Habegger HIT-TRAC 128E User manual

User Guide
TGT. 12.03.2019 Technical Page 1 of 21
©Copyright by Habegger Maschinenfabrik AG Version 03 / 12.03.2019
Original User Guide
Version: 03
HIT-TRAC 128E
08401_HIT-TRAC 128E v=0.5-2.5 m/min 7.5kW Emergency
08501_BA zu HIT-TRAC 128E 7.5kW

User Guide
TGT. 12.03.2019 Technical Page 2 of 21
©Copyright by Habegger Maschinenfabrik AG Version 03 / 12.03.2019
Prüfzertifikat
Wir bestätigen, dass die genannte Maschine geprüft wurde und den Auftragsanforderungen, Spezifikationen, Zeichnungen
sowie gültigen Normen und Vorschriften in jeder Hinsicht entspricht.
Motorseilzugmaschine HIT-TRAC®128 mit Elektromotor
Certificat d'inspection
Nous déclarons que le produit faisant l'objet du certificat a été contrôlé et est conforme aux exigences de la commande, aux
spécifications, aux dessins ainsi qu'aux normes et prescriptions en vigueur à tout point de vue.
Machine motorisée de traction par câble HIT-TRAC®128 avec moteur électrique
Test certificate
We hereby confirm that the machine described below was tested and satisfies the requirements posed in the order, specifi-
cations, drawings as well as the relevant valid standards and regulations in all respects.
Motor-driven rope pulling machine HIT-TRAC®128 with electric motor
Geräte Nr. /N° de la machine / Machine no.:
185005 / HSS-ID-no 605
Art. Nr./ N° art./ Product. no.:
08401
Motor-Nr. / N° du moteur / Motor no.:
7.5 kW
Steuerung-Nr / N° du contrôle / control no.:
HI.64-128.075.G18V000
Datum/Date/Date:
22/02/2019
Unterschrift/Visa/Visa: i.A.

User Guide
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©Copyright by Habegger Maschinenfabrik AG Version 03 / 12.03.2019
Contents
1General specifications ........................................................................................................................................................... 6
1.1 Drive mechanism.......................................................................................................................................................... 6
1.2 Housing cover ............................................................................................................................................................... 6
1.3 Rope.............................................................................................................................................................................. 6
1.4 Operation ..................................................................................................................................................................... 6
1.5 Electrical control system .............................................................................................................................................. 6
1.6 Limit switch................................................................................................................................................................... 7
1.7 Lowering and breaking ................................................................................................................................................. 7
2Assembly and performance .................................................................................................................................................. 8
3Safety instructions................................................................................................................................................................. 9
3.1 Proper use .................................................................................................................................................................... 9
3.2 Safety instructions in this user guide............................................................................................................................ 9
3.3 General safety instructions......................................................................................................................................... 10
3.4 Approved users........................................................................................................................................................... 13
3.5 Warranty and Guarantee ........................................................................................................................................... 13
3.6Actions in case of emergency ..................................................................................................................................... 13
4Technical specifications....................................................................................................................................................... 14
5Operation ............................................................................................................................................................................ 15
5.1 Preparation................................................................................................................................................................. 15
5.2 Insert rope .................................................................................................................................................................. 16
5.3 Pulling and hoisting .................................................................................................................................................... 18
5.4 Lowering ..................................................................................................................................................................... 18
6Faults ................................................................................................................................................................................... 19
6.1 Emergency lowering ................................................................................................................................................... 20
7Maintenance ....................................................................................................................................................................... 20
8Replacement parts .............................................................................................................................................................. 20
9Disposal ............................................................................................................................................................................... 21
10 Accessories.......................................................................................................................................................................... 21
10.1 Wireless remote control............................................................................................................................................. 21
10.1 Generators.................................................................................................................................................................. 21

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Warranty and Guarantee
Habegger will grant the user replacement as well as installation and removal of any parts which are rendered unusable due
to material or manufacturing errors.
The warranty period (guarantee period) is 12 months.
Warranty and guarantee claims for personal injury or damage to property are not included if they can be traced back to one
or more of the following causes:
-improper use of the rope pulling machine;
-improper operation and maintenance of the rope pulling machine;
-Failure to comply with the information provided in the user guide regarding operation and maintenance of the rope
pulling machine;
-unauthorised structural changes to the rope pulling machine;
-inadequate monitoring of machine parts which are subject to wear and tear;
-improper repairs being carried out;
-Catastrophic events caused by external influences and force majeure;
-Utilisation of externally procured replacement parts if these have not been designed and constructed to be fit for
purpose and to meet the required degree of safety.
-It is in your interests to only use replacement parts from HABEGGER.
Preface
You have made a wise decision in opting for the HABEGGER motor-driven rope pulling machine HIT-TRAC 128. Using this new
type of rope pulling machine you can pull, hoist and lower loads. Servicing and maintenance are very simple and guarantee
hassle-free and reliable operation when handled correctly.
You may already know how your newly purchased rope pulling machine works.
We at HABEGGER still recommend, however,
that you read the user guide carefully prior to starting up the machine for the first time! It contains all the essential infor-
mation you require about motor-driven rope pulling machines.
Important information in the user guide will help you to:
-Avoid hazards
-Reduce repair costs and downtime, and
-to increase the reliability and lifespan of your rope pulling machine.
Always keep a copy of this user guide at the motor-driven rope pulling machine’s location and ensure that it is read and im-
plemented by every person who works with the machine. It should be available to every user in order to avoid handling er-
rors.
Alongside the user guide and the mandatory regulations for accident prevention in the operator’s country and country of
operation, the recognised industry rules for safe and correct work must be observed.
We wish you every success and hope that you enjoy using your
HABEGGER product.

User Guide
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©Copyright by Habegger Maschinenfabrik AG Version 03 / 12.03.2019
EC declaration of conformity
We,
HABEGGER Maschinenfabrik AG Thun
Mittlere Strasse 66
CH-3600 Thun
hereby declare that the
HIT - TRAC 128E
conforms to the health and safety requirements of the EC Machinery Directives in its conception and design, as well as in the
version placed on the market by us.
In the event of improper use, as well as modifications or changes which are unauthorised by us, this statement loses its valid-
ity.
This declaration of conformity also loses its validity if the relevant user guide and maintenance manual are not followed or
are violated.
Applicable EC directives: EC Machinery Directives 2006/42/EG
Applied harmonised standards: DIN EN 14492-1: 2010-06
EN 60204-1: 2006
EN ISO 12100: 2011-01
Location: Thun
Date: 12. March 2019
Technical manager CEO
Thomas Gerber Urs Schneider

User Guide
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©Copyright by Habegger Maschinenfabrik AG Version 03 / 12.03.2019
1General specifications
The motor-driven rope pulling machine HIT-TRAC 128 is designed for pulling, hoisting and lowering loads.
1.1 Drive mechanism
A special HABEGGER steel cable of desired length which is guided over the relevant guide elements by the driving wheel and
then ejected in an unloaded state is used as the drive mechanism.
1.2 Housing cover
The removable cover on the driving wheel prevents the entry of foreign objects and protects against accidents resulting from
improper access. There is also an anti-derailment device for the traction cable integrated into the housing cover.
-Close and secure the housing cover over the driving system before carrying out any work.
1.3 Rope
The machine is equipped for rope diameters of 28 mm in the factory:
This rope is suitable for all hoisting, pulling and lowering work.
-Only suitable, original HABEGGER ropes should be used.
1.4 Operation
The machine is powered using a 3-phase rotary current motor
1.5 Electrical control system
Speed control
The machine is fitted with a speed control.
The frequency converter and the control system are securely fixed inside the electrical box. The input comes from a plug for
three-phase A.C. current along a 5m long supply cable. Also connected to the control box, via a 5m long control cable, is a
pendant station with the control buttons UP/DOWN, the emergency stop button and a potentiometer for speed control.
Customised models
For special purposes a control cable or a radio control can be attached. On these occasions even closer attention should be
paid to the rope pulling machine during hoisting and lowering. The empty rope’s free exit and entry must be guaranteed.

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©Copyright by Habegger Maschinenfabrik AG Version 03 / 12.03.2019
1.6 Limit switch
Cover monitoring
The closed position of the cover is monitored using two limit switches. As soon as the cover is opened, the motor stops. This
means that the rope pulling machine can only be operated when the cover is closed.
Hook observation
The limit switch stops the hoisting movement when the hook is pulled against the housing or when the cable shaft is swiv-
elled forwards (insert cable).
-The limit switch only responds when the motor is rotating in the correct direction (the rotary field of the
power connection).
1.7 Lowering and breaking
Standard apparatus
You can place the load precisely in the desired position using the control buttons UP/DOWN.
Breaking during lowering takes place using the motor without an energetic recovery system in the mains. When stationary or
powered off this takes place using the spring-loaded holding brake. As this energy is converted into heat, the output due to
heat in the control box is limited during lowering.
-Heavier loads may only be lowered over short distances.

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©Copyright by Habegger Maschinenfabrik AG Version 03 / 12.03.2019
2Assembly and performance
HIT-TRAC 128 with cable and without cover
1
Driving wheel
7
Pendant station
2
Rocker
8
“Raise” button
3
Thrust roller
9
“Lower” button
4
Anchor bolts
10
Emergency stop button
5
Rope shaft
11
Cover monitoring switch
6
Plug for three-phase A.C. current

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©Copyright by Habegger Maschinenfabrik AG Version 03 / 12.03.2019
3Safety instructions
The HABEGGER motor-driven rope pulling machine HIT-TRAC 128 complies with current technical stand-
ards. To protect against accidents it is equipped with effective safety devices as required by the recog-
nised safety standards, guidelines and laws.
But laws, regulations and safety devices do not provide any protection against carelessness and negli-
gence!
Use the motor-driven rope pulling machine only when it is in perfect condition and when taking the user
guide into consideration.
Before working with the motor-driven rope pulling machine you should carefully read and take note of
the following safety instructions.
It is all about your safety!
3.1 Proper use
The motor-driven rope pulling machine HIT-TRAC 128 is designed for pulling, hoisting and lowering loads.
The maximum tensile force is: 128 kN (12800 kg)
-The HIT-TRAC is not to be used to transport people under any circumstances.
-It is forbidden to carry people in a hanging HIT-TRAC structure.
-Please note the safety instructions on the machine and in this user guide in the interests of your health!
3.2 Safety instructions in this user guide
The following symbols and specifications are used for hazards, instructions and important information:
-Instructions are very important information which must be complied with in order to properly operate the
specified technology.
-Caution! Information regarding the machine,
machine parts and the environment.
-Danger! Information regarding danger to the heath and life of the operator and other persons in the mo-
tor-driven rope pulling machine’s operating area.

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3.3 General safety instructions
Location
-Always ensure that the device is in a fixed and secure location during operation.
-Always stand outside the danger zone of the load to be moved and never within range of the exiting cable.
-Use a motorised winch for longer cables (longer than approx. 50m).
-You require enough space in which to move. You should therefore ensure that you have a large enough plat-
form.
-Do not use a ladder as a platform.
-If you do not have a suitable platform, deploy pulleys and choose a better location.
-When setting up the machine please ensure that no external hazards can exert influence on the rope pull-
ing machine, the traction rope, the load or the operating personnel during operation. (e.g. falling objects,
passing vehicles, overhead power lines, etc.)
Anchorage
The anchorage point must be able to withstand the expected tensile force (possibly test beforehand).
The best anchorage points are:
-fixed objects and structures
-rings which have been cemented in place
-Eyelets or poles
Natural anchorage points:
-strong/heavy boulders
-Trees
-other suitable objects
Technical anchorage points:
-Habegger field anchor with piles
-Rock bolt, concrete anchor
-Round timber anchor in the ground
-These anchors are highly dependent on soil conditions.
Secure the machine to the anchoring bolts with sufficiently strong straps or loops.
-The machine must be able to freely position itself in the direction in which the rope is moving. Danger of
housing breaking!
Do not use any damaged ropes or connecting loops.
Rope couplings and safety devices should not be able to detach themselves in the event of a rope being loose.
-If the machine is being used in one location for an extended period of time, check the anchors regularly!

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Traction rope
The reliability of the driving system is dependent on the condition of the traction rope.
Rope construction and inherent stability (crush resistance, impact resistance) must be able to withstand the active loads.
-You should therefore only use ropes provided or approved by HABEGGER.
-The traction rope should not be lubricated.
We will accept no responsibility for any damages and liabilities resulting from the use of ropes which are unsuitable or have
not been approved by us.
The rope diameter must be in accordance with the information on the identification plate.
-Danger of injury! Apply and screw down the housing cover over the driving system before carrying out any
work.
-Wear gloves when handling wire ropes.
-Secure freely suspended loads against twisting so that the rope will not twist.
-Damage to the rope: squashed, untwisted, non-circular ropes, bent rope or ropes with kinks or broken
strands should not be used.
-Ropes with protruding strands: remove protruding strands.
-Damage to either end of the rope: If possible, shorten rope.
-Replace the rope when more than 10% of the rope is worn out at its thinnest point.
Rope connections, sleeves, compression heads, short splices, etc. should not be fed through the driving system.
When diverting the rope over sharp edges, obstacles, etc., protect the cable using appropriate floor rollers or wooden or
plastic supports.
The rope must be professionally laid, i.e. it must be from the winch so that there are no loops, kinks or twists.
The free end of the traction rope is coloured.
-Danger! Stop the machine as soon as the coloured end reaches the machine during lowering.
-Danger! To relieve the rocker, the unloaded end of the rope should not hang down more than 10 m.

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©Copyright by Habegger Maschinenfabrik AG Version 03 / 12.03.2019
Load
The load is attached to the traction hook using the appropriate means of fastening. This prevents the load from slipping or
tipping during operation.
Appropriate means of fastening are, e.g., eyelets, loops, straps, harnesses.
The load’s inherent stability must be guaranteed in order to prevent any slipping or tipping during operation.
Be aware of obstacles which would cause the load to tip or jam.
Refrain from using unchecked loads (e.g. buckets, containers) during the operating stroke or in intermediate positions or
monitor them with a load-weighing device.
Please take possible stress peaks (in static positions) from external influences into consideration during periods of resting
during operation and anchoring work.
Excessive blows to and stresses on the rope pulling machine (e.g. anchoring to machines which have been moved, wind, etc.)
should be prevented by use of a strain release wire.
-Danger! Do not store load, pulleys and ropes in the danger zone!
-Secure freely suspended loads against twisting!
Pulling, hoisting and lowering
Check that you have the correct direction of rotation for hoisting and lowering before commencing operation. If the direction
of rotation is incorrect, consult an electrician to check the direction of rotation of the phases and, if required, to correct them
(check any extension cables which may be present). (See chapter 2).
The careful installation of the cable drive and the machine assembly is the best guarantee of smooth operation.
Place the rope on the rocker as shown on the information sheet (see chapter 5.2, observing the location of the rope with the
load hook)
Check the length of rope and the machine’s hoisting abilities by pulling!
Keep an eye on the load when it is moving!
When pulling diagonally upwards, the rope pulling machine can tip over. Place wood underneath or avoid diagonal pull using
a pulley.
If anything is unclear, request supervision from an assistant, via radio communication if required.
-Close and secure the housing cover over the driving system using screws before carrying out any work.
This way the rope is protected against derailment and no foreign objects can enter.
The free end of the rope must also be able to exit the rope pulling machine unhindered.
-Never allow the hook to touch the housing.
When lowering, ensure that the rope is long enough. Stop at least 2 m before the end of the cable and shim or rehang the
load.

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3.4 Approved users
The motor-driven rope pulling machine may only be operated by specialists and authorised persons. As the opera-
tor of the motor-driven rope pulling machine, ensure that the user guide manual is made available to the user and
ensure that they have read and understood this.
3.5 Warranty and Guarantee
Warranty and guarantee claims for personal injury or damage to property are not included if they can be traced back to non-
compliance with the following user guide:
3.6 Actions in case of emergency
Check before starting operation if and where you can get mobile phone reception or where there is an available telephone.
Check the availability of a first-aid kit.

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4Technical specifications
Hoisting/lowering tensile force
128 kN
Rope speed
approx. 0.5 to 2.5 m/min
Duty cycle hoisting
lowering
100%
100%
Rope path: hoisting/lowering
unlimited/unlimited
Width / length / height dimensions:
920 mm / 1670 mm / 1086 mm
Effective driving wheel diameter:
694 mm
Dead weight rope pulling machine
800 kg
Gear oil
12 l / 80 W 90
Traction rope:
Model
Diameter
Length
Breaking load
HABEGGER 6 x 26 WS + FC galvanised, compressed
28 mm
optional
600 kN
Driving motor:
Model / output
Electric motor
7WAGC 134M4 BR60
7.5 kW 1440 rpm
Voltage - nominal current
Standard / protection class
Duty cycle during intermittent operation
Mechanism group (DIN 15 020)
3 x 400 V –15.1 A
VDE 530 / IP 44
Duty cycle = 100%
1 CmDIN 15 020
Current supply, residual- current circuit breaker
Plug
RCCB Typ B
CEE 32 32A (3xL+N+PE)
Spring-loaded brake
Nominal braking torque
Armature voltage
60 Nm
195 V
Control system version
HI.64-128.075.G18V000
Sound power level LWA
max. 85 dB

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5Operation
5.1 Preparation
Tensile force
-Estimate using the load to be moved or calculate using a load-weighing device.
-Smaller or larger tensile forces will arise depending on whether the load is simply being pulled or whether it is
being hoisted.
-The tensile force may not be larger than the rope pulling machine’s nominal tensile force of 128 kN (employ
rope tension meter).
For larger forces:
-Reduce the tensile force using pulley blocks. Use the correct anchors and means of fastening (straps) for the
force.
Determine and prepare mounting options for the load:
Identify a location where the machine can be anchored and attach the rope pulling machine in the pulling direction using the
correct means of fastening.
-The rope pulling machine must be able to freely position itself in the direction in which the rope is mov-
ing. Danger of housing breaking!
Laying the rope.

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5.2 Insert rope
Insert the rope only once you have carried out all the preparatory works, i.e. you have anchored the rope pulling machine
and attached the load. This means that the rope can be pre-tensioned by hand and placed on the desired point on the driving
wheel without an idle stroke. The rope is placed in the driving wheel as shown in the following diagram (also see chapter 2):
1.
Remove fixing screws from cover and remove cover.
2.
Lift rope shaft latch and pivot rope shaft forwards
3.
Move the front side of rocker to the rear using the operating lever (towards mounting bolts) until it clicks
into place. Both of the thrust rollers in the rope groove are now raised and there is enough space to place
the rope in the groove.
4.
Loop the rope (load hook at the bottom)
5.
Place the unloaded end of the rope in the rope groove beneath the guiding rollers, pushing it into the
rope groove as far as possible.
6.
Place rope in the lower rope groove and place on the thrust rollers. If this proves problematic, the thrust
rollers can also be pressed directly against the rope by resetting the operating lever. The spring which
provides the required basic pressure in the thrust rollers is tensioned using the operating lever. This low-
ers the guiding pulley.
7.
Place the loaded end of the rope in the guiding pulley and, further forward, in the swung out rope shaft.
The loaded end should be underneath the partition plate and also in the lower rope shaft
8
If the unloaded end of the rope should exit to the front, place this between the two guiding pulleys, pull
the rope towards the front above the partition plate and place in the rope shaft. If it should exit to the
top, place it between the guiding pulleys and lead it upwards, over the plastic and the upper plate.
9.
Swivel rope shaft inwards until it clicks into place so that both ropes are being led through it or lead the
unloaded rope upwards using the relevant guide
The rope shaft is monitored and the rope pulling machine only works when it is in the correct position.
10.
If not already completed, push rocker downwards using operating lever until lever clicks into place.
11
Tighten the rope at the side of the hook until it rests in the V-groove.
12.
Information: The cover can only be attached when the operating lever is in the correct position and the
rope is in the V-groove.
13.
Double check rope placement is correct.
14.
Replace both covers and secure with the fixing screws.

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5.3 Pulling and hoisting
-Check that you have the correct direction of rotation for hoisting and lowering before commencing opera-
tion.
-If the direction of rotation is incorrect, consult an electrician to check the direction of rotation of the
phases and, if required, to correct them (check any extension cables which may be present).
-Any extension cables up to 30 m long must have a minimum cross section of 5x2.5 mm 2.
-For longer cables this must be at least 5x4 mm 2.
After inserting the cable, start the motor by pushing the button on the pendant station.
Press the “Raise” button. (see chapter 2)
When hoisting, ensure that neither the housing nor the cable are being diverted or tilted by objects or obstacles. The freely
exiting rope may not be impeded.
-Keep an eye on the rope during movement.
Never allow the hook to touch the housing.
Stopping the driving wheel:
Release button
In emergencies, e.g. in the case of jams:
Press the “Emergency stop” button. (see chapter 2)
Spring-loaded brake
The spring-loaded brake is securely mounted on the motor’s free shaft end. It is protected against moisture and foreign ob-
jects by a protective cap with a rubber seal.
The braking torque of 60 Nm is set in the factory and should not be changed. In de-energised states, the brake is engaged
using the built-in compression springs.
5.4 Lowering
Press the “Lower” button. (see chapter 2)
-Danger of falling! Pay attention to end of rope! The unloaded rope should slide into the machine freely
and without kinks.
-Stop lowering at least 2 m before the end of the rope.

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6Faults
Faults
possible causes
Procedures
Motor will not start when button is
pressed
Cover is missing or not screwed on
Power cable not plugged in
Extension cable not connected
Rope shaft not swivelled in
Extension cable broken
Fuse in the supply has blown
Emergency stop button on pendant
station pressed
Hook touching housing and
Limit switch pressed
other causes
Replace cover and screw on
Insert plug
Connect cable
Swivel rope shaft inwards until latch
clicks
Replace cable
Clarify cause, secure
Replace
Unscrew button
Press the “Lower” key and the over-
ride button on the control box
Call an electrician, diagram is
in control cabinet
The motor is not moving despite
making noise
Broken rectifier, holding brake will not
release
Pull on cable is greater than permitted
tensile force
Replace rectifier
Reduce load or employ pulley block
pulling system
Rope is not moving despite driving
wheel turning
Rocker not swivelled in
Rope incorrectly inserted
too small or too thin rope
inserted
Cable severely worn out
Driving wheel or rope too heavily
greased
Groove in driving wheel heavily soiled
no load on rope
Swivel rocker inwards
Insert rope according to diagram
Insert correct rope
Insert new rope
clean
clean
Load rope

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6.1 Emergency lowering
Optional emergency operation controls
If the control system is equipped with emergency operation controls, the power unit’s frequency converter can be bypassed.
The load can be hoisted and lowered in this manner.
Switch on emergency operation Switch off emergency operation
1. press EMERGENCY STOP button 1. press EMERGENCY STOP button
2. switch on emergency operation 2. switch off emergency operation
3. release EMERGENCY STOP button 3. release EMERGENCY STOP button
7Maintenance
The following checks and maintenance work should be carried out:
Task
At the start of
operation
As required
Comments
General visual checks:
- driving system
- housing
- Anchor bolts, anchoring straps
X
Screw check
X
after first use or
Overhauls
Clean driving wheel
X
Direction of rotation for electric mo-
tor
X
X
UP button =
Rotation of driving wheel in
anticlockwise direction
Sprocket re-lubrication
X
Gear grease
Rope: Visual checks
- compression sleeve
- eye hooks with fastenings
X
Checking for deformities,
Damage, tears
or broken wires
Rope: Cleaning
X
Rope: Diameter check
X
for worn out ropes,
when rope diameter < 26 mm
Change the rope!
Oil level in sight gauge
X
The machine, the rope and the accessories must be checked at least every 2 years (see sticker
on machine) by a qualified professional. In this way all parts will be checked for deformities,
wear and tear, and cracks. The results of these checks should be entered into the test book.
The checks should be arranged by the operator.
Additionally, local regulations, as well as additional checks for severe operating conditions in
short operating distances, must be implemented by a qualified professional.
8Replacement parts
Replacement parts are provided on a separate list. This can be requested from HABEGGER.