HADEF 42/87P-EX User manual

Rev.04
5.52.291.01.01.04
Pneumatic Wire Rope Winch
42/87P-EX
Explosion proof design
II 2G Ex h IIB T4 Gb or II 2D Ex h IIIA T135°C Db
II 2G Ex h IIB T3 Gb or II 2D Ex h IIIA T200°C Db
DANGER!
Not to be used with IIC gases and IIB gases hydrogen sulphide and ethylene oxide and light metal
and shock sensitive dusts!
It is not allowed to use the equipment in area at risk from explosion where gas AND dust does both
exist at the same time!
Installation, Operating and
Maintenance Instructions

2
5.52.291.01.01.04
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
1.1 Indications to determine the used part of the theoretical usage life. ...........................4
2Safety................................................................................................... 4
2.1 Warning notice and symbols............................................................................................4
2.2 Duty of care of the owner..................................................................................................4
2.3 Requirements for the operating personnel .....................................................................5
2.4 Appropriate use .................................................................................................................5
2.5 Basic safety measures ......................................................................................................6
2.6 Explosion protection .........................................................................................................7
3Transport and Storage ..................................................................... 11
3.1 Transport ..........................................................................................................................11
3.2 Safety device for transport .............................................................................................11
3.3 Storage .............................................................................................................................11
4Description ........................................................................................ 11
4.1 Areas of application ........................................................................................................11
4.2 Design...............................................................................................................................12
4.3 Functions..........................................................................................................................12
4.4 Important components....................................................................................................12
5Technical data................................................................................... 14
6Installation......................................................................................... 14
6.1 Installation of winch ........................................................................................................14
6.2 Selection of wire ropes ...................................................................................................15
6.3 Wire rope fastening .........................................................................................................15
6.4 Winding up of wire rope..................................................................................................15
6.5 Wire rope deflection ........................................................................................................16
6.6 Tools .................................................................................................................................16
7Control ............................................................................................... 17
8Operation........................................................................................... 18
9Commissioning................................................................................. 18
9.1 General .............................................................................................................................18
9.2 Compressed air connection ...........................................................................................19
9.3 Gear...................................................................................................................................19
9.4 Wire rope ..........................................................................................................................19
9.5 Limit switch for wire rope path (as option) ...................................................................20
9.6 Slack rope switch (as option) .........................................................................................20
10 Safety check...................................................................................... 20
11 Functional test .................................................................................. 20
11.1 Checks before the initial start-up...................................................................................20

5.52.291.01.01.04
3
12 Maintenance...................................................................................... 20
12.1 General ............................................................................................................................. 20
12.2 Monitoring........................................................................................................................ 21
12.3 Pneumatic motor ............................................................................................................. 21
12.4 Limit switch for wire rope path (as option)................................................................... 21
12.5 Slack rope switch (as option)......................................................................................... 22
13 Inspection ......................................................................................... 22
13.1 General Overhaul for motor-driven units...................................................................... 22
13.2 Periodic checks ............................................................................................................... 22
13.3 Wire rope.......................................................................................................................... 22
13.4 Inspection intervals......................................................................................................... 23
13.5 Roller chain...................................................................................................................... 23
13.6 Chain wheel ..................................................................................................................... 23
14 Service............................................................................................... 24
14.1 Wire rope.......................................................................................................................... 24
14.2 Gear .................................................................................................................................. 24
14.1 Chain drive....................................................................................................................... 24
14.2 Cleaning ........................................................................................................................... 25
14.3 Pneumatic motor ............................................................................................................. 25
14.4 Lubricant selection ......................................................................................................... 25
14.5 Lubricant for food industry – selection (as option*) .................................................... 25
15 Trouble .............................................................................................. 26
16 Remedy ............................................................................................. 27
17 Decommissioning ............................................................................ 27
17.1 Temporary decommissioning ........................................................................................ 28
17.2 Final decommissioning/disposal................................................................................... 28
18 Additional documents...................................................................... 28
18.1 Pneumatic connections diagram ................................................................................... 28
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 EN ISO 9001.
The production of components at our work is subject to strict, intermediate checks.
After assembly, the products are subject to a final test with overload.
For the operation of hoists, the national accident prevention apply in Germany, amongst others.
Lifting equipment for use in areas prone to explosion complies with current legislation, standards and
regulations and is classified in the applicable Ex-protection class.
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 serves for safe and efficient use of this hoist. Illustrations serve to explain something and may
differ from the illustration of the existing unit as they only serve as an example.
Documentation of component manufacturers that may be supplied additionally, must be observed, in case of
differences between these documentation and our manuals, the specification of the our manual must be
observed.
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.

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5.52.291.01.01.04
1.1 Indications to determine the used part of the theoretical usage life.
For motor driven units.
The equipment (rope hoists, chain hoists, winches as well as crane hoisting units) are classified in drive
groups (duty classification) according to their intended mode of operation, running times and load collectives
and dimensioned according to the requirements derived from these.
They are thus only designed for a limited period of use with regard to the overall dimensioning and
certification.
After the total period of use as elapsed, measures must be taken where parts are checked and exchanged
as per indication by the manufacturer. After that a new maximum usage period is determined. See also the
valued accident prevention regulations, “winches, lifting and pulling devices”.
NOTICE!
Commitment
A general overhaul may only be performed by HADEF or by a specialized company, authorized by HADEF!
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.
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.

5.52.291.01.01.04
5
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
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.
DANGER!
It’s only allowed to use the unit in the EX-classification which is named on the type plate; or in lower
classes.

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5.52.291.01.01.04
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.
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.
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.

5.52.291.01.01.04
7
DANGER!
Special safety measures for use in areas prone to explosion.
No use in zone 0 or zone 20
Not to be used with IIC gases and IIB gases hydrogen sulphide, ethylene oxide and light metal and shock
sensitive dusts!
No use in temperature class T5 or T6.
It is not allowed to use the equipment in area at risk from explosion where gas AND dust does both exist
at the same time!
During assembly and operation of explosion-proof equipment, the relevant regulations of i.e. BG-Chemie
about the use of equipment in area at risk from explosion, must be adhered to by the user/owner.
Please make sure that external ventilation is sufficient.
Please wear conductive shoes. Gloves should have a shunt resistance of < 108Ω.
It is not allowed to take off clothes.
The surface temperature of the devices could increase by a variety of external circumstances. For this
reason, the surface temperature is to be monitored.
Avoid ignitable dust deposits.
Remove dust deposits daily before commencing work and ensure that dust cannot settle between moving
parts.
Never remove dust with compressed air - remove it with a wet bolt of cloth.
Defective units or units that show abrasion of its surface rust on chains, hooks, or suspension devices,
must be taken out of service.
Please observe the prescribed intervals.
Assembly and maintenance work must only be carried out in an atmosphere not prone to explosion.
Check the grease level of the bearings regularly
Exchange friction surfaces in time and (an exception to this are electric units - maintenance of the brakes
must only be effected by HADEF).
Protect the device from impact, friction, rough handling and moisture.
DANGER!
The operator is responsible for professional equipotential bonding (earthing) for power-operated
devices!
Special scope
Use of different EX-zones is depended from the EX-classification of the unit. Find the EX-classification on its
type plate.
Unit classified
in EX-classification
No use
in EX-zone
3G
0,20,1,21,22
3D
0,20,1,21,2
2G
0,20,21,22
2D
0,20,1,2
2.6 Explosion protection
The EX classification of the unit is indicated on a
separate plate, situated on the unit.
Illustration 1

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5.52.291.01.01.04
Example of ATEX classification:
II
2
G
Ex h
IIB
T4
Gb
CE-marking European Union
explosion-proof operating material
II
device group / application
I
II
danger of mine damp
other areas prone to explosion
2device category
1
2
3
for use in zone 0
for use in zone 1
for use in zone 2
G
EX atmosphere
G
D
...caused by gas, steam, fog
...caused by dust
Ex h type of protection
for mechanical devices, including e. g.
“c” construction safety
“k” encapsulation of liquids
IIB explosion group II (gases)
IIA
IIB
IIC
limit gap widths (MESG) > 0,9 mm
limit gap widths (MESG) ≤ 0,9 to ≥ 0,5 mm
limit gap widths (MESG) < 0,5 mm
T4 Temperature class - gases
(for dust only the temperature in °C
is stated)
T1
T2
T3
T4
T5
T6
limit temperature 450 °C
limit temperature 300 °C
limit temperature 200 °C
limit temperature 135 °C
limit temperature 100 °C
limit temperature 85 °C
Gb EPL (equipment protection level)
Ga
Gb
Gc
e.g. Group II (for gases, vapours, mist):
level of protection: very high (complies with zone 0)
level of protection: high (complies with zone 1)
level of protection: enhanced (complies with zone 2)
2.6.1 EX-Category
EX - Zone
1+21
2+22
1+21
2+22
Device category
2
2
Expl.-group of gases
Expl.-group of dust
IIB
IIIA
IIB
IIIA
Temperature class - gases
Temperature class - dust
T4
T135°C
T3
T200°C
DANGER!
The classification for the device can be found on the EX-type plate on the unit.
The device must only be used in the classification stated or in a lower classification.
2.6.2 Surface temperature of the devices
DANGER!
The temperature class mentioned on the EX-type plate on the unit must be observed, - make sure
that the max. surface temperature is even fallen short of.
DANGER!
The maximum surface temperature of the equipment must always be lower than the ignition
temperature of the gas/vapour/dust/air mixture. Equipment which has been classified in higher
temperature classes is, of course, also approved for use in applications with lower temperature
classes. As gas/air mixtures for T5 do not occur with normal use, and only very rarely occur for T6,
for specific gas/air mixtures such as carbon disulphide (IIC), our hoists are not rated for these
temperature classes and must not be used for these classes.

5.52.291.01.01.04
9
Temperature
class
Ignition tem-
perature of gas
°C
max. surface
temperature of the
operating material in
°C
T1
>450
450
T2
>300 <450
300
T3
>200 <300
200
T4
>135 <200
135
T5
>100 <135
100
T6
>85 <100
85
2.6.3 EX zone classification
Areas that are prone to explosion are classified into zones. The owner must determine the zone that exists.
Information on the zone classification can be found in IEC 60079-10 and in national standards. The following
table contains an overview of the zone classification in combination with the device category.
Gases
Vapours
Mist
device category
(Gases) Dust device category
(dust)
explosive
atmosphere
is present
Zone 0 1G Zone 20 1D
continuously, long-term or
frequently
Zone 1
2G
Zone 21
2D
occasionally
Zone 2
3G
Zone 22
3D
rarely or short-term

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5.52.291.01.01.04
2.6.4 Explosion hazards … recognizing and preventing!

5.52.291.01.01.04
11
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.
During longer downtimes of motor-operated units, the brake may reduce the function by corrosion.
NOTICE!
Use only in the intended atmosphere with a humidity of up to 100%, but not under water!
Depending on the type of device, it is suitable for use in area at risk from explosion in the EX-classification
stated.
The EX-classification is mentioned on the EX-type plate on the hoist. The use of the unit is only allowed for
the EX-classification mentioned on the EX-type plate or lower EX classification.
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 p
otentially 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

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5.52.291.01.01.04
4.2 Design
HADEF pneumatic wire rope winches for
stationary use are fitted with holes for installation.
The housing is made of steel plate. The two
housing halves are connected with a torsion-
resistant traverse. Transport eyes are situated at
the upper edges of the h
ousing. The drum is
situated parallell to the drive.
4.2.1 Wire rope exit
The wire rope exit is determined by the
asymmetrical torque of the motor.
rope exit direction A
4.3 Functions
The lifting gear are operated by pressing the push buttons on the control switch. The brake which is
integrated prevents the load from being lowered automatically after releasing the control keys.
4.4 Important components
Motor
Pneumatic motos. Operating pressure 6 bar.
Gear
▫Type 1506 - 4108 - spur gear
▫Type 5106 - 7104 - planetary gear
NOTICE!
As standard, the gear is filled with oil. For transport reasons, a plug screw is fitted - replace the plug screw
by a ventilation screw (attached) before putting the unit into operation. In other cases the ventilation screw is
already assembled.
Limit switch
▫Serial winch is a lifting winch.
▫Pulling winch as option.
Function: Operational and emergency limit switch.
It is possible to connect an external electric limit switch.
Overload protection
A pressure reducing valve prevents that an overload is lifted.
DANGER!
The overload protection serves exclusively to protect against damage to the device due to
overloading
when moving loads. Its function must not be integrated into the operational work process!
Control
▫Indirect control
▫Winches with limit switch are operated through valves.
Control switch
▫for indirect control by push button valves
▫control hose with integrated stress-relief rope
Disengaging clutch (as option)

5.52.291.01.01.04
13
The disengaging clutch separates the drum from its drive. The clutch is actuated by a hand lever which is
locked by a spring-pin. Before operation, this spring-pin must be pulled by hand and hold until the hand lever
has moved some steps. It engages automatically after the switch operation has ended.
When the clutch is disengaged it is possible to pull the uncharged wire rope off the drum by hand. Should
there be an after-run of the drum, brake it with the foot brake.
CAUTION!
The foot brake must not be used to brake loads! This is not possible (if normal forces act). Unintended
switching is also prevented.
4.4.1 Emergency brake release - hoist (option)
Manual emergency brake release for
lowering the load in case of power
supply failure by means of lever (A).
Electric Electric-EX Pneumatic + EX
Illustrattion. 2
Pressure roller (as option)
The pressure roller prevents
the skipping of rope
windings, when the unloaded rope will on-
or
unwinded.
The respective rope layers will pressed
functionally correct .
Illustration 3
DANGER!
The following is not allowed:
Disengaging under load.
Manipulation of the disengaging device.
Maintenance unit
It serves for the necessary preparation of the operation air so that the pneumatic motor can work troublefree.
If not assembled by the manufacturer, it must be assembled by the customer.
CAUTION!
Should the unit be assembled at the customer, the maintenance unit is supplied without oil.
Before putting the unit into operation, the main air supply line must be cleaned and the oiler of the
maintenance unit must be filled with oil. Should this not be done the unit may be severely damaged.
Special Parts
For use in explosion dangerous areas, are be installed some special units, special treated surfaces or made
in special material.
A

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5.52.291.01.01.04
5 Technical data
Type
capacity
1st
layer
kg
capacity
top layer
kg
Wire rope
storage
1st layer
lage
m
Wire rope
storage
top layer
m
rope
layers
number
Wire rope
speed
digkeit
Lifting/
Lowering
1st layer
m/min
Wire
rope
speed
speed
Lifting/
lower-
ing
top
layer
m/min
nec.
wire
rope ø
mm
nec. min.
breaking
load
kN
Motor-
output
kW
air
consump-
tion
at
6 bar
m³ /min
air
connection
noise
emission *
1 m/ 3 m
distance
tolerance
+2 dB(A)
dB(A)
weight
without
wire rope
approx.
kg
1515 500 320 26 ( 23 ) 172 ( 154 ) 5 15/28 22/41 6 20 1,8 3,3 R 3/4 " 94/84 75
2309 990 650 28 ( 25 ) 172 ( 154 ) 4 10/17 1,.5/27 9 40 1,8 3,3 R 3/4 " 94/84 160
2409 1000 650 28 ( 25 ) 141 ( 126 ) 4 10/17 12,5/27 9 40 1,8 3,3 R 3/4 " 94/84 160
3405 2000 1400 33 ( 29 ) 141 ( 126 ) 5 5/9 7,5/13,5 12 80 1,8 3,3 R 3/4 " 94/84 260
4107 3200 2000 32 ( 30 ) 141 ( 126 ) 5 7/12 10/17 16 128 5 5,4 R 1" 94/84 440
5105 5000 3200 36 ( 34 ) 141 ( 126 ) 5 5/9 7,5/13,5 20 200 5 5,4 R 1" 94/84 600
6105 7500 5000 50 ( 46 ) 213 ( 191 ) 5 3/5 7,5/13,5 24 300 5 5,4 R 1" 94/84 1000
7104 10000 6300 52 ( 49 ) 213 ( 191 ) 4 2,5/4 6/10 28 400 5 5,4 R 1" 94/84 1320
Duty classification FEM/ISO 4301 - 1Am/M4, operation pressure 6 bar
values in (...) are valid for grooved drum
* measured at a distance of 1 m from the surface of the unit and 1,6 m over the assembly area (tolerance +2dB(A))
6 Installation
DANGER!
Assembly, disassembly and maintenance operations must only be carried out in an atmosphere not
prone to explosion!
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.
The winch must always be aligned with the horizontally adjusted drum, regardless of the installation
position
6.1 Installation of winch
Type
Capacity
1st layer
kg
A B C
Ø D /
Anchoring
screws
Strength class
8.8
Number of
screws
1506
1515
1516
500 650 400 - 11/M10 4
2306
2309
2316
990 720 580 - 17/M16 4
2406
2409
2416
1000 720 580 - 17/M16 4
3405
3406
3416
2000 750 725 - 17/M16 4
4107
4108
3200 900 900 - 24/M22 4
5105
5106
5000 1000 1000 - 30/M27 4
6105 7500 1300 1300 100 26/M24 8
7104 10000 1410 1430 100 30/M27 8
Illustration 4

5.52.291.01.01.04
15
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
The winding direction of the wire rope is determined by the manufacturer.
The winding direction cannot be changed.
Before cutting the wire rope, wrap it firmly with a fine binding wire or strong adhesive tape.
6.3.1 Wire rope fastening
The wire rope is fastened with retainer key. The retainer key is attached to the consignment for winches
supplied without wire rope.
Push the wire rope through the hub of the
flanged wheel and through the key pocket.
Pull some centimeters out.
Wrap it completely round the retainer key (1)
Place it back into the key pocket.
Illustration 5
By pulling the wire rope, the retainer key gets
stuck into the pocket and locks the wire rope
safely.
It may be necessary to insert the retainer key a
little bit into the hub with a soft tool before the wire
rope can be loaded.
Illustration 6
The wire rope feed out direction is determined by
the motor.
See chapter "Installation".
Illustration 7
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.

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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 8
NOTICE!
Should the drum be extended and for some models with limit switch, the distance "M" must be increased.
Standard values:
15 x 1/2 drum length for standard wire ropes
30 x 1/2 drum length for twist-resistant or non-twisting wire ropes
6.5.1 Wire rope pulley (provided by the customer)
Table dimension "M" for standard drum length
Type "M "min
m
1506, 1515, 1516 4,3
2306, 2309, 2316 4,5
2406, 2409, 2416 4,5
3405, 3406, 3416 4,6
4107, 4108 5,4
5105, 5106 6,1
6105 8,1
7104 8,8
6.6 Tools
Capacity
Size
Tool
Use
500 kg
990, 1000, 2000 kg
3200 kg
5000 kg
7500 kg
10000 kg
SW17
SW24
SW32
SW41
SW36
SW41
Winch assembly
Wire rope
assembly
misc. Pneumatic air
connections
misc.

5.52.291.01.01.04
17
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.
Control buttons
Control symbols shown are for optical information only and can vary depending on the control module.
Emergency stop
Illustration 9
Arrow keys = Lifting / Lowering
Illustration 10
System start (optional)
Illustration 11
Push button functions (E)
Relieved push button = stand still
push button half pushed = slow speed
push button pushed completely = fast speed
Illustration 12
Red Emergency-Stop button
button pushed = stand still
turn the button clockwise = free functions
Illustration 13
NOTICE!
Lockable Emergency-Stop buttons must first be opened with the key before unlocking!
Emergency release – Hoist (as option)
In order to be able to drain the load in
the event of a power supply failure, it is
possible to release the brake manually
by means of lever (A).
Elektric Elektric-EX
Pneumatic + EX
Illustration 14
DANGER!
The emergency drain may only be used in the event of a power supply failure and not in the event of a
technical fault on the unit!
A

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5.52.291.01.01.04
NOTE!
A minimum weight of approx. 20% of the rated load is necessary for lowering. This value depends on
application and ambient conditions!
8 Operation
The following, important points must be observed when operating the equipment:
Read the safety instructions.
Never load the devices beyond their working load limit.
The prescribed maintenance intervals must be adhered to.
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
NOTICE!
The overload is set at the factory according to the specifications in the test book. During operation, the
nominal load of the unit must not be exceeded!
9 Commissioning
9.1 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).

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9.2 Compressed air connection
Before commencing work on the equipment, the main air supply line must be closed and secured against
inadvertent opening!
9.2.1 Main connection
The connections must be made according to the pneumatic connection diagram.
Connect to the existent hose nozzle.
The hose must be secured with a hose clamp.
Nominal width of the air connection hose
0,52-0,75 kW - NW 13 mm
1,5 kW - NW 19 mm
2,5 kW - NW 25 mm
If hose length exceeds 15 m, a larger cross section must be selected.
9.2.2 Control hose connection
Control switches with hoses are connected at the factory, unless otherwise agreed.
9.2.3 Maintenance unit
It is important that an automatic maintenance unit, consisting of oiler, filter ,water separator and air pressure
reducer is installed in the main air supply - if not assembled by the manufacturer this must be assembled by
the customer.
It serves for the necessary preparation of the operation air so that the pneumatic motor can work trouble-
free. Installation must be as close as possible to the motor; - in no cases should the distance to the motor
exceed 10 m.
Should higher pressure occur in the supply net, it will be reduced to the operating pressure of 6 bar by the
pressure reducing valve. The oiler enriches the air with oil. Setting of oil addition: approx. 2 drops of oil must
be added per minute.
NOTICE!
HADEF does not assume any responsibility for damage caused by non-observance of the instructions.
CAUTION!
Should the unit be assembled at the customer, the maintenance unit is supplied without oil.
Before putting the unit into operation, the main air supply line must be cleaned and the oiler of the
maintenance unit must be filled with oil. Should this not be done the unit may be severely damaged.
CAUTION!
The maintenance units are not approved for use with synthetic oil.
They must not be connected to compressed air systems which are supplied by compressors with synthetic
lubricants.
9.3 Gear
NOTICE!
For transport, some gear types are fitted with a plug screw. Replace the plug screw
by a ventilation screw
(attached) before putting the unit into operation.
9.4 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.

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9.5 Limit switch for wire rope path (as option)
The limit switch (if exist) must be adjusted before commissioning and after maintenance work has been
made. Intermediate checks for correct function are necessary.
The switching point for the upper load position must be set in such a way that even in case of unfavourable
cable winding the permitted highest load position is not overrunned. In individual cases it may be necessary
for the customer to install an external emergency switch. The limit switch for the lowest load position is
always driven exactly independently of the cable length.
NOTICE!
An exact driving up to the upper end position is only possible in the first wire rope layer with grooved rope
drum.
Exactness decreases with larger wire rope length and several wire rope layers.
9.6 Slack rope switch (as option)
In case of slack rope i.e. by setting down of the load, the slack rope switch prevents further unwinding of the
wire rope.
9.6.1 Function
The weight of roller lever and guide pulley actuates rotation of the switching shaft with eccentric disc in case
of slack wire rope. The eccentric disc pushes the switching pin of the limit switch down until the switching
contacts in the circuit for "lowering" open.
Lowering without load is impossible.
Should this, however, be necessary i.e. during installation or adjustment work, the wire rope must be tensed
by little load or the roller lever must carefully be actuated by hand. The switch can also be taken out of
service by dismantling the eccentric disc.
The slack rope switch will be installed in our factory according to customer's requirements. Installation
depends on the position of the winch and wire rope exit.
NOTICE!
Before commissioning, the switch must be adjusted by the customer.
The function is only possible in wiring direction "lowering". After th
e switch has actuated, "lifting" must still
be possible.
10 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 oil levels in the gear boxes are sufficient.
All movements of the load comply with the symbols on the control switch.
The wire ropes are winded up correctly, are lubricated and are in good condition.
11 Functional test
11.1 Checks before the initial start-up
Check lifting by moving up/down and slow/fast without load.
Suspend the nominal load and check the function of the brake.
12 Maintenance
12.1 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.