Tractel Carol EX 150 Installation guide

Carol™ EX
Installation, operating and maintenance manual
English Original manual EN
Manuel d’installation, utilisation et maintenance
Français Traduction du manuel original FR
Installations-, Gebrauchs- und Wartungsanleitung
Deutsch Übersetzung der Originalanleitung DE
Handleiding voor installatie, gebruik en onderhoud
Nederlands Vertaling van de oorspronkelijke handleiding NL
Manual de instalación, de utilización y de mantenimiento
Español Traducción del manual original ES
Manuale d’installazione, d’impiego e di manutenzione
Italiano Traduzione del manuale originale IT
Manual de instalação, de uso e de manutenção
Português Tradução do manual original PT
Stallasjons-, bruks- og vedlikeholdshåndbok
Norsk Oversettelse av originalanvisning NO
Installations-, bruks- och underhållsanvisning
Svenska Översättning av originalbruksanvisningen SE
EN
Manual gear winch150kg & 300kg
FR
Treuil manuel à engrenages 150kg & 300kg
NO
Manuell vinsj med planetgir 150kg & 300kg
DE
Manuelle Zahnradwinde 150kg & 300kg
SE
Handvinsch med utväxling
NL
Enkelvoudige handlier 150kg & 300kg
ES
Cabrestante manual de engranajes 150kg & 300kg
IT
Argano manuale a ingranaggi 150kg & 300kg
PT
Guincho manual com engrenagens 150kg & 300kg

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Figure, Abbildung, Figuur, Figura, Figur
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EN
PRODUCT DEVELOPED AND MANUFACTURED ACCORDING TO EUROPEAN STANDARD
EN 13157 - REGISTERED DESIGN
To ensure the constant improvement of its products, Tractel®reserves the right to change the
equipment as described below and, in this case, to supply products which differ from the
illustrations in this instruction manual.
Reproduction prohibited
1. General warning ...............................................................................................................7
2. Presentation of the machines............................................................................................8
2.1. Construction.................................................................................................................8
2.2. Dimensions..................................................................................................................8
2.3. Technical specifications ...............................................................................................8
2.4. Maximum loads depending on the layer used (for Ø 4mm rope (Carol™ EX 150) or 5
mm (Carol™ EX 300))..................................................................................................8
2.5. Accessories .................................................................................................................8
2.6. Operation.....................................................................................................................9
3. Handling –Storage...........................................................................................................9
4. Use, assembly and set up.................................................................................................9
4.1. Fastenings...................................................................................................................9
4.2. Rope............................................................................................................................9
4.3. Rope assembly............................................................................................................9
4.4. Disengaging.................................................................................................................9
5. Servicing and maintenance...............................................................................................9
6. Contraindications for use ................................................................................................10
7. Precautions for use.........................................................................................................10
8. Compulsory regulatory checks........................................................................................11
9. Taking out of use............................................................................................................12
10. FAQs..............................................................................................................................12
11. Spare parts.....................................................................................................................12
12. Example of the Declaration of Conformity.......................................................................13
1. General warning
This machine is governed by European regulations and, more specifically, machinery directive
2006/42/EC and the European standard EN 13157.
•Before using this winch, the user must read this instruction manual and comply with all the
instructions in order to ensure the safe and efficient use of the equipment.
•This instruction manual must be available to all operators. The manufacturer will provide
additional copies on request.
•Carol™ EX winches are designed to enable lifting and hauling operations.
Please ensure that the operator has read this manual and is qualified to operate the machine
in the conditions provided for in this manual. This will ensure the safety of both people and the
environment.
•Never use this winch with a load which exceeds the maximum load indicated (see p. 5 § 2.4).
•This machine is used to lift loads. Under no circumstances should it be used to hold a load with
the rope taut, in particular if the load is likely to increase as this could cause the rope or winch
to break (barges, circus tents, etc.).
•This machine may not, under any circumstances, be used to lift people.
•This machine may not, under any circumstances, be used above people unless the load is
secured by some other means.

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EN
•Before use, the operator must always check that the machine, rope, hook, markings and
fastenings are in good working order.
•The manufacturer shall not accept any liability for consequences resulting from the use or
installation of equipment not provided for in these instructions; or for the consequences of
removal, modification or replacement of original parts or components with parts or components
from other sources without the written agreement of Tractel®.
•It is strictly forbidden to motorise these machines.
2. Presentation of the machines
The Carol™ EX is a manual lifting and hauling winch that meets all current regulations and
requisites.
2.1. Construction
•Frame with an aluminium structure and thick steel sheet (or stainless steel depending on the
option).
•Polymer drum.
•Entirely protected reduction system.
•Drum disengaging system (no disengaging when loaded).
•Automatic brake
•Ergonomic handle unit with rotating handle. The handle clips on and off to prevent it from being
used by unauthorised people.
•Natural rustproof protection (aluminium/polymer) or treatment (for steel parts).
2.2. Dimensions
For dimensions, see figure 1
For possible rope release, see figure 2
2.3. Technical specifications
Model
Capacity on
1st layer
Kg
Capacity on
the last layer
Kg
Number of
layers
Rope
Ø
mm
Capacity
(m)
Carol™ EX 150
250
150
6
4
24
Carol™ EX 300
400
300
3
5
8.5
Model
Max. handle
force
Kg
Minimum lift
per turn of the
handle mm
Weight (ropeless
winch)
Kg
Carol™ EX 150
8
40
3.7
Carol™ EX 300
14
41
3.7
The rope diameter indicated above corresponds to the load on the top layer.
Important: it is obligatory to check that the rope resistance coefficient complies with the lifted load (coefficient 5).
2.4. Maximum loads depending on the layer used (for Ø 4mm rope (Carol™
EX 150) or 5 mm (Carol™ EX 300)).
Models
1st layer
2nd layer
3rd layer
4th layer
5th layer
6th layer
Carol™ EX 150
250 Kg
220 Kg
200 Kg
180 Kg
160 Kg
150 Kg
Carol™ EX 300
400 Kg
340 Kg
300 Kg
2.5. Accessories
The Carol™ EX may be delivered complete with ropes and accessories. The pulleys and pulley
blocks used with these winches must comply with standard EN 13157.

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EN
2.6. Operation
When using the winch, the load is raised or lowered depending on the direction in which the handle
is turned. When the handle is released, the brake comes on and holds the load in place.
Automatic brake activation
A load of at least 10 kg for the Carol™ EX 150 or 15 kg for the Carol™ EX 300 is required for the
brake to activate automatically.
3. Handling –Storage
This light machine can be carried and needs no fixing means.
It is advisable to store the equipment in weatherproof conditions.
4. Use, assembly and set up
The following precautions should be respected.
4.1. Fastenings
See figure 3.
Fixing with four Ø 10 mm screws
Use at least type 8.8 screws.
4.2. Rope
Make sure the rope used is right for the application.
By default, the winch is prepared for work with Ø 4 mm rope (Carol™ EX 150) or 5 mm (Carol™ EX
300).
Reminder: the safety coefficient of steel rope must be 5 in lifting and 3 in hauling.
4.3. Rope assembly
See figure 4
The winding direction of the rope must be strictly observed. To lift the load, turn the handle clockwise:
a clicking sound is heard. To lower the load, turn the handle anti-clockwise.
See figure 5
Rope assembly:
1) Pass the rope through the drum until it protrudes at the rear of the winch.
2) Pass the rope through the first hole of the rope clamp.
3) Pass the rope through the second hole of the rope clamp until 2 cm of rope protrudes and
tighten the screw (using a BTR no. 3 spanner).
4) Pull on the rope to tighten it against the clamp.
5) Fit the rope clamp back inside the drum.
4.4. Disengaging
See figure 6
•Never disengage when the winch is loaded. In the event of mishandling, a device blocks the
disengaging lever when a load is applied to the winch.
•The winch is also provided with a security device that prevents the rope from being wound in
the wrong direction. In such a case, the winch disengages automatically.
5. Servicing and maintenance
The delivered winches are ready to be used (after installing the rope if not supplied by the
manufacturer).
A maintenance check is required at least once a year and must be carried out by a skilled person
or body:

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EN
Regularly grease the gears with EP.2 grade grease for open gearing.
Regularly and before every use: check the condition of the rope, hook and safety latch.
If the rope and hook are not supplied by the manufacturer along with the machine, check that the
rope and hook used guarantee a level of safety according to breaking factor 5 (Machinery directive
2006/42/EC).
Regularly check the state of the brake (static tests: nominal load + 50%).
Regularly monitor the wear of brake linings (a). When they are no longer visible, they must
be replaced, see figure 7
Automatic brake application:
The brake will apply automatically when a winch is placed under a minimum load of:
•10 kg for the Carol™ EX 150
•15 Kg for the Carol™ EX 300.
6. Contraindications for use
Before using the equipment, check for potential causes of overloading such as: adhesion to
the ground, suction, jamming, etc. All forbidden and incorrect uses or operations are
presented below:
It is forbidden to:
•lift loads in excess of the nominal load indicated on the machine plate;
•unwind the drum completely (keep two or three residual winds);
•pull at an angle;
•swing the load;
•use the winch to lift staff;
•walk under a load;
•use ropes with a different diameter and texture from the specifications in this instruction manual
(breaking factor 5);
•use damaged ropes or spliced ropes;
•use hooks without a latch, which do not correspond to the loads indicated on the machine or
which are in poor condition;
•insert objects into moving parts;
•perform operations on a machine while it is loaded;
•disengage the drum while loaded;
•let the load free fall;
•motorise the machines;
•use the machine rope as a chain;
•use handles other than the original ones;
•use the machine for operations other than those for which it is intended;
•use the winch as an anti-fall device, regardless of the height of the drop and the load applied;
•use parts or components other than the original ones provided by the manufacturer;
•tow by positioning a fixed point on the winch.
There must not be any obstacle in the load moving area either; any obstacles might cause sharp
changes in the rope tension and break it.
7. Precautions for use
•Long descents are liable to overheat and damage the braking system. It is strongly advisable
to wait a few minutes half way (around 12 meters for the Carol™ EX 150 and around 4 metres
for the Carol™ EX 300) through descent phases.
•The operating temperature should be between –10°C and +50°C.