HADEF 260/23 User manual

Rev.02
5.52.246.00.01.02
Manual Spur Gear Wire Rope Winch
260/23
Installation, Operating and
Maintenance Instructions

2
5.52.246.00.01.02
NOTICE!
The installation or mounting instructions for incomplete machines you’ll find in chapter <Installation=.
o
by Heinrich de Fries GmbH
Heinrich de Fries GmbH, Gauss Str. 20, D-40235 Düsseldorf
Heinrich De Fries GmbH will be named HADEF in the following text.
Original operating- and maintenance instructions in German language.
Translation in other languages is made of the German original.
A copy may be requested in writing or is available for download on www.hadef.com
Subject to changes.
Table of Contents
1Information .......................................................................................... 3
2Safety ................................................................................................... 3
2.1 Warning notice and symbols............................................................................................3
2.2 Duty of care of the owner..................................................................................................4
2.3 Requirements for the operating personnel ..................................................................... 4
2.4 Appropriate use .................................................................................................................5
2.5 Basic safety measures ...................................................................................................... 5
3Transport and Storage ....................................................................... 6
3.1 Transport ............................................................................................................................ 6
3.2 Safety device for transport ...............................................................................................6
3.3 Storage ...............................................................................................................................6
4Description .......................................................................................... 6
4.1 Areas of application ..........................................................................................................6
4.2 Design................................................................................................................................. 7
4.3 Functions............................................................................................................................ 7
4.4 Important components......................................................................................................7
5Technical data..................................................................................... 8
6Installation........................................................................................... 8
6.1 Winch assembly................................................................................................................. 8
6.2 Selection of wire ropes .....................................................................................................8
6.3 Wire rope fastening ...........................................................................................................8
6.4 Winding up of wire rope.................................................................................................... 9
6.5 Wire rope deflection .......................................................................................................... 9
7Control ................................................................................................. 9
8Commissioning................................................................................. 10
8.1 General .............................................................................................................................10
8.2 Wire rope ..........................................................................................................................11
9Safety check...................................................................................... 11
10 Functional test .................................................................................. 11
11 Maintenance ...................................................................................... 11
11.1 General .............................................................................................................................11
11.2 Monitoring ........................................................................................................................11
12 Inspection.......................................................................................... 11
12.1 Periodic checks ...............................................................................................................11

5.52.246.00.01.02
3
12.2 Wire rope.......................................................................................................................... 11
12.3 Inspection intervals......................................................................................................... 12
13 Service............................................................................................... 12
13.1 Wire rope.......................................................................................................................... 12
13.2 Gearing............................................................................................................................. 12
13.3 Safety crank and load pressure brake .......................................................................... 12
13.4 Lubricant - Selection....................................................................................................... 13
13.5 Lubricant for food industry –Selection (as option*).................................................... 13
14 Trouble .............................................................................................. 13
15 Remedy ............................................................................................. 13
16 Decommissioning ............................................................................ 13
16.1 Temporary decommissioning ........................................................................................ 13
16.2 Final decommissioning/disposal................................................................................... 13
1 Information
The products meet European Union requirements, in particular the valided EU Machine Directive.
The entire company works acc. to a certified quality assurance system as per ISO 9001.
The production of components at our work is subject to strict, intermediate checks.
After assembly, each product is subject to a final test with overload.
For the operation of hoists, the national accident prevention regulations apply in Germany, amongst others.
The stated performance of the devices and meeting any warranty claims require adherence to all instructions
in this manual.
Before delivery, all products are packed properly. Check the goods after receipt for any damage caused
during transport. Report any damage immediately to the forwarding agent.
This manual allows a safe and efficiently use of equipment. Images of this manual are for a principle
understanding and can be different from the real design.
NOTICE!
We refer to the prescribed equipment tests before initial start-up, before putting back into operation and the
regular periodic inspections.
In other countries any additional national regulations must be observed.
2 Safety
2.1 Warning notice and symbols
Warnings and notice are shown as follows in these instructions:
DANGER!
This means that there is a high risk that leads, if it is not avoided, to death or severe injury.
WARNING!
This means that there is a risk that could lead, if it is not avoided, to death or severe injury.
CAUTION!
This means that there is little risk that could lead, if it is not avoided, to slight injury or damage to
the device or its surrounding.
NOTICE!
Gives advice for use and other useful information.
Danger from electricity.
Danger from explosive area.

4
5.52.246.00.01.02
2.2 Duty of care of the owner
DANGER!
Failure to follow the instructions of this manual can lead to unpredictable hazards.
For any resulting damage or personal injury, HADEF assumes no liability.
The unit was designed and built following a risk analysis and careful selection of the harmonized standards
that are to be complied with, as well as other technical specifications. It therefore represents state-of-the-art
technology and provides the highest degree of safety.
Our delivery includes the hoist supplied beginning at its suspension and ending at the load hook and if
supplied with control, the control line/hose that leads to the hoist. Further operating material, tools, load
attaching devices as well as main energy supply lines must be assembled according to the valid rules and
regulations. For explosion-proof equipment, all these parts must be approved for use in area prone to
explosion, or they must be suitable for use in area prone to explosion. The owner is responsible for this.
However, in everyday operation this degree of safety can only be achieved if all measures required are
taken. It falls within the duty of care of the owner/user of the devices to plan these measures and to check
that they are being complied with.
Complete the operating and installation instructions by any instructions (regarding supervision or
notifications)that are important for the special kind of use of the equipment, i.e. regarding organization of
work, work flow and human resources.
In particular, the owner/user must ensure that:
The unit is only used appropriately.
The device is only operated in a fault-free, fully functional condition, and the safety components, in
particular, are checked regularly to ensure that it is functioning properly.
The required personal protective equipment for the operators, service and repair personnel is available
and is used.
The operating instructions are always available at the location where the equipment is used and that they
are legible and complete.
The unit is only operated, serviced and repaired by qualified and authorized personnel.
This personnel is regularly trained in all applicable matters regarding safety at work and environmental
protection, and that they are familiar with the operating manual and, in particular, the safety instructions it
contains.
Any safety and warning signs on the devices are not removed and remain legible.
customers equipment at site must comply with currently applicable ATEX-regulations
WARNING!
It is not allowed to make constructive changes of the equipment!
2.3 Requirements for the operating personnel
The units may only be operated by qualified persons that are appropriately trained and that are familiar with
it. They must have their employer’s authorization for operation of the units.
Before starting work, the operating personnel must have read the operating and installation instructions,
especially the chapter "Safety Instructions".
This is especially important for operating personnel that rarely uses the equipment, i.e. for installation or
maintenance work.
DANGER!
In order to avoid severe injury, please pay attention to the following when using the equipment:
Use protective clothes/equipment.
Do not wear long hair hanging down open.
Do not wear rings or other jewelry.
Do not wear clothes that are too big/wide.
Do not reach into ropes, chains, drive parts or other moving parts with your hands

5.52.246.00.01.02
5
2.4 Appropriate use
The permitted safe working load of the devices must not be exceeded! An exception can be made during the
load test before initial operation, carried out by a licensed qualified person.
Defective devices and load suspension devices must not be used until they have been repaired! Only
original spare parts must be used. Non-compliance will result in any warranty claims becoming void.
Liability and warranty will become void if unauthorized modifications of the units are made by the user!
The permissible ambient temperature when operating the devices:
Type of drive
Device classification for
not explosive atmosphere
Explosive atmosphere
according to ATEX )* )**
Manually driven
-20°C/+50°C
-20°C/+40°C
Motor driven
-20°C/+40°C
-20°C/+40°C
) * At an atmospheric pressure range from 0.8bar to 1.1bar and an oxygen content of approx. 21%
) ** Devices of this category have been specially modified and labeled by the manufacturer
DANGER!
The permissible ambient temperature must not be exceeded!
Vertical lifting and lowering of unguided loads, horizontal movement of loads and inclined movement of
loads, movement of flaps, covers etc. up to the maximum rated load.
NOTICE!
If the units are not used appropriately, it is not possible to ensure safe operation.
The owner and operator have sole liability for all personal injury and damage to property arising from
inappropriate use.
DANGER!
In particular, use is not permitted:
for tearing loose fixed loads, dragging of loads as well as diagonal pulling
for pulling against a fixed point without additional safety and/or measuring equipment against exceeding
the nominal load
in potentially explosive atmospheres, unless the equipment has been modified for this purpose and
this is shown on special type plates it carries for this purpose.
in reactor containments
for transporting persons
for holding lifted loads
for scenic use
when persons are under suspended loads
2.5 Basic safety measures
Observe installation-, operation and maintenance instruction.
Take notice of caution notes at units and in the manual
Observe safety distances.
Ensure good visibility during operations
Use the equipment only for its intended purpose
The equipment is only intended for moving goods. Persons must not be moved under any circumstances.
Never load the equipment beyond the specified permissible load capacity.
Observe the relevant national accident prevention regulations.
Should the hoist be used outside of Germany, please pay attention to the national regulations that apply.
Building walls, ceilings, floors or constructions - on which the units are mounted or suspended - must be
checked by a structural engineer for sufficient stability.
After the unit has been standing for a longer period of time, visually inspect all components that are
important for its function and replace damaged components with new original spare parts.

6
5.52.246.00.01.02
Do not use a defective unit; listen for abnormal operating noises.
In case of malfunctions, stop the operation immediately and rectify the fault.
Report damage and defects immediately to a responsible person
When working with the unit, warn persons in the immediate vicinity.
Observe the provisions for load suspension equipment in accordance with the relevant national
regulations for the positive and non-positive slinging of loads.
The sling or load must be securely attached to the load hook and rest on the bottom of the hook.
The safety latches of hooks must be closed.
The housing must not be in contact with anything.
Motor drive is prohibited.
WARNING!
The following is not allowed:
to lift another load than the nominal safe working load
to manipulate the sliding clutch if units are equipped with
The use of elongated or damaged chains or wire ropes. Replace them immediately by new, original
parts.
Never loop the load chain around a load nor place or pull the chain over edges.
Never repair damaged load hooks (e.g. by hammering), but replace them by original hooks.
3 Transport and Storage
CAUTION!
Transport may only be done by qualified personnel. No liability for any damage resulting from improper
transport or improper storage.
3.1 Transport
The devices are checked and if so adequately packed before delivery.
Do not throw or drop the equipment.
Use adequate means of transport.
Transport and means of transport must be suitable for the local conditions.
3.2 Safety device for transport
NOTICE!
Should a safety device for transport exist, please remove it before commissioning.
3.3 Storage
Store the equipment at a clean and dry place.
Protect the equipment against dirt, humidity and damage by an appropriate cover.
Protect hooks, wire ropes, chains and brakes against corrosion.
DANGER!
Units that show corrosion must be taken out of service!
4 Description
4.1 Areas of application
The devices must be as far as possible installed in a covered room.
If they are used in the open, protect the units against the effects of weather such as rain, hail, snow, direct
sunshine, dust, etc. - we recommend to use a cover in parking position. If the device is set up in a
continuously humid environment with strong temperature fluctuations, the correct functionings are
endangered by the forming of condensation.

5.52.246.00.01.02
7
NOTICE!
Use only in the intended atmosphere with a humidity of up to 100%, but not under water!
DANGER!
In particular, use is not permitted:
for tearing loose fixed loads, dragging of loads as well as diagonal pulling
for pulling against a fixed point without additional safety and/or measuring equipment against exceeding
the nominal load
in potentially explosive atmospheres, unless the equipment has been modified for this purpose and
this is shown on special type plates it carries for this purpose.
in reactor containments
for transporting persons
for holding lifted loads
for scenic use
when persons are under suspended loads
4.2 Design
HADEF wire rope winches for stationary use are
fitted with holes for installation. The housing is
made of steel plate.
The winch can be installed in any position
desired, make sure, however, the wire rope exit is
correct.
For outside use we recommend to use a
protective roof.
4.2.1 Wire rope exit
Wire rope exit "A" 300 kg and 600 kg
Wire rope exit "B" 1000 kg up to 3000 kg
4.3 Functions
The load is lifted/ lowered, by turning the winch handle. The incorporated load-pressure-brake prevents
automatic lowering of the load after release of the winch handle. Little after run of the load or turn of the
winch handle is due to the system and not a mistake.
4.4 Important components
Housing
Made of steel plate
Brake
Load pressure brake
Gear
Spur gear
Safety crank
Safety crank with load pressure brake and fold grip
Drumdisengaging (optionally)
Mechanism For easier pulling out the uncharged wire rope.

8
5.52.246.00.01.02
5 Technical data
Capacity
FEM
group
wire
rope
Ø
nec.
minimum
breaking
load
useable
wire rope length
number of
rope layers
wire rope path per
crank turn
crank effort
minimum
load
weight
without rope
approx.
1st layer
top layer
1st layer
top layer
1st layer
top layer
kg
kg
mm
kN
m
m
mm
daN (kg)
kg
kg
300
172
1Dm
4
9
2,3
35,4
9
32
6
30
10
600
336
1Dm
6
17
1
12,3
6
28
10
60
11
1000
614
1Dm
8
34
3,5
33
6
20
11
100
27
1500
927
1Dm
10
51
2,5
21
5
14
12
150
27,5
2000
1700
1Dm
12
64
3
8
2
16
32
60
23
3000
2500
1Dm
13
96
3
7
2
10
30
90
32
6 Installation
Please observe the following points in order to avoid any damage to equipment or injury of person:
Wear safety gloves.
Install the winch on a stable ground.
Make sure attachment surface is flat and that installation is made stress-free, - use shim parts if
necessary.
The winch must be set up and attached in such a way that it cannot change position neither by the load
nor by other influences.
6.1 Winch assembly
The winches can be installed in any position desired, make sure, however, that the prescribed rope exit is
correct.
Die 1000kg und 1500kg Winden können an 2 verschiedenen Seiten montiert werden.
Make sure the attachment surface is flat/plain and that installation is made stress-free to ensure safe
functioning.
Use the screws mentioned in the table for installation. Tighten all screws evenly.
Distance of holes
Capacity
1st layer
holes of the
installation area
fastening screws
A
B
A1
B1
strength
8.8
Tightening
moment
kg
mm
mm
mm
Mm
300
168
268
-
-
M8
25
600
168
268
-
-
M8
25
1000
170
212
150
190
M12
87
1500
170
212
150
190
M12
87
2000
180
280
-
-
M16
215
3000
220
380
-
-
M16
215
All 4 bolts must always be mounted.
6.2 Selection of wire ropes
Wire ropes acc. to EN 12385-4 - Lifting ropes
Stainless wire ropes and special wire ropes are available on request.
Diameter and nec. minimum breaking load must be acc. to the data mentioned in the table in chapter
"Technical Data" resp. acc. to the details mentioned on the type plate.
Recommendation of wire ropes
Steel-reinforced wire ropes
For larger pulling rope forces, fibre-core wire ropes can also be used.
For unguided loads, - non-twisting or at least twist-resistant wire ropes.
For several rope layers winded through the drum, - steel-reinforced wire ropes.
WARNING!
It is not allowed to use plastic wire ropes or plastic-coated wire ropes.
6.3 Wire rope fastening
There is a plate on the winch indicating the wind up direction.

5.52.246.00.01.02
9
We recommend to solder the wire rope end thoroughly.
300 kg up to 1500 kg - fastening of the wire rope to the
flanged wheel.
When turning the crank clockwise, the wire rope must
wind up onto the drum anti-clockwise.
Fix the wire rope end to the rope drum by cramming it to
the flanged wheel from outside.
Illustration 1
2000 kg and 3000 kg fastening of the wire rope on the
drum
When turning the crank clockwise, the wire rope must
wind up onto the drum also clockwise.
Fix the wire rope end to the rope drum by cramming it.
Illustration 2
DANGER!
In case of incorrect winding direction, the load pressure brake is not working.
6.4 Winding up of wire rope
The wire rope must always be winded up tensioned. When the last wire rope layer is winded onto the drum,
the flanged wheel must exceed the top layer by at least 1 1/2 times of the wire rope diameter.
NOTICE!
According to validated regulations and accident prevention regulations, the wire rope length must be
chosen so that at least 2 rope layers remain on the drum when the wire rope is unwinded.
6.5 Wire rope deflection
Wire rope pulleys must be installed in a
position centrically to the rope drum.
In order to ensure correct winding up of the
wire rope on the drum, the max. wire rope
deflection angle must not be exceeded.
maximum wire rope deflection angle
4° for standard wire ropes
2° for non-twisting resp. twist-resistant wire
ropes
The minimum dimension (M) from the drum
until the middle of the pulley must be adhered
to.
Illustration 3
7 Control
Only people that are familiar with the operation of the lifting devices and cranes may be entrusted with their
operation. They must be authorized by the employer for the operation of the equipment. The employer must
ensure that the operating instructions are available near the equipment and that they are accessible for the
operating personnel.

10
5.52.246.00.01.02
Lifting and lowering by turning the hand crank.
Lifting load –turn clockwise.
ö
Hold load –release hand crank. The load holds
automatically. Acc. The different types, the crank
can removed in each position or the crank grip
can fold back.

Lowering load –turn anti clockwise.
õ
Winches 1000 kg + 1500 kg
Free-wheeling mechanism of the drum
Disengaging of the rope drum
Turn the drum with the crank until the locking bolt (1) is
reachable with the hand.
Turn the drum per hand 2-3 mm in direction (A). Pull the
locking bolt (1) in direction (B) and turn it by max. 90°.
The free-wheeling mechanism is now activated.
Engaging the rope drum:
Turn the locking bolt (1) until it locks in the locking nut.
Turn the rope drum by hand until the locking bolt locks
totally in the drum.
CAUTION!
It is not permitted to disengage the drum under load.
8 Commissioning
8.1 General
The operator of the unit is responsible for the entire system.
According to the Ordinance on Industrial Safety and Health, a hazard analysis must be carried out by the
operator.
Observe the respective national standards, regulations and directives of the responsible bodies at the place
of operation.
NOTICE!
Hoists up to 1000 kg capacity and without motor-driven trolleys of hoisting unit must be tested by a
<qualified person= before putting into operation for the first time.
Hoists of 1000 kg capacity and up or with more than one motor-driven hoist movement; i.e. lifting and
trolley movement, must be tested by a <licensed qualified person= before putting in operation.
An exception is <hoists ready for operation= acc. validated national regulations with EU-declaration of
conformity.
Definition <qualified person= (former expert)
A <qualified person= has learned, due to occupational training and experience and the job that the person has
done, the skills needed to tests the material for one’s work.
Definition <licensed qualified person= (former approved expert)
A <licensed qualified person= has, due through special occupational training, knowledge about testing of the
material for one’s work and knows the national accident prevention regulations and other prescriptions and
technical regulations. This person must test the material for one’s work regularly with regard to design and
kind of use. The license will be given to qualified person be the approved supervision authorities (ZÜS).

5.52.246.00.01.02
11
8.2 Wire rope
Wire ropes must be free from corrosion, dirt or damage.
They must be lubricated before commissioning.
No lubrication shortens the lifetime of the wire rope and the maintenance intervals.
WARNING!
It is not allowed to use plastic wire ropes or plastic-coated wire ropes.
9 Safety check
Before putting into service initially or when putting back into service, it must be checked whether:
All fastening screws (if existent), socket pins, flap socket and safety devices are tightened and secured.
The wire ropes are winded up correctly, are lubricated and are in good condition.
10 Functional test
Function must be tested with capacity load, which is shown on the type plate.
Test brake by lifting and lowering the load. The load must be hold safety.
11 Maintenance
11.1 General
All monitoring, servicing and maintenance operations are to ensure correct functioning of the equipment;
they must be effected with utmost care.
Only <qualified persons= may do this work.
Servicing and maintenance work must only be done when the hoist is not loaded.
Records must be kept of all test results and measures taken.
11.2 Monitoring
The monitoring and servicing intervals stated are valid for operation under normal conditions and single-shift
operation. In case of severe operating conditions (e.g. frequent operation with full load) or special
environmental conditions (e.g., heat, dust, etc.), the intervals must be shortened correspondingly
12 Inspection
12.1 Periodic checks
Independently from the regulations of the individual countries, lifting devices must be checked at least yearly
by a qualified person or licensed qualified person regarding its functional safety.
12.2 Wire rope
Adequate performance of the servicing and monitoring work acc. to the validated, national regulations
<Basics for cable drives – monitoring during use=.
A visual check must be effected before every new work shift.
Wear
Deformation
Fissures
Corrosion
Report any damage immediately to the responsible person and exchange damaged or worn wire ropes and
load tackles.

12
5.52.246.00.01.02
12.3 Inspection intervals
on commission-
ing
daily checks
1st service
after 3 months
inspection,
service every
2 months
inspection,
service every
3 months
inspection,
service every
12 months
inspection,
service every
24 months
Inspection of the equipment by a qualified person (periodic
inspection)
X
Check screw connections
X
X
Check brake function
X
X
check brake air gap (only for electric devices) *)
X
check overload protection if existent
X
clean and lubricate the wire rope
X
X
X
check wire rope and wire rope end fastenings for damage
and wear
X
check the load tackle and load hook for cracks and
deformation
X
*) not for EX design
13 Service
13.1 Wire rope
Maintenance of the wire rope must be carried out in accordance with the currently valid ISO 4309.
CAUTION!
In case of corrosion, cracks or reaching the wear limit, the affected rope must be replaced with a new
original rope.
13.2 Gearing
The gear unit is filled with high-quality long-life grease at the factory. The bearing points are equipped with
maintenance-free plain bearings.
For use as directed and normally, the greasing is sufficient for approx. 5 years.
In the case of extreme use, e.g. dust, wetness, etc., replace worn parts after 2 years if necessary and re-
lubricate the gear unit with grease.
Make sure that no grease gets on the load pressure brake
(1).
13.3 Safety crank and load pressure brake
Winches which are fitted with safety cranks have a load pressure brakes installed in the crank.
The abrasion of brake rings must be checked. Gap max. >30°.
Caution!
Change of worn brake rings and repair of cranks only by manufacturer.
Brake linings should be free of oil, grease, dirt and dampness, because of an increased abrasion.
If lowering will work slowly, let drip some drops oil
in the gap of crank nave.
Grease the rotating parts of crank grip, slightly.
Illustration 4

5.52.246.00.01.02
13
13.4 Lubricant - Selection
FUCHS
SHELL
ESSO
MOBIL
TOTAL
CASTROL
KLÜBER
Renolit FEP 2
Alvania EP 2
Unirex EP 2
Mobilux EP 2
MULTIS EP2
--
--
Stabylan 5006
--
--
--
--
Optimol Viscoleb 1500
Klüberoil 4UH 1-1500
--
--
--
--
--
--
Wolfracoat 99113
Chain lubricant OKS 451
13.5 Lubricant for food industry –Selection (as option*)
SHELL
MOBIL
CASTROL
KLÜBER
Gearing
FM Grease HD2
Mobilgrease FM 222
--
Klüberoil 4UH 1-1500 N
Load chain
--
Lubricant FM 100
Optimol Viscoleb 1500
--
Load hook;
Pulleys
Gear rim;
Drive pinion
FM Grease HD2
Mobilgrease FM 222
--
--
* must be mentioned by order
14 Trouble
Please pay attention to the following in case of problems:
Troubles with the equipment must only be repaired by qualified personnel.
Secure the unit against unintended operation start.
Put up a warning note indicating that the unit is not to be used.
Secure the working area of moving parts of the unit.
Please read the chapter "Safety instructions".
Notes on the repair of faults are found in the following table.
For the repair of failures please contact our service department.
CAUTION!
Trouble caused by wear or damage to parts such as wire ropes, chains, chain wheels, axes, bearings,
brake parts, etc., must be remedied by replacing the parts with original spare parts.
15 Remedy
Trouble
Cause
Remedy
Load is not lifted
Rope is not winded correctly - rope turning direction for lifting is not correct
Place the wire rope correctly
Brake is worn or defective.
Check brake parts and replace the safety crank if neces-
sary.
Brake discs are humid or oiled
Repair or overhaul effected by the manufacturer.
Load pressure brake does not open.
Brake mechanism or brake discs are locked.
Loosen the brake by slightly pushing the winch handle by
hand (in direction lowering)
16 Decommissioning
WARNING!
It is essential that the following points are observed in order to prevent damage to the equipment or critical
injury when the device is being decommissioned:
It is mandatory that all steps for decommissioning the machine are carried out in the indicated sequence:
First secure the working area for decommissioning, leaving plenty of space.
Read the chapter "Safety instructions".
Disassembly is carried out in reverse order to the assembly.
Please make sure that all operating material is disposed of in accordance with environmental regulations.
16.1 Temporary decommissioning
Measures are as above.
Also read the chapter <Transport and storage=.
16.2 Final decommissioning/disposal
Measures are as above.
After disassembly, ensure that the disposal of the equipment and any materials it contains is carried out
in accordance with environmental regulations.