kuzar K-57 Lifting Towers User Manual

kuzar K-57 Lifting Towers

Specifications

• Model: K-57
• Manufacturer: KUZAR SYSTEMS S.L.
• Version: V.06-24
• Max. Load Dynamic Mode: 500 kg (1102 lb)
• Max. Load Structural Mode: 1200 kg (2646 lb)
• Maximum Height: 7 m (23 ft)
• Origin: Made in Spain (EU)

FAQs

Q: What is the maximum load capacity of the K-57 in different modes? A: The K-57 can handle a maximum load of 500 kg in Dynamic Mode and 1200 kg in Structural Mode.

Q: Where is the K-57 manufactured? A: The K-57 is proudly made in Spain (EU).

Q: Are there any specific safety instructions for using the product? A: Yes, always ensure proper assembly and follow the provided guidelines to prevent accidents.

Q: Can additional components be added to the K-57 for enhanced functionality? A: Yes, additional sets and parts are available for customization and improved performance.

PRODUCT OVERVIEW

• A – Pulley sets
• B – Winch set
• C – Base set
• D – Stabilizer set
• E – Lateral reinforcement
• F – Fixation for strut

Pulley protector for strut

• Pulley protector for strut
  

• Upper pulley set on Section 1 Base
  

• Upper pulley set on sections 2 to 5
  

• Lower pulley set
  

• Cable fixation
  

• Stop pieces for section 2 to 4

• Stop piece for section 5
  

• Nylon roller

• Inertial break

• Fixation screw for forks support

• Upper stop piece

• Lower stop piece

• Fixation for strut
  
  
  
  

SPARE PARTS LIST

Code Description

• 1003K  Allen screw M8 x 16

• 1004NK  Conic screw M5 x 12

• 1015K Allen screw M12 x 25

• 1019K  Special M12x38 hexa screw

• 1020K  Allen screw M8 x 25

• 1022KAllen screw M12 x 40

• 1026K  Conic screw M8 x 20

• 1027K Special screw M8 x 16

• 1028K Allen screw M10 x 30

• 1029K Allen screw M8 x 35

• 1030K Conic screw M8 x 25

• 1032K Special flat M12 screw

• 1033K Nylon runner screw

• 1036K Allen screw M8 x 30

• 1041K Allen screw M6 x 35

• 1042K Conic screw M8 x 30

• 1043NK Allen screw M14 x 200

• 1044K Conic screw M10x40 DIN 7991

• 1046K Special Screw M12 x 45

• 1060K Allen screw M10x80 DIN 912

• 1070K Allen screw M12 x 50

• 1075K Transport handle

• 1114K Cable (with shackle) fixation plate

• 1226K Short leg K-57

• 1227K Long leg K-57

• 1375K Section 1 (Base) (K-57)

• 1376K Section 2 (K-57)

• 1377K Section 3 (K-57)

• 1378K Section 4 (K-57)

• 1379K Section 5 (K-57)

• 1380K Section 6 (K-57)
  1381K Left lateral reinforcement

• 1382K Right lateral reinforcement

• 1383K Rear reinforcement support

• 1385K  Upper stop piece made of steel, section 2-4

• 1386K Upper stop piece made of steel, section 5

• 1390K Aluminium front support for pulley

• 1391K  Pulley profile support

• 1392K  Ø12 mm needle bearing

• 1393K Axial needle bearing
  1394K  Rear aluminium pulley holder support

• 1395K  Piece “L” steel pulley holder

• 1396K  Fixation piece for strut

• 1397K  Screwed piece strut fts fixation

• 1398K  Axial needle bearing protective cup

• 1401K Winch plate K-57

• 1402K  Complete stabilizer kit for K-57

• 1405K K-57 Wheel

• 1410K  Steel base K-57

• 2008K  Ø90×12 mm Steel pulley

• 2008NK  Ø90×17 mm Steel pulley

• 2119K Spirit level indicator

• 2136K Long left strut

• 2137K Long right strut

• 2138K Lock rest

• 2142K Section Top

• 2143K Section screw top

• 2144K Brake ramp

• 2145K Spring

• 2146K Ø22 mm Inertia brake rod

• 2156K Pin

• 2157K Clip “R” / “R” Shape clip

• 2160K Lifting reinforced fork

• 2166NK Cable entry Ø90 wide pulley cover

• 2168NK Complete stabilizer K-57

• 2169K Big stabilizer ball

• 2170K Big stabilizer handle

• 2171K Big stabilizer plate

• 2172NK Threaded bolt M24 x 500

• 2174K Lower pulley support piece

• 2175K Pulley cover Ø90

• 2176K Large stop piece

• 2177K Large nylon roller

• 2179K Upper pulley support piece

• 2185LK KAT Lock (v.14)

• 2189LK Long security leg lock

• 2190K Transport security knob for legs

• 2193K Strut support plate (v.14)

• 2197K Fork support K-57

• 2232K Steel plate for 1st section pulley

• 2233K Steel angle for 1st section pulley

• 2234K Aluminium shell Ø25×3 mm

• 2301K aluminium strap

• 3228K Anchor points for slings

• 3244K M8x40 Conic Screw

• 4004K 900 kg Winch Long handle

• 4015K Reinforced upper pulley support

• 4020K Winch AL-KO 1201 Plus

• 4081K Cable end piece

• 4090K Input pulley protector

• 5003K Ø100 blue wheel

• 5016K Ringed with tab and R Clip

• 5017K  Ringed with tab and Linchpin

• 7001K  Auto-block nut M8

• 7002K  Auto-block nut M10

• 7006K  Auto-block nut M12

• 7007K  Butterfly nut

• 7008K  Auto-block M14 nut DIN 985

• 7009K Nut M12

• 7010K  Auto-block nut M6

• 7013K M10x25 conic screw

• 7020K  Steel spacer piece Ø30×15 mm7873K Tornillo allen M14x235 mm DIN 912 / M14x235 mm allen screw

• 7880K  Fastener steel pin

• 7881K  Security ring clip

• 8001K M8 washer

• 8003K  M10 washer

• 8004K M12 washer

• 8006K  Wide M8 washer

• 8009K  M14 washer

• 8013K  Wide M12 washer

• 8021K  Aluminium shell Ø25×3 mm

• 9057K  Cable K-57 Ø6 mm

INTRODUCTION.

• Dear user. Thank you purchasing your Kuzar K-57 lifter. We hope you will be very satisfied with it.
• This manual has been written so that you can understand how to effectively use the lift and most importantly, so that you can use it safely. It is important that you fully read the manual and follow the instructions carefully before using your lift. All Kuzar lifts undergo a very strict quality control process during their manufacture.
• So that your lift always works properly please only purchase original Kuzar parts from an authorized distributor or dealer. The user waives all warranty rights if using parts other than Kuzar or if the product is manipulated in any way by an unauthorized third party.
• When requesting parts, please refer to the diagrams of this manual and quote the serial number and year of manufacture located on your lifter.

TECHNICAL SPECIFICATIONS.

Kuzar lifter, model K-57 has been designed for vertically lifting lighting, trussing etc in the Professional sound and light sector. For various Kuzar supports available please refer to our website www.kuzar.es or catalogue.

1. Max. load Dynamic Mode: 500 kg (1102 lb) / Structural Mode: 1200 kg (2646 lb)
2. Min. load: 25 kg (55 lb)
3. Max. height: 7 m (23 ft)
4. Folded height: 1.90 m (6.23 ft)
5. Work surface: 2.34 x 2.25 m (7.7 ft x 7.4 ft)
6. Folded base area: 55 cm x 79 cm (1.8 ft x 2.59 ft)
7. Weight: 223 kg (492 lb)
8. Winch: 1200 kg certified
9. Cable: Steel DIN 3060. Tensile strength 180 kg/mm2. Anti-torsion & anti-corrosion Ø6 mm cable diameter.
10. Construction material: Alluminium profiles 6082 T6.
11. Antirust protection priming paint bathed black steel, covered with cured polyester dust.
12. Kuzar Automatic Trigger (KAT) on each section which automatically slots in to the sections during elevation, locking them in place.
13. Anchor of the legs by safety catches.
14. Adjustable stabilizer plates in the legs with nonslip rubber base support.
15. Spirit level for vertical alignment.
16. Swivel wheels for transporting the lifter to its working position.

SAFETY GUIDELINE.

1. Situate the tower on a solid and flat surface.
2. Check that the legs are fully inserted and secured in to their housing with the safety locks.
3. Ensure that the lifter is in a vertical position and use the spirit level located on the base profile to check. If necessary, adjust its alignment with the plates by turning the handle in the appropriate direction.
4. Check that the tower is locked in its working position with the safety lock.
5. When used outdoors, place the tower on a hard surface and if necessary secure it against excess wind force via cable braces.
6. Do not use ladders nor lean them against the lifter.
7. Be careful with any cables, prominent objects etc. placed above the tower.
8. Do not stand underneath the load.
9. Do not move the tower when it is elevated or loaded.
10. Before using the tower, check the condition of the cable. This must be free of cuts and frays. Never use damaged cables.
11. Never dismount the winch handle or any element of the winch under any circumstances.
12. Once the tower is set up in its working position we recommend the winch han-dle is locked to avoid anyone interfering with it.
13. The minimum load for a safe operation of the brake is 25 kg. The brake will not function without this minimum load.
14. Do not grease or lubricate the brake mechanism of the winch.
15. This lift cannot lift human beings.
16. For transportation it is necessary to retract all profiles and lock them with the corresponding safety lock.

 OPERATION DYNAMIC MODE.

1. Place the tower on a flat, solid surface where it is going to be used.
2. Remove the legs from their transport supports and insert them in their working position. Check that they are fully inserted and fixed with their safety lock.
3. Place the reinforcement bars in the upper strut fixation point, fixing them with the pin and clip. Proceed to allocate them on the legs, adjusting the outrigger stabilisers if necessary, until the bar hole coincides with the leg fixing point hole and insert the pin and clip. Place the tower in its working position and level until the spirit level is centred. The wheels must not touch the ground.
4. Ensure that the lifter is in a vertical position and use the spirit level located on the base profile to check the bubble is centred. If necessary, adjust its alignment with the stabilizer plates by turning the handle in the appropriate direction.
5. Change the forks to their horizontal working position and fix them with the fastener pins, place the load on the forks using a Kuzar Accessory if necessary, and ensure that the tower is only used to lift loads vertically. Make sure the calculated load of the material to be lifted is totally accurate. The higher permitted load is always at the beginning of the forks, closest to the lifting carriage.

Elevation:
Unlock the KAT security lock on the first profile and place it in LIFT position. Turn the winch handle clockwise. When the sec-tion reaches its desired height, lock the section by placing the KAT in LOCK position and proceed to unblock the next section to be raised and lift in the same way as the previous one. Carry out the same operation until reaching the required height. All KAT security locks must be in their locked position. Slacken the winch cable so that the load is locked and not dependent on the winch.

WARNING: The tower can be left in any intermediate height if necessary. Just make sure that the KAT locks are always fixed and introduced. In the unlikely event of cable breaking the KAT locks will ensure that the tower stays UP and SECURE.
Your security is our main concern.

IMPORTANT – HOW TO PLACE THE LOAD ON THE LIFTER
Always load as close to the tower as possible.
Follow the instruction in the next picture to place the load correctly, the diagram shows the load out of the gravity center, with distances to the lifting carriage for maximum lifting. Notice that the maximum load diminishes according to the distance from the body of the tower.

To lower the tower: Slightly elevate the tower and release the first KAT security lock. The lock must be able to release smoothly from its locking position. If it is not coming out smoothly it means there is too much weight resting on it and you need to elevate the tower slightly more until it can be pulled out smoothly. Rotate the winch anti-clockwise while pulling the KAT lock out with the other hand. If the security system is not constantly pulled out with one hand, the tower will lower until it rests again on the next KAT lock position.- HOW TO PLACE THE LOAD ON THE LIFTER Always load as close to the tower as possible. Follow the instruction in the next picture to place the load correctly, the diagram shows the load out of the gravity center, with distances to the lifting carriage for maximum lifting. Notice that the maximum load diminishes according to the distance from the body of the tower.

To lower the tower: Slightly elevate the tower and release the first KAT security lock. The lock must be able to release smoothly from its locking position. If it is not coming out smoothly it means there is too much weight resting on it and you need to elevate the tower slightly more until it can be pulled out smoothly. Rotate the winch anti-clockwise while pulling the KAT lock out with the other hand. If the security system is not constantly pulled out with one hand, the tower will lower until it rests again on the next KAT lock position.

When the first section is lowered, place the KAT lock in lock position and unblock the KAT system for the next section in exactly the same way as the previous one and continue to lower until it has also reached the bottom. Follow the same procedure for the rest of the sections Once the load is lowered, block all the sections.

Attention! If the tower is lowered with the cable slack, without tension and one of the KAT safety locks is activated, a dangerous situation could occur because the load will descend very abruptly, potentially destabilizing the entire installation, causing a serious accident.

Transport:
Turn the handle of the stabilizers to release tension on the legs in order to pull them out. Then, place the legs in their transport compartments located on the base of the tower. Pull out the forks and place them in a vertical position. The tower is now ready to trans-port.

LIFTING THE LOAD IN STRUCTURAL MODE.

1. Structural mode requires lifting the load with the help of a manual or electric hoist. The tower is used as a structure, fully locked at the desired working height and the load is then lifted with the hoist.
   The tower has the option of reversing the position of the lifting carriage 180º. Therefore, depending on the use, the load can be positioned from two different heights.

2. Place the tower on a flat, solid surface where it is going to be used.

3. Remove the legs from their transport supports and insert them in their working position. Check that they are fully inserted and fixed with their safety lock.

4. Place the reinforcement bars in the upper strut fixation point, fixing them with the pin and clip. Proceed to allocate them on the legs, adjusting the outrigger stabilizers if necessary, until the bar hole coincides with the leg fixing point hole and insert the pin and clip. Place the tower in its working position and level until the spirit level is centred. The wheels must not touch the ground.

5. Make sure the calculated load of the material to be lifted is totally accurate. The highest permitted load is always at the beginning of the forks, closest to the lifting carriage.

6. Place the hoist in the appropriate position. The load will be elevated by the hoist & not the tower. Unlock the KAT security lock on the first profile. Turn the winch handle clockwise to raise the hoist and the tower sections. When the section reaches its desired height, block the section and proceed to unblock the next section to be raised and lift in the same way as the previous one. Carry out the same operation until reaching the required height. All KAT security locks must be in their locked position. Slacken the winch cable so that the load is locked and not dependent on the winch.
   Now that the tower is at the desired working height and fully locked you can attach your load to the hoist and proceed to elevate it.

7. The tower has eye bolts in each profile that allow tension wires to be attached if desired.

8. To lower the tower: Once the equipment has been removed from the hoist you can proceed to lower the tower. Slightly elevate the tower and release the first KAT security lock. The lock must be able to release smoothly from its locking position. If it is not coming out smoothly it means there is too much weight resting on it and you need to elevate the tower slightly more until it can be pulled out smoothly. Rotate the winch anticlockwise while pulling the KAT lockout with the other hand. If the security system is not constantly pulled out with one hand, the tower will lower until it rests again on the next KAT lock position. When the first section is lowered, place the KAT lock in lock position and unblock the KAT system for the next section in exactly the same way as the previous one and continue to lower until it has also reached the bottom. Follow the same procedure for the rest of the sections Once the load is lowered, block all the sections.
   Attention! If the tower is lowered with the cable slack, without tension and one of the KAT safety locks is activated, a dangerous situation could occur because the load will descend very abruptly, potentially destabilizing the entire installation, causing a serious accident.

Transport:

Turn the handle of the stabilizers to release tension on the legs in order to pull them out. Then, place the legs in their transport compartments located on the base of the tower. Pull out the forks and place them in a vertical position. The tower is now ready to trans-port.

MAINTENANCE

1. All cables must be checked regularly. Faulty cables must be replaced immediately. Do not use the lifter with faulty cables as it is potentially very dangerous. Only use DIN 3060 cables, supplied from authorised personnel.
2. The lifter is delivered ex factory completely greased. Depending on its mechanical Use though, we recommend that the crown wheel of the winch, the pads & bushings of the drive shaft, the handle thread and the profiles of the lift are periodically greased. ATTENTION: Do not apply oil or grease to the brake mechanism. The brake discs have been pre-grea-sed with special heat and pressure-resistant grease. To avoid malfunction to the winch brake, no other products must be used except the original provided by the company. It is not necessary to grease the brake discs.
3. Your lifter should be inspected at least once a year by authorized personnel.
4. Only original Kuzar spare parts must be used to guarantee the reliability and operational safety of your lifter. The user shall lose all warranty claims if he uses anything other than original spare parts or modifies this product in any way.
5. In case a spare part is required please indicate the reference number which can be found in the spare parts list at the back of this manual.

WARRANTY.

All Kuzar lifts come with 2 years warranty. This warranty period is from the date of purchase. Kuzar will repair any defect product caused by either faulty materials or poor workmanship free of charge within this period as long as the parts are fitted by autho-rized personnel. Should the product have been manipulated in any way or a repair attempted by unauthorized personnel the warranty will be invalid. This warranty does not cover damage occurred by improper use.

CERTIFICATIONS

Kuzar reserves the right to make any modification/alteration to the lift without prior noti-ce. Any modification/alteration would be an innovation, intended to improve the product.

Test report about an acceptance inspection

DECLARATION OF CONFORMITY

References

• Inicio - Kuzar - Torres elevadoras y estructuras truss

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