Harken Riggers Winch 200 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 200
Installation Manual – Intended for specialized personnel or expert users
INRW200_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 11-12
Cleaning 13
Assembly 14-16
Declaration of Conformity 17
Parts
Exploded View 18-19
Parts List 20-21

2 Riggers Winch 200 01/03/19

3 Riggers Winch 200 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.

4 Riggers Winch 200 01/03/19
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 200 kg for lifting loads.
Self-Tailing
Stripper Arm
Handle
Winch
Drum
Self-Tailing
Jaws
Winch
Plate
Rope Guide
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" .
A. USE
Harken®Riggers Winch 200 is designed to be used as a manually powered, rope-handling winch secured on a
universal mounting plate, for lifting, lowering and pulling loads.
CONTENTS SUPPLIED
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
A96889300 20STA Harken Radial Winch 1
F83256700 B10AL Harken Winch Handle (lock-in) 1
A96885500 Plate 1

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Part
No.
Winch Ø
Height (H) Weight
Rope entry
height (LE)
Rope Ø
(Min - Max) Plate Ø
Gear
ratio
Power ratio
(Handle length)Drum (D) Base (B)
in mm in mm in mm lb kg in mm in mm in mm 1 8" 10"
INRW200 2
7
/ 8 73 5
3
/ 8 137 6
7
/ 32 158 7.9 3.6 2
13
/ 16 71
1
/ 4 -
1
/ 2 6- 12 7
7
/ 8 200 2.76 15.36 19.20
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 3.6 kg
Powerful – Up to 20:1 power ratio with ratcheting handle
for confined spaces.
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 on the mounting plate.
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: 200 kg
Break Load: 2000 kg
Self-Tailing
Stripper Arm
Hardcoat, PTFE-
Impregnated
Aluminum Drum
and Castle
Bronze and Stainless
Steel Gears
Sleeve
Bearings
Self-Tailing
Jaws
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; these include
ratchet straps, fibre slings and strops and karabiners. 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; these
include ratchet straps, fibre slings and strops and karabiners, 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 rope guide 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 rope guide should not take any significant 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 200 - 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 rope guide
30o
max. deflection
30o
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)Rope guide end recessed 1 mm or less.
3) Winch base securely fastened to plate (small amount of play between winch drum and base is normal)
4) Rope guide is pointing away from 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 on counter-clockwise handle
rotation
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

8 Riggers Winch 200 01/03/19
Operation
PERSONAL PROTECTIVE EQUIPMENT
Wear gloves to protect against rope abrasion or chafe when operating winch.
LIFTING LOAD
1. Feed the rope through the rope guide 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.

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3.Begin turning handle counter-clockwise. Gears engage automatically depending on
direction handle is rotated.
Rotate drum: rotate handle counter-clockwise
Ratchet handle: rotate handle clockwise
Rotating the handle through a series of complete revolutions is the most efficient
way to operate. A back and forth action through a smaller arc can be used for
confined spaces if required.
Gears engage
Drum rotatesr
Gears disengage
Handle ratchets
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 200 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 200 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 200, can cause serious injury and also invalidate the warranty. Installation
and maintenance of Harken®Riggers Winch 200 must be carried out exclusively by trained personnel.

11 Riggers Winch 200 01/03/19
Disassembly
6. Completely unscrew three screws n°17
DISASSEMBLY
Tools You Will Need
Medium flat-blade screwdriver
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°20 and the cover n°19 3. Unscrew the three screws n°17
(4 Nm/35 in-lb)
4. Remove the self-tailing arm n°18 by
rotating and lifting it.
5. Lift off the drum n°13
7. Remove the self-tailing arm support
n°12 and slide out the bushing
8. Slide out the central shaft n°7 9. Remove the pin n°6
Torque to apply when assembling

12 Riggers Winch 200 01/03/19
Disassembly
11. Slide off gear n°3 12. Slide off gear n°11 13. Unscrew the screw n°10 and remove
the washer n°9. (4 Nm/35 in-lb)
2. Remove jaws n°15.1. Unscrew the 3 screws n°16
( 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

13 Riggers Winch 200 01/03/19
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 Pages 15 - 17 for
exploded diagrams and parts list.
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
G
G
A
A
Harken®Grease
G
Harken®Pawl Oil
O
Loctite®270
L
Anti-seize
A
G
G
G
L
O
O

14 Riggers Winch 200 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 plate.
W XXXXX
XXXXXXXXX
Assembly
Last two numbers of the year of
production, i.e. 10 for 2010.
L
L

15 Riggers Winch 200 01/03/19
1. Install nut on rope guide.
NOTE. Rope guide should be installed
with no thread locker.
2. Wind rope guide 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
rope guide in place with the end of the rope
guide pointing away from centre of plate.
4. Remove winch handle socket. 5. Slide off the hub n°20 and the cover
n°19
6. Unscrew the three screws n°18
(4 Nm/35 in-lb)
9. Note down serial number of winch and
record
7. Remove the self-tailing arm n°17 by
rotating and lifting it.
8. Lift off the drum n°13
Tools You Will Need
Medium flat-blade screwdriver
Allen Key #5
Protective gloves
ASSEMBLY PLATE PROCEDURE
Torque to apply when assembling

16 Riggers Winch 200 01/03/19
10. Mount winch to plate using 5 x M5
bolts. 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 rope guide is aligned correctly according to the diagram. Misalignment of the rope guide 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 rope guide is at 7
o'clock, 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.

17 Riggers Winch 200 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 200 – INRW200
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. Load limits
W XXXXX
XXXXXXXXX
1 2
3 5
6 7
4 8
W XXXXX
XXXXXXXXX
Label affixed to plate
Done at:
_______________________________________________
On:
________________________
Signature
_______________________________________________
Name
Harken UK Ltd
Bearing House, Ampress Lane
Lymington SO41 8LW
England
Harken UK LTD 9th Apr 2015
Catherine Ash-Vie
INRW200
Serial No. / N. di serie
rope diameter
diametro fune minimum 4 turns
clockwise
EN13157:2009
Max Working Load (MWL)
200 kg
via Marco Biagi, 14
22070, Limido Comasco (CO) - Italy
www.harken.com
([phone]
Riggers Winch 200
ø 8-12 mm

18 Riggers Winch 200 01/03/19
Parts
EXPLODED VIEW 1/2
14
13
15
16
12
17
18
19
20

19 Riggers Winch 200 01/03/19
Parts
EXPLODED VIEW 2/2
2
1
4
5
11
4
5
7
3
6
10
9
8
4
5

20 Riggers Winch 200 01/03/19
Parts
Riggers Winch 200
Pos. Q.ty Code Description
11A941369 00 Assy Housing Winch 20
Housing W20
Bushing Ø9xØ11x9*
Bushing Ø9xØ11x12*
Heli-coil M6x9
Bushing Ø55xØ62x34*
Washer Ø33.5xØ58x5.5
Bushing Ø28xØ33x25*
21A941386 00 Assy Skirt Winch 20
Skirt W20
31A941367 00 Assy Gear Z18
Gear Z18
Bushing Ø9xØ11x7*
44S00008 00 03 Pawl Ø8*
54S00038 00 01 Pawl Spring Ø8*
61S41370 00 04 Pin
71S41363 00 02 Shaft Winch 20
81S41876 00 63 Winch Serial Number Sticker
91S268890080 Washer
10 1M06040 03 Screw M6x12 UNI 5933*
11 1S41362 00 41 Gear Z21
12 1S41294 00 A0 Stripper arm support
13 1S41356 00 53 Drum W20
14 1S28167 00 97 Red line*
15 1A941365 00 Assy Jaws W20
Lower Jaw W20
Upper Jaw W20
Peeler W20
Spring
16 3M6009103 Screw UNI EN ISO 1207:1996 - M5x35
- A4*
17 1S41357 00 19 Stripper Arm W20
18 3M6007103 Screw M6x50 UNI6107*
19 1S41358 00 A5 Cover 1 Speed W20
20 1 A94136400 Socket Assy W20
Socket Handle W20
Washer Ø7.7xØ25x5.8
Screw M8x20 UNI 6109*