Operating Instructions Hang-Glider / Paraglider Towing Winches, Model: HGW Double-Drum

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Operating Instructions Hang-Glider / Paraglider Towing Winches, Model: HGW Double-Drum [im Bild: Hang-Glider and Paraglider WINCHES] Manufacturer

1 Operating Instructions Hang-Glider / Paraglider Towing Winches, Model: HGW Double-Drum [im Bild: Hang-Glider and Paraglider WINCHES] Manufacturer Model Quality-certification number Authorized applications Auto-Kirchner HGW K6 Hang-glider towing Paraglider towing Flat towing Two-seater towing

2 Contents 1. General Functional Description 2. Winch Construction 2.1 Diagram of Operating Principle 2.2 Operator Console 2.3 Engine 2.4 Torque Converter 2.5 Cable-Guiding Equipment Azimuth Pulley System Cable-Cutting Device Cable brake Guide Pulleys / Spooling Mechanism Cable-guiding by means of cable brake 2.6 Towrope Dyneema Rope 3. Start-up / Preparations for Towing 3.1 Threading of the towrope 4. Maintenance / Tuning Work 5. Start-up preparation for the winch operator 6. General Rules for Towing 7. Special Towing Procedures 8. Intermediate gear

3 1. General Functional Description The HGW K6 winch serves as a towing winch for hang gliders and paragliders. The winch remains stationary during towing; the towrope is reeled in with a defined tractive force and wrapped around the drum. The winch has two winding drums, which can be used independently of each other, with only one of them in operation at a given time. The driving unit consists of a combustion engine with automatic gearbox, a modified torque converter and a special shift gear box. The oil-driven and modified torque converter provides smooth towing without jerk. By means of tractive power regulation (3) the adjusted maximal tractive power is automatically limited, when it is reached. This avoids overloading of the hang-glider/paraglider. Only modified torque converters of the manufacturer are allowed to be used! In case of using normal or such torque converters, which are not modified by the manufacturer, as well as manipulations of the shiftgear box, any liabilities and warrant will cease! A Dyneema Rope of 3,2mm in diameter is used as a towrope, which passes through a guiding assembly by means of several pulleys. In an emergency, the winch operator can cut the towrope at any time with a cutting device, thereby disconnecting the pilot from the winch. 2. Winch Construction The actual towing winch is mounted on an one-axle trailer chassis. It consists of: - trailer axle with tow pipe (max. axle load 750kg) - rectangular box tube support frame - controls for left and right drums - VW Golf driving motor - automatic transmission (VW) - intermediate gear - tractive-force indicator - drums - cable-winding device - cable-guiding system - shock rope - fuel tank - rotating beacon - depending on the model, with or without cable brake

4 2.1 Diagram of Operating Principle Diagram of Cable-Guiding Equipment

2.2OperatorConsole 1a left drum brake 1b right drum brake 2a left drum operation 2b right drum operation 3 preset tractive force 4 starter button 5 main switch 6 throttle 7a cutting mechanism left 7b

5 2.2OperatorConsole 1a left drum brake 1b right drum brake 2a left drum operation 2b right drum operation 3 preset tractive force 4 starter button 5 main switch 6 throttle 7a cutting mechanism left 7b cutting mechanism right 8 tractive force indicator 9 charge control 10 fuel-tank indicator 11 oil pressure gauge 12 temperature gauge 13 emergency stop switch 14 control lamp circuit 15a left cable brake 15b right cable brake

6 16 tractive force indicator

7 2.3 Engine Only second hand VW-Golf motors are used, which had been reconditioned appropriately. The motors have electronic ignition and an electronic carburettor with a control device. As fuel regular gasoline or premium gasoline is used. Setting data: Idling speed Valve clearance Ignition point 800 r.p.m. not adjustable Maintenance free/ hydraulic valve lifter 19 before t.d.c 2.4 Converter The torque converter between the engine and the automatic transmission is modified so as to precisely regulate the towing process, resulting in a smooth launch. Only such converters are allowed to be used that were modified by the manufacturer of the winch, otherwise there is no safety for the whole towing action. 2.5 Cable-Guiding Equipment Consisting of several components, the cable-guiding equipment allows the towrope to be pulled in at a variety of angles, without kinks and with a minimum of friction, being wound on the drum in a regular manner (see illustration) Azimuth Pulley System This consists of two pairs of pulleys: the guide pulleys and support pulleys. The entire system is mounted in the operating direction of the cable and pivoted, allowing the towrope to always be pulled without kinks and with a minimum of friction Cable-Cutting Device After the cable brake, the cable passes through a cutting device. In the case of an emergency, the towrope is severed and the pilot is disconnected from the winch. The cable-cutting device is designed in such a way that the towrope can only pass through when the cutting device is tensed (i.e., operational).

8 It can be activated via the throttle (6 and 13), in which case both cables are severed and the engine is shut down via the emergency stop. In addition, each side can be cut separately using the right or left buttons on the instrument panel. Before beginning the towing operation a cutting test has to be carried out. Important: at the end of a day s towing, the tension must be released in the cutting device. Only original parts of the manufacturer are allowed to be used. Otherwise any liabilities and warrant will cease. Locking mechanism guillotine anvil (counterblade) tension spring This figure shows the cutting device for the Dyneema rope. Here, an anvil is provided (the rope is chopped). In case a steel rope is used, an anvil is not to apply, the cutting knife lies tightly against the counterplate (the steel rope is squeezed out ). Attention! Use only special tools and spare parts of the manufacturer! Attention! Increased risk of injury! The felling device may be operated only by instructed winch operators! Cable Brake The cable brake prevents kinks from forming on the drum while pulling out the cable, as well as slack loops and overruns when the towing vehicle suddenly stops.

9 Caution: Towing must never take place when the cable brake is on!! Lever position for towing Lever position for pulling out cable

5 Cable-guiding by means of cable brake Towrope being guided trough the cable brake. The towrope has to be unconditionally threaded under the brake roll. 2.6

10 2.5.4 Guide Pulleys / Spooling Mechanism The spooling mechanism is located between the cable-guiding equipment and the drum. By means of a gear transmission and drive belt the guide pulleys move across the width of the drum in sync with the drum speed. By this the towrope is orderly led on the drum Cable-guiding by means of cable brake Towrope being guided trough the cable brake. The towrope has to be unconditionally threaded under the brake roll. 2.6 Towrope Dyneema Rope Dyneema rope is a braided coatless plastics towrope of 3.2 mm diameter, the break strength amounts to 600 N. Because of the high flexibility and the little weight of the towrope the reefing rope may be omitted and larger height in releasing the towline will be achieved. Repair instructions see next page.

11 Bifurcated rope + clearance rope: Drogue chute: Reefing line: Weak link: 5 mm Dyneema rope (of little expansion) or 6 8 mm rope cord with protective hose keeps the towrope tensed while reeling it in and allows the winch operator to see whether the pilot has decoupled does not apply in case of Dyneema towrope breaking load of 150N for single towing, 200N for tandem towing; keeps the aircraft and towrope from becoming overstressed Repairing a Dyneema towrope

13 3. Start-up / Preparations for Towing 1. The winch is positioned on solid ground and remains coupled to the towing vehicle. 1.a The winch is set down. In doing so, both stern timbers are lowered and adjusted. Thereupon the carrying wheel ist turned upward until the supports stand firmly on the floor. In addition a wedge has to be placed under the wheels. 2. Apply the towing vehicle handbrake. 3. Ground the winch. Fasten grounding stake to chassis of winch. 4. Set up rotating beacon and test it. The beacon light starts automatically with engaged gear. 5. Ensure that all guide pulleys and return pulleys are running smoothly. 6. Tension the cutting device left and right with the special cocking lever, carry out function test, then tension again. 7. Release left and right brakes. 8. Lead the ends of the rope over the metering roller and the fairleads and draw them by means of the taut wire through the winding device and the azimuth roll system. 9. Connect towrope to shock rope. 10. Check fill levels of engine (gasoline, oil, coolant). Because of environment protection do not refill preferably operational supply material in the towing area.! 11. Set gearshift to off position. 12. Engage cable brake. 13. Extend towrope to the required length. 14. Apply brakes left and right. 15. Disengage cable brake. 16. Allow engine and transmission to reach operating temperature before the first tow. 3.1 Threading of the towrope The towrope is threaded from the drum around the metering roller through the fairlead to the cable brake. Thereupon the rope is described by the cable brake and afterwards it is led through the azimuth system.

4. Maintenance / Tuning Work As towing safety depends in large part on the equipment used being in perfect working order, the winch must be regularly serviced to ensure operational safety.

14 4. Maintenance / Tuning Work As towing safety depends in large part on the equipment used being in perfect working order, the winch must be regularly serviced to ensure operational safety. Engine: Before towing begins, check the fill levels of coolant, engine oil (SAE 15W-40) and gasoline. Make sure that the coolant contains enough antifreeze in the winter. A qualified workshop should check and, if necessary, adjust the engine s setting data (see 2.3) once a year. The motor has to warm up before towing. Beacon light: The pilot lamp starts automatically with engaged gear. Converter: With frequent towing the converter oil should be changed once a year. Specification: Dexron 10100; filling capacity 3 liters. Because of the modification of the converter this, however, should be done only by the manufacturer. Azimuth system: Before towing begins, check all pulleys to make sure they are running smoothly. Lubricate them if necessary. Cable-cutting device: Inspect the cutting gap, check that cutting blade is operating smoothly, and carry out an operational check before towing begins. In doing this the cutting device is tensioned and a piece of rope is put in. Thereupon

15 the cutting device is released. In doing this the rope has to be cut through completely. Guide pulleys: Check that they are running smoothly. Spooling mechanism: Make sure that the mechanism is adjusted properly: movement must reverse its direction at a distance from the drum wall the width of the cable. Lubricating nipple: There are lubricating nipples on the following places: metering roller arm, brake power assist unit, cable brake and winding device. At regular intervals relubrication is necessary on each point. For this a customary grease pistol and customary lubricating grease have to be used. Shock rope: - check cord, particularly the eyes, for wear; replace if necessary. - Predetermined breaking point: exchange in case of abrasion (long hole) or after 250 towings. - check drogue chute for damage, being careful that drogue chute does not twist when being reeled in - check all joins Winding of a new towrope: For winding a new towrope, this is at first laid out in whole length. It will then be wound in tension (minimum 15 kg) and the process will be repeated. In doing so, the primary rope is not mounted. The end of the rope is fixed on the rope drum by means of a stripe of an adhesive tape so that it can be unwound completely, when the rope runs out. It must not be knotted with the drum. The winch is delivered with 2x1000m Dyneema towrope. Ropes of larger length are possible upon agreement with the manufacturer. Cable brake The deceleration of the cable brake is adjusted at the Bowden cable setscrew on the cable brake and/or on the brake power assist unit.

16 For this the M6 counternut on the setscrew is released and the Bowden cable tension is reduced or increased respectively by means of the counternut. After adjustment the setscrew is secured again by means of the counternut. All setscrews of the bowden cable have to be regularly controlled, if both screw nuts are tightened fast! 5. Start-up preparation for the winch operator 1. Tighten both drum brakes (1a and 1b) 2. Select corresponding drum with drum operating lever (2a and 2b). (Control lamp (14), when the lamp is on) 3. Set both cable brakes (13) in towing posotion 4. Switch on motor (4) 5. The winch is ready for start by releasing the corresponding drum brake (1a and 1b) the towing can be started (See 2.5.3) 6. General Rules for Towing 1. Only those winch-towing procedures are allowed which conform to the appendix to these operating instructions. 2. There must be visual as well as reliable radio contact between the launch point and the winch. If optic signals cannot be clearly made out, there must be radio contact between the winch and hang-glider pilot. 3. If several launch points are being used simultaneously, there must be clear communication between them, especially regarding the launch order. Simultaneous parallel launches are not permitted. 4. The pilot may assume the function of launch director himself as long as he has an unrestricted pilot s license with a winch-launch rating and there is a control-free radio connection from the pilot to the winch operator. 5. The winch in operation is to be identified by a rotating beacon. The light is activated by flipping on a switch. 6. The towrope must be extended in a straight line and be free from obstructions and any kind of kinks or loops. 7. Before towing begins the winch operator must ensure that:

17 - the winch, including the towrope, is serviceable - the cable-cutting devices are in working order - the winch is properly grounded - the towing area is free from obstructions - radio and visual contact to the launch point exists - the area is closed off to spectators - the towrope has been extended - sufficient towing area and airspace are available. 8. The towrope may be attached only when the aircraft and pilot are ready for takeoff and the towing area is clear. 9. The winch operator must stop the launch procedure in case of danger. 10. Maximum altitude may only be attained gradually. During climbing, towing speed is to be kept within aircraft manufacturer specifications. 11. The winch and its lateral areas are not to be flown over with the towrope attached. 12. The towrope must not be allowed to come into contact with any obstacles during the entire process of towing and cable retrieval. 13. Changes in direction with the towline attached are only permissible when the towing procedure, as defined in the appendix to the operating instructions, provides for changes in direction and when a minimum safety altitude of 150m GND is maintained. 14. Communication from the launch point to the winch operator, winch operator response: model, pilot, other information. 7. Special Towing Procedures Flat towing Here the current instructions of the German Hang-glider Association (DHV) are effevtive. Pace towing Pursuant to DHV not allowed in Germany. The winch complies with the requirements to carry out pace towing.

Both towing procedures should be carried out only by experienced winch opertors! 8. Intermediate gear The intermediate gear is driven by a double chain.

18 Both towing procedures should be carried out only by experienced winch opertors! 8. Intermediate gear The intermediate gear is driven by a double chain. The tension of the chain is secured by means of a swivel. There are two control levers on the instrument board (2a/2b right for right drum, left for left drum). By means of a Bowden cable it is impeded that both drums are switched on at the same time. Switching: Switching of the drum can be effectuated in two manners; 1: Standstill of the motor; at that the corresponding control lever (2a/2b) is pushed down and shifted forward; thereupon the motor is started, the shift dog clicks into place and the drum rotates after the brake has been released. 2: Idling of the motor: The correspondingcontrol lever (2a/2b) is pushed downward, now the winch operator waits until an acoustic alarm signal sounds, and then he shifts the control lever (2a/2b) forward, the shift dog clicks into place and the drum rotates after the brake has been released (This noiseless switching is achieved by means of an electro-hydraulic disc brake, which stops the driveshaft temporarily and releases it again). Maintenance: After 500 towings the chain should be lubricated with a customary chain oil spray, furthermore attention has to be paid to the tension of the chain.

Hand winch with worm gear Type WH 7 S in accordance with DIN EN 13157

This original user manual must be read before start-up and be available to the user at all times. Hand winch with worm gear Type WH 7 S in accordance with DIN EN 357 Do not use for! Intended use: In acc.