HADEF 43/86E-Liftboy Assembly instructions

5.52.288.00.01.06 Rev.06
HADEF Electric Wire Rope Winch
Type 43/86E-Liftboy
Installation, Operating and
Maintenance Instructions

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5.52.288.00.01.06
NOTICE!
The installation or mounting instructions for incomplete machines you’ll find in chapter “Installation”
o


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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
1 Information......................................................................................... 3
1.1 Indications to determine the used part of the theoretical usage life............................4
2 Safety ................................................................................................. 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
3 Transport and Storage ...................................................................... 7
3.1 Transport..........................................................................................................................7
3.2 Safety device for transport..............................................................................................7
3.3 Storage .............................................................................................................................7
4 Description......................................................................................... 8
4.1 Areas of application.........................................................................................................8
4.2 Design ..............................................................................................................................8
4.3 Functions .........................................................................................................................9
4.4 Important components ....................................................................................................9
5 Technical data ................................................................................. 10
6 Installation ....................................................................................... 11
6.1 Winch fastening – hole measures ................................................................................11
6.2 Selection of wire ropes..................................................................................................12
6.3 Wire rope fastening .......................................................................................................12
6.4 Winding up of wire rope ................................................................................................13
6.5 Wire rope deflection ......................................................................................................13
6.6 Tools...............................................................................................................................13
7 Operation ......................................................................................... 14
7.1 Disengaging clutch (as option).....................................................................................15
8 Operation ......................................................................................... 15
9 Commissioning ............................................................................... 16
9.1 General ...........................................................................................................................16
9.2 Power supply .................................................................................................................16
9.3 Gear ................................................................................................................................17

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9.4 Wire rope........................................................................................................................18
9.5 Limit switch for wire rope path (as option) ..................................................................18
9.6 Slack rope switch (as option) .......................................................................................18
10 Safety check .................................................................................... 18
11 Functional test................................................................................. 19
11.1 Checks before the initial start-up .................................................................................19
12 Maintenance .................................................................................... 19
12.1 General ...........................................................................................................................19
12.2 Monitoring......................................................................................................................19
12.3 Brake motor ...................................................................................................................19
12.4 Overload protection.......................................................................................................20
12.5 Limit switch for wire rope path (as option) ..................................................................20
12.6 Slack rope switch (as option) .......................................................................................21
13 Inspection ........................................................................................ 21
13.1 General Overhaul for motor-driven units.....................................................................21
13.2 Periodic checks .............................................................................................................22
13.3 Wire rope........................................................................................................................22
13.4 Inspection intervals .......................................................................................................22
14 Service ............................................................................................. 22
14.1 Wire rope........................................................................................................................22
14.2 Gearbox..........................................................................................................................23
14.3 Electric motor ................................................................................................................23
14.4 Lubricant selection........................................................................................................23
14.5 Lubricant for food industry – selection (as option*) ...................................................23
15 Trouble............................................................................................. 23
16 Remedy ............................................................................................ 24
17 Decommissioning ........................................................................... 25
17.1 Temporary decommissioning.......................................................................................25
17.2 Final decommissioning/disposal..................................................................................25
18 Additional documents..................................................................... 25
18.1 Electric wiring diagrams ...............................................................................................25
18.2 Radio control (as option) ..............................................................................................25
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.

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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.
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.

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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.
Devices for use in area prone to explosion must (from customer's side) be earthed with a shunting
resistor of < 10
6
Ωagainst earth.
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!

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5.52.288.00.01.06
The permissible ambient temperature when operating the devices:
Power unit



DANGER!
It is not allowed:
pulling loose of stuck loads, dragging of loads and inclined pulling is not allowed.
in explosive atmosphere, except the unit is especially modified for it and marked by an indication label
In reactor containment vessels.
to transport people
The device is not suitable for use on stages and in studios
persons must not stand under a suspended load
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.
Take care for a free view on the load.
Only use the hoists appropriately.
The equipment is to be used exclusively for movement of goods. Under no circumstances my persons be
moved.
Never load the devices beyond their working load limit.
Pay attention to the accident prevention regulations (UVV).
Should the hoist be used outside of Germany, please pay attention to the national regulations that apply.
Supporting structures and load-attached devices used in conjunction with this equipment must provide an
adequate safety factor to handle the rated load plus the weight of the equipment. In case of doubt, consult
a structural engineer.
If the equipment has not been used for a period of time, carry out visual checks of all main components
such as chains, load hooks etc. and replace any damaged parts with new, original spare parts before
putting the equipment back into operation!
Device classification for
Not explosive atmosphere Explosive atmosphere
according to ATEX
Manual -20°C/+50°C -20°C/+40°C
Motor -20°C/+40°C -20°C/+40°C
) * Devices in this category have been specially modified and labeled by the manufacturer
DANGER!
The 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.
2.4.1 Winches with disengaging clutch (as option)
Only for pulling out the uncharged wire rope
Only for horizontal load
Only for special kinds of use (i.e. lowering of floaters in liquids) when there is no danger for persons or
danger of damage of material.
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.

5.52.288.00.01.06
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Do not use a hoist that is defective, pay attention to any abnormal noise it makes during operation.
Stop working immediately in case of disturbances and remedy failures.
Any damage and faults must be reported to a responsible supervisor immediately.
If the unit is put into motion, any persons in the immediate vicinity must be informed by calling to them!
Please pay attention to the regulations for load carrying devices UVV for both positive and non-positive
methods of attaching loads.
The lifting tackle or the load must be securely attached to the hook and be seated at the bottom of the
hook.
The safety catch of hooks must be closed.
When charged, the housing may not be in contact somewhere.
Check brakes daily before commencing work.
The devices are not suitable for continuous operation. The duty cycles of the motors (see the technical
data chapter) as well as the remaining life time of the equipment in accordance with FEM group and
usage (see calculation of remaining safe working period) must be observed.
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.

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5.52.288.00.01.06
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.
Ambient temperature -20°C up to +50°C. Power-operated units -20 up to +40°C. Humidity 100 % or less but
not under water
During longer periods of standstill, corrosion may reduce the function of the brake.
DANGER!
It is not permitted to use the unit in an area at risk from explosion!
4.2 Design
HADEF electric 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 by threaded bolts and distance tubes. The rope
drum between the two housing halves offers wire rope exits in several directions. Different installation
positions are possible, - make sure the drum axle is always positioned horizontally.
Available for single phase current or 3-phase current.
Single phase current 3-phase current
4.2.1 Wire rope exit
For winches with ungrooved drum the rope can be winded round the drum in both directions.
In case of changes of the winding direction of the wire rope, electrical wiring must also be changed according
to the wiring diagram.
Winches with grooved rope drum and winches with overload protection (serial equipment for 1000 kg and
up) are supplied with rope exit direction A.
rope exit direction A rope exit direction B
The direction of rope exit for winches with grooved rope drum is determined by the grooves and by the
overload protection, if existant.
Winches from 250 kg capacity and up are optionally available with disengaging clutch. This may be
advantageous in cases where to load is pulled horizontally and afterwards the wire rope should be pulled off
the drum quickly by hand.
NOTICE!
For winches with grooved drum the direction of unwinding the wire rope cannot be changed afterwards.

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4.3 Functions
The lifting gear are operated by pressing the push buttons on the control switch. The spring-pressure brake
installed in the electric motor of the lifting gear prevents the independent lowering of the load after the push
button has been released.
4.4 Important components
Standard 3-phase current motor
Standard AC motor at 125 -2000 kg load capacity.
Gear
▫125 kg worm gear
▫250 - 3200 kg worm gear with additional spur wheel pair
For winches from 1000 kg and up - the sealing screw of the gear must be exchanged before first start up
by the ventilation screw.
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 by current cut-off
▫Serially fitted with electronic overload protection for units of 1000 kg and up.
▫Electronic overload protection for units up to 1000 kg available as option.
The overload protection is adjusted by the manufacturer according to the regulations that apply. The
overload protection prevents lifting a load that is too heavy by switching off the hoisting motor. When putting
the winch into operation or after current of the winch has been cut off or after the overload protection has
operated, press the button "lowering" shortly to re-activate the relay. A re-adjustment i.e. for maintenance
reasons is possible.
Control
▫Low voltage control (direct control depends on the kind of unit)
▫Indirect control with phase sequence relay. The phases must be exchanged if the turning direction is
wrong.
▫Units with limit switch are fitted with low voltage control.
▫Radio control is available as option.
Control switch
▫Control switch suitable for single hand use.
▫The control switch housing is made of shock- and fracture-proof plastic.
▫The control cable is fitted with stress-relief rope (not applicable for radio control).
▫2 step buttons for 2 wire rope speeds
Overheat protection electric motor
Default Optional Electro-EX
- PTO
*
/PTC
**
PTC
**
*
Thermocouple´
**
PTC thermistor with tripping device
Disengaging clutch (as option)
▫Not available for 125 kg capacity.
▫For pulling out the uncharged wire rope.
▫Disengagement operated by hand.
Unintended disengagement or disengagement by standard force effort is not possible under load.

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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 1
DANGER!
The following is not allowed:
Disengaging under load.
Manipulation of the disengaging device.
5 Technical data
3-phase current 400V - 50Hz
Capa
-
city
1st
layer
kg
ire rope
storage
1st
layer
m
ire
rope
speed
1st
layer
m/min
Capa
-
city
top
layer
kg
ire rope
storage
top
layer
m
ire
rope
speed
top
layer
m/min
Rope
layers
number
nec.
wire
rope ø
mm
nec. min.
breaking
load
kN
Mechanism
group
FEM
9.511
Motor
-
output
k
C
urrent
consumption
A
N
oise
emission *
dB(A)
eight
without
wire rope
approx.
kg
125 6 (5) 8 90 32 (30) 11 4 4 5
1Bm
0,37 1,1 78 26
125 6 (5) 16 90 32 (30) 22 4 4 5 0,75 1,9 79 26
125 6 (5) 11 / 2,8 90 32 (30) 15 / 3,8 4 4 5 0,35 /
0,07 1,3 / 0,7 79 26
250 7 (5) 5 180 35 (34) 7 4 4 9 0,37 1,1 78 37
250 7 (5) 10 180 35 (34) 14 4 4 9 0,75 1,9 79 37
250 7 (5) 7 / 1,8 180 35 (34) 9 / 2,2 4 4 9 0,35 /
0,07 1,3 / 0,7 79 37
500 5 (4) 2,5 340 30 (29) 4 4 6 18 0,37 1,1 78 38
500 5 (4) 5 340 30 (29) 8 4 6 18 0,75 1,9 79 38
500 5 (4) 4 / 1 340 30 (29) 5,5 / 1,4 4 6 18 0,35 /
0,07 1,3 / 0,7 79 38
990 8 (6) 4,5 780 30 (29) 6 3 8 36 1,1 3,2 79 80
990 8 (6) 9 780 30 (29) 12 3 8 36 2,2 6 79 80
990 8 (6) 9 / 2,2 780 30 (29) 12 / 3 3 8 36 1,8 /
0,44 5,3 / 2,5 79 80
1000 8 (6) 4,5 780 30 (29) 6 3 8 36 1,1 3,2 79 80
1000 8 (6) 9 780 30 (29) 12 3 8 36 2,2 6 80 80
1000 8 (6) 9 / 2,2 780 30 (29) 12 / 3 3 8 36 1,8 /
0,44 5,3 / 2,5 80 80
2000 8 (6) 4,5 1560 30 (28) 6 3 11 71 2,2 6 80 150
2000 8 (6) 4,5 / 1 1560 30 (28) 6 / 1,5 3 11 71 1,8 /
0,44 5,3 / 2,5 80 150
3200 9 (8) 4,5 2500 37 (36) 5,5 3 16 114 3 7 80 215
3200 9 (8) 4,5 / 1 2500 37 (36) 5,5 / 1,4 3 16 114 3 / 0,8 6,7 / 3,6 80 215

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Alternating current 230V - 50Hz
Capa
-
city
1st
layer
kg
ire rope
storage
1st
layer
m
ire
rope
speed
1st
layer
m/min
Capa
-
city
top
layer
kg
ire rope
storage
top
layer
m
ire
rope
speed
top
layer
m/min
Rope
layers
number
nec.
wire
rope ø
mm
nec. min.
breaking
load
kN
Mechanism
group
FEM
9.511
Motor
-
output
k
Current
consumption
A
Noise
emission *
dB(A)
eight
without
wire rope
approx.
kg
125 6 (5) 7,8 90 32 (30) 11 4 4 5
1Bm
0,37 4 78 28
125 6 (5) 16 90 32 (30) 22 4 4 5 0,75 7,1 78 28
250 7 (5) 5 180 32(30) 7 4 4 9 0,37 4 78 38
250 7 (5) 10 180 32(30) 14 4 4 9 0,75 7,1 78 38
500 5 (4) 2,5 340 30 (29) 4 4 6 18 0,37 4 78 40
500 5 (4) 5 340 30 (29) 8 4 6 18 0,75 7,1 78 40
990 8 (6) 4,5 780 30 (29) 6 3 8 36 1,75 11 79 90
1000 8 (6) 4,5 780 30 (29) 6 3 8 36 1,75 11 79 90
2000 8 (6) 2,3 1560 30(28) 3 3 11 71 1,75 11 79 160
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))
3-phase current motor 400V/50Hz or alternating current motor 230V/50Hz.
IP55 – F – max. 1000 m above sea level.
Order-related Special data, refer to the motor nameplate.
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 fastening – hole measures
Capacity
1st layer
kg
screws
number
anchoring screws
ø D
strength class 8.8
A
mm
B
mm
C
mm
E
mm
125 4 M 8 231 405 205 375
250 4 M 10 290 405 260 375
500 4 M 10 290 405 260 375
990 4 M 12 379 575 345 535
1000 4 M 12 379 575 345 535
2000 4 M 16 480 600 440 550
3200 4 M 16 565 600 525 550
Bild 2

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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
If the winch is fitted with overload protection, the winding direction of the wire rope is determined.
Winding direction "A" is supplied as standard.
When the winding direction is changed, electrical wiring in the terminal box must be changed accordingly.
The kind of wire rope fastening and the winding direction are determined for winches with grooved drum by
the direction of the grooves on the drum.
Before cutting the wire rope, wrap it firmly with a fine binding wire or strong adhesive tape.
6.3.1 125 kg
Fasten the wire rope with countersunk screw
and clamping disc in the hub situated at the
inner side of the big flanged wheel.
In order to avoid any kinks of the wire rope
take into consideration that the wire rope exit is
correct when winding the rope onto the drum.
Illustration 3
6.3.2 250 kg - 3200 kg
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)
and place it back into the key pocket.
Illustration 4
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 5

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13
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 6
NOTICE!
Should the drum be extended and for some models with limit switch, the distance "M" must be increased.
Standard values:
15x 1/2 drum length for standard wire ropes
30x 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
Capacity
kg
"M" min
m
125 0.97
250 1.08
500 1.04
990 1.45
1000 1.45
2000 1.45
3200 1.85
6.6 Tools
Capacity
Size
Tool
Use
125 kg SW6
Rope fastening
Clamp disc
125 kg
250 + 500 kg
990 + 1000 kg
2000 + 3000 kg
SW13
SW17
SW19
SW24
Winch fastening
div. Rope installation
div.

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7 Operation
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 7
Arrow keys = Lifting / Lowering
Illustration 8
System start (optional)
Illustration 9
Push button functions (E)
Relieved push button = stand still
push button half pushed = slow speed
push button pushed completely = fast speed
Illustration 10
Red Emergency-Stop button
button pushed = stand still
turn the button clockwise = free functions
Illustration 11
NOTICE!
Lockable Emergency-Stop buttons must first be opened with the key before unlocking!

5.52.288.00.01.06
15
7.1 Disengaging clutch (as option)
The drum is disengaged through a switch button situated at the gear shaft.
engaged (A)
disengaged (B)
In order to release the switch, pull it out
approx. 10 mm against the pressure of the
spring (1) and turn it 90° to the left, - anti-
clockwise (2).
In this position there is situated a little slot
where a dowel pin engages.
Release the button
The drum is disengaged.
Engage (C)
In order to engage the drum, pull the switch
button out (1) and turn it 90° to the right,
clockwise (3).
Release the button
In this position the dowel pin engages. into the
slot, - make sure that engagement is correct.
The drum is connected to its drive.
Illustration 12
DANGER!
The following is not allowed:
Disengaging under load.
Manipulation of the disengaging device.
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.
When changing the motor turning direction, allow the motor to come to a standstill first.
The prescribed maintenance intervals must be adhered to.
Observe the duty cycle, i.e. intermittent operation S4-40% ED (as per VDE 0530) means that in a period
of 10 minutes the motor can operate – no matter the height of the load – for 4 minutes. It is therefore
irrelevant whether the 4 minutes are continuous (i.e., in case of very high lifting heights) or are made in
intervals.
DANGER!
It is not allowed:
pulling loose of stuck loads, dragging of loads and inclined pulling is not allowed.
in explosive atmosphere, except the unit is especially modified for it and marked by an indication label
In reactor containment vessels.
to transport people
The device is not suitable for use on stages and in studios
persons must not stand under a suspended load

16
5.52.288.00.01.06
9 Commissioning
9.1 General
Should the unit be used in Germany:
Please observe the validated, national accident prevention regulations.
For other countries:
Inspections as above. Please observe the national rules and regulations and the instructions in this manual!
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).
9.2 Power supply
9.2.1 Mains connection
Hoist motor technical data can be found it in the "Technical data" chapter.
The following tables show the assignment of the fuses.
Select connection cross-sections as per VDE 0100.
Put sleeves on the ends of the cables.
Insert the connection cable into the connection plug without strain.
Secure lines as per VDE 0100.
9.2.2 Control line connection
Pendant with cable and plug-in connection. Plug-in before use.
Any changes of the power supply cable must only be effected by qualified personnel.
9.2.3 Power connection of the brake
The low-maintenance D.C. spring-pressure brakes are connected at the factory according to the wiring
diagram.
NOTICE!
The power supply cable must be equipped by the customer with slow-blow fuses and mains connection
switch.
CAUTION!
Precondition for actuation of the overload protection is the correct winding direction of the wire rope!
This may be mixed up for winches with three phase current motor.
The symbols on the control switch than do not match to the wiring direction of the wire rope.
In this case, the winch must be stopped immediately.
Exchange two phases of the main current supply.
Test the winding direction of the wire rope.

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17
9.2.4 Wiring diagram
Wiring diagrams are situated in the terminal box or can be requested from HADEF by metioning of serial
number.
9.2.5 Assignment recommendation of line cross-sections and fuses
Assignment of line cross-sections and fuses must be done acc. to VDE0100.
For total motor output add all motor output data. The technical data of the motors are found in chapter
„Technical Data“ resp.on the motor name plates.
Motor output
up to
k
Fuse
Slow-blow
A
Start up
-
/
Nominal current
Ia / In
Line cross section (mm²) for line length L (m)
L < 50 50 < L < 100 100 < L < 150
1,1
10
3-7- times
1,5 2,5 4
2,2
16
4
20
2,5
4
6
5,5
35
4
10
12
50
6
10
NOTICE!
The values listed in the table refer to 400V/50 Hz three-phase current and are recommendations.
The exact determination of the supply line must be carried out on site by a specialist.
Alternating current design
Motor output
k
Fuse
Slow-blow
A
Start up
-
/
Nominal current
Ia / In
Line cross section (mm²) for line length L (m)
L < 50 50 < L < 100 100 < L < 150
0,55
10
3-7fach
1,5
- -
2,2
16
2,5
NOTICE!
The values listed in the table refer to 230V/50 Hz alternating current current and are recommendations.
The exact determination of the supply line must be carried out on site by a specialist.
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.

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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.
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 the 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.

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19
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.
12.2 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
12.3 Brake motor
Brake: 180 V DC
inch
Capacity
kg
Motor
Nominal brake
moment
Nm
Nominal air gap
mm
air gap
max.
mm
min.
mm
125
-
500
3 phase current
5
0.2
0.4
1,5 friction lining
thickness
1000
3 phase current
15
0.3
0.45
1,5 friction lining
thickness
2000
3 phase current
26
0.3
0.45
1,5 friction lining
thickness
3200
3 phase
current
32
0.3
0.7
8,0 rotor strength
125
-
500
Alternating current
5
0.2
0.8
7,5 rotor strength
1000
-
2000
Alternating current
16
0.2
0.5
7,5 rotor strength
12.3.1 Assembling the brake
1 Insert the retaining ring (1) into the shaft slot.
2 Insert the feather key (2) into the motor shaft.
3 Fix hub (3) with retaining ring (1).
4 Assemble the friction plate (4) if existent.
5 Push the rotor (5) onto the hub (3).
6 Lock the magnet body with the 3 fastening
screws (6).
7 Set air gap “a” (refer to “adjusting the air gap”)
8 Assemble the dust-protection ring (7) if
existent.
9Electric connection
Illustration 13
12.3.2 Disassembly of the brake
Disassembly is performed in reverse order to the assembly.

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12.3.3 Adjusting the air gap
View "X" on the brake.
1 Loosen the locking screws (6) by half a turn.
2 Turn the cap screws (8) into the magnetic body
(9) anti-clockwise.
3 By turning the locking screws (6) clockwise,
move the magnetic body (9) towards the
anchor plate (10) using a feeler gauge until
nominal air gap “a” is reached (see table).
4 Unscrew the cap screws (8) from the magnetic
body clockwise.
5 Tighten the locking screws (6).
6 Check the air gap again and re-adjust if
necessary.
Illustration 14
12.4 Overload protection
If the hoist does not lift the permitted load, the overload protection must be adjusted. Adjustment may only be
done by a service company, authorised by the manufacturer!
DANGER!
The factory setting of the overload protection is secured by a seal. Any guarantee becomes invalid if this setting is
changed. Should maintenance be necessary, please contact a service company that is authorised by the
manufacturer.
Depending on the type of hoist, the following variants are possible:
12.4.1 Electronic hoisting power limiter (as option, except serial AT)
Power consumption of the hoist motor is measured during lifting movement of a load
by an adjustable power measuring device (overload guard). The setting is made via a
separate relay for main and creep lifting speed. Power consumption of the motor is
load-dependent and increases with the load. If the set value is exceeded, the relay
responds immediately and switches the motor off via switching elements. After the
overload protection has been activated the LOWER button must be pressed first so
that the LIFT function can be activated again. Before lifting again the load must be
reduced to the nominal load!
Illustration 15
12.5 Limit switch for wire rope path (as option)
12.5.1 Setting of the switching points
At first, adjust the cams for "lowering". Therefore lower the load to its lowest end position and adjust the
cams. The number of switching cams can vary job-oriented.
1 Unscrew the screws of the cover and remove
the cover.
2 Loosen the central screw (1)
3 Set the switching point of every cam disc
(A,B…and possibly other) with set screw
(2A,2B…and possibly other).
4 Tighten the central screw (1) again.
5 Install the cover again and make sure the
rubber seal is placed correctly.
Illustration 16