURE
1. Install nut on pigtail.
NOTE. Pigtail should be installed with
no thread locker.
2. Wind pigtail into mounting hole (adjacent
to "line in" arrow) as far as possible without it
protruding through the plate.
3. Wind nut back down onto plate to lock
pigtail in place with the end of the pigtail
spiralling towards the winch line entry point
4. Remove winch handle socket. 5. Slide off the hub n°28 and the cover n°29 6. Unscrew the three screws n°27
(4 Nm/35 in-lb)
9. Note down serial number of winch and
record
7. Remove the self-tailing arm n°26 by
rotating and lifting it.
8. Lift off the drum n°22

17 Riggers Winch 500 01/03/19
10. Mount winch to plate using 5 x M5
bolts (painted red). Blue Loctite (243)
should be used.
NOTE. To obtain correct Maximum
Working Load (MWL), all five bolts, must
be securely tightened (8 Nm/71 in-lb) into plate.
WARNING! Failure to use correct number of mounting fasteners and/or failure to tighten them correctly 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.
WARNING! Winch can only be aligned one way. Ensure stripper arm is aligned correctly according to the
diagram. Incorrect alignment of the stripper arm can cause the rope to fall out of the jaws, leading to release
of load, possibly resulting in severe injury or death.
WARNING! Ensure pigtail is aligned correctly according to the diagram. Misalignment of the pigtail can
cause rope overrides, and loading stress, leading to loss of control, possibly resulting in severe injury or death.
11. Reassemble drum, stripper arm and
socket. When the pigtail side of the plate is
toward you, the stripper arm should point
to 11 o’clock (330 degrees approx).
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 [email protected]
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.
Storage
Store in clean/dry place
Avoid impact damage which could damage jaws and skirt; ensure good packaging when shipping.

18 Riggers Winch 500 01/03/19
Declaration of Conformity
Explanation of Label
Manufacturer — Harken Italy S. p. A.
Via Marco Biagi, 14, 22070 Limido Comasco (CO) Italy
Telephone: [phone]
Web: www.harken.it, Email: [email protected]
EC Declaration of Conformity
Harken UK Ltd, EU Representative declares that the product described hereafter:
RIGGERS WINCH 500– INRW500
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 13157:2009 Cranes — Safety - Hand powered lifting equipment
A technical file is retained for this equipment by the authorized manufacturer.
1. 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 EN13157:2009 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: last two numbers of the year of production
(i.e. 10 = year 2010)
8. Warning! Maximum lifting load (maximum load for lifting persons)
W XXXXX
XXXXXXXXX
Harken UK LTD 10th Nov 2014
Label affixed to drum skirt
Done at:
_______________________________________________
On:
________________________
Signature
_______________________________________________
Name
Harken UK Ltd
Bearing House, Ampress Lane
Lymington SO41 8LW
England
Catherine Ash-Vie
1 2
3 5
6 7
4 8
W XXXXX
XXXXXXXXX
INRW500
Serial No. / N. di serie
rope diameter
diametro fune minimum 4 turns
clockwise
EN13157:2009
Max Working Load (MWL)
500 kg
via Marco Biagi, 14
22070, Limido Comasco (CO) - Italy
www.harken.com
([phone]
Riggers Winch 500
ø 8-12 mm

19 Riggers Winch 500 01/03/19
Parts
EXPLODED VIEW 1/2
20
16
15
17
18
23
22
24
25
21
26
27
28
29

20 Riggers Winch 500 01/03/19
Parts
EXPLODED VIEW 2/2
2
1
14
13
9
10
5
6
11
30
8
3
4
6
5
7
12
19