HADEF 45/10E Assembly instructions

2 5.52.262.00.01.08
NOTICE!
The installation or mounting instructions for incomplete machines you’ll find in chapter “Installation”
©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..........................................................................................7
4.1Areas of application ..........................................................................................................7
4.2Design.................................................................................................................................8
4.3Functions............................................................................................................................8
4.4Important components......................................................................................................8
4.5Gearing...............................................................................................................................8
5Technical data...................................................................................10
6Installation.........................................................................................10
6.1Winch assembly...............................................................................................................11
6.2Selection of wire ropes ...................................................................................................11
6.3Wire rope fastening.........................................................................................................11
6.4Winding up of wire rope..................................................................................................12
6.5Wire rope deflection........................................................................................................13
6.6Tools.................................................................................................................................13
7Operation...........................................................................................14
8Operation...........................................................................................15
9Commissioning.................................................................................15
9.1General .............................................................................................................................15
9.2Power supply ...................................................................................................................15
9.3Gear...................................................................................................................................16

5.52.262.00.01.08 3
9.4Wire rope..........................................................................................................................16
9.5Limit switch for wire rope path (as option)................................................................... 17
9.6Slack rope switch (as option).........................................................................................17
9.7Pressure roller (as option)..............................................................................................17
9.8Rope guiding device (Optional) .....................................................................................17
10Safety check ..................................................................................... 17
11Functional test.................................................................................. 17
11.1Checks before the initial start-up...................................................................................17
12Maintenance...................................................................................... 17
12.1General.............................................................................................................................18
12.2Monitoring........................................................................................................................18
12.3Brake motor .....................................................................Fehler! Textmarke nicht definiert.
12.4Overload protection ........................................................................................................18
12.5Limit switch for wire rope path (as option)................................................................... 18
12.6Pressure roller (as option)..............................................................................................19
12.7Slack rope switch (as option).........................................................................................19
12.8Rope guiding device (Optional) .....................................................................................20
13Inspection ......................................................................................... 21
13.1General Overhaul for motor-driven units......................................................................21
13.2Periodic checks...............................................................................................................21
13.3Wire rope..........................................................................................................................21
13.4Inspection intervals.........................................................................................................22
14Service............................................................................................... 22
14.1Wire rope..........................................................................................................................22
14.2Gear ..................................................................................................................................22
14.3Hoist gear.........................................................................................................................22
14.4Rope guiding device .......................................................................................................23
14.5Electric motor ..................................................................................................................24
14.6Lubricant selection .........................................................................................................24
14.7Lubricant for food industry – selection (as option*).................................................... 24
15Trouble .............................................................................................. 24
16Remedy ............................................................................................. 25
17Decommissioning ............................................................................ 26
17.1Temporary decommissioning ........................................................................................ 26
17.2Final decommissioning/disposal...................................................................................26
18Additional documents...................................................................... 26
18.1Electric wiring diagrams.................................................................................................26
18.2Radio control (as option)................................................................................................26
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.

8
4.
H
ha
St
S
G
r
4.
F
du
Th
F
Wi
In
to
F
4.
Th
in
bu
4.

4.

A
re
p
th

Fu
It i
2
Des
A
DEF electri
ve been de
a
ble frame fi
e
rial winch w
i
ooved drum
2
.1 Wire
o
r winches w
ring assem
b
e wire rope
f
o
r winches w
i
nding directi
case of cha
t
he wiring di
NO
o
r winches w
i
3
Fun
e lifting gea
r
s
talled in the
tton has be
4
Imp
Standard 3
5
Gea
Planetary g
NOT
s
standard,
p
lace the pl
e
ventilation
Limit switc
▫Serial w
▫Pulling
nction: Ope
s
possible t
i
gn
c
wire rope
w
v
eloped for s
t
t
ted with as
s
i
th ungroove
as option.
rope exit
i
th ungroov
e
b
ly in nearly
a
f
eed out dir
e
i
th grooved
d
on "A" is su
p
n
ges of the
w
a
gram.
T
ICE!
i
th grooved
d
c
tions
r
are operat
e
electric mo
t
e
n released.
o
rtant com
-
phase curr
e
r
ing
ear
I
CE!
t
he gear is
f
u
g screw by
a
s
crew is alr
e
h
i
nch is a lifti
n
w
inch as opti
r
ational and
e
o
connect an
w
inches Typ
t
ationary us
s
embly hole
d drum.
e
d drum and
a
ll directions
e
ction is det
e
d
rum, the wi
p
plied as sta
w
inding dire
c
d
rum the dir
e
d by pressi
t
or of the lift
i
ponents
e
nt motor
f
illed with oi
a
ventilation
e
ady assem
n
g winch.
on.
e
mergency l
external ele
e
45/10 E
e
.
s
.
winches wit
.
rmined for
n
ding directi
ndard.
c
tion of the
w
Wire r
o
e
ction of un
n
g the push
ng gear pre
l
. For trans
screw (atta
b
led.
imit switch.
ctric limit sw
h
out overloa
w
inches with
o
n of the wir
w
ire rope, ele
o
pe exit
w
inding the
buttons on
v
ents the in
p
ort reason
c
hed) before
w
itch.
d
protection,
overload pr
o
e
rope is giv
ctrical wirin
w
ire rope ca
n
t
he control
d
ependent l
o
s
, a plug sc
r
putting the
u
the wire ro
p
o
tection.
e
n by the gr
o
g
must also
not be chan
g
s
witch. The
s
o
wering of t
h
r
ew is fitted
u
nit into ope
r
5.52.262
p
e exit can b
o
oves on th
b
e changed
ged afterwa
s
pring-press
h
e load after
for some
r
ation. In oth
.00.01.08
e chosen
e
drum.
a
ccording
r
ds.
u
re brake
the push
w
inches -
e
r cases

5.52.262.00.01.08 9
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
Phase sequence monitoring relay
All devices with low voltage control are equipped with a phase sequence and phase failure monitoring relay
as a standard. This will prevent incorrect phase sequence when connecting to the mains supply and will
switch off the device if phase failure occurs. In addition, all devices with low voltage control are equipped
with thermal sensors to protect the lifting motor and end switches for lifting/lowering as a standard.
Overheat protection electric motor
Default Optional Electro-EX
PTO
*
PTC
**
PTC
**
Thermocouple´ PTC thermistor wi h tripping device
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
Slack rope switch (as option)
Avoids slack rope when the rope is uncharged
Illustration 2
Rope guiding device (Optional)
The type mentioned in these instructions serves as example. Other versions are possible.
For correct positioning of the wire rope on the
rope drum.
An automatic stopping mechanism (limit switch)
for the winch is installed, in case of tearing of one
of the roller chains.
Illustration 3

10 5.52.262.00.01.08
5 Technical data
FEM 9.511 group – 1Bm
Wire rope speed Rope layers
Capacity
1 kg 2000 3200 4000 5000 6300 8000 10000 12500 16000 20000
2 kg 1750 2800 3500 4400 5500 7050 8800 11000 14000 17500
3 kg 1550 2500 3100 3900 4950 6300 7800 9900 12500 15500
4 kg 1400 2250 2800 3600 4450 5700 7100 9000 11400 14000
5 kg 1300 2050 2500 3200 4050 5200 6500 8200 10400 13000
Wire rope Ø mm 10 12 13 14 16 18 20 22 25 28
nec. min. breaking load kN 71 114 142 178 224 284 355 444 568 710
Wire rope storage
1 m 20 23 22 25 20 22 22 22 22 22
2 m 45 52 49 55 52 50 50 52 47 50
3 m 72 84 80 88 84 84 84 87 84 84
4 m 103 120 112 126 120 120 120 122 120 120
5 m 135 160 150 165 155 155 155 160 160 160
Wire rope speed
I 1 m/min 3,5/14 2/9 1,5/6 1/5 ¼ 1/3,5 0,7/2,5 0,6/2,2 0,5/1,8 ---
II m/min 5,5/23 3/12,5 2,5/11 2/8 1,7/7 1,3/5,5 ¼ 0,8/3,5 0,6/2,5 0,5/2,1
III m/min 8,5/35 4,5/19 3,5/14 3/12 2,5/10 1,9/7,5 1,5/6 1,2/4,5 0,9/3,5 0,8/3
I 2 m/min 4/16 2,5/10 2/7,5 1,5/5,5 1/5 1/4 0,8/3 0,6/2,5 0,5/2 ---
II m/min 6/27 3,5/14,5 3/12,5 2/9 1,9/7,5 1,5/6 1,2/5 1/4 0,7/2,8 0,6/2,4
III m/min 9,5/40 5/22 4/16,5 3,5/14,5 3/11 2/8,5 1,7/6,5 1,3/5 1/3,9 0,8/3,4
I 3 m/min 4,5/18 2,5/11,5 2/8,5 1,5/6,5 1,5/5,5 1,1/4,5 0,9/3,5 0,7/2,8 0,6/2,3 ---
II m/min 7/30 4/16 3,5/14 2,5/10 2/8,5 1,7/7 1,3/5,5 1,1/4,5 0,8/3,2 0,6/2,7
III m/min 11/44,5 5,5/24,5 4,5/18,5 4/16 3/12,5 2/9,5 1,9/7,5 1,5/6 1,1/4,4 0,9/3,8
I 4 m/min 5/20 3/12,5 2/9,5 1,8/7,3 1,5/6,5 1,2/5 1/4 0,8/3 0,6/2,5 ---
II m/min 8/33 4,5/18 3,8/15 2,5/11 2,5/9,5 1,8/7,5 1,5/6 1,2/5 0,8/3,5 0,7/2,9
III m/min 12/49,5 6/27 5/20 4,5/18 3,5/14 2,5/10,5 2,1/8 1,7/6,5 1,2/4,9 1/4,2
I 5 m/min 5,5/22 3,5/14 2,5/10 2/7,5 2/7 1,4/5,5 1,1/4,3 0,9/3,5 0,7/2,8 ---
II m/min 8,5/36,5 5/20 4/16,5 3/12,5 2,5/10,5 2/8 1,6/6,5 1,3/5,4 1,9/3,8 0,8/3,2
III m/min
13,5/54,5 7/30 5,5/22 5/19,5 4/15,5 2,5/11,5 2,3/9 1,8/7 1,385,3 1,1/4,6
Motor output I kW 1,4/5,5 1,4/5,5 1,4/5,5 1,4/5,5 1,4/5,5 1,4/5,5 1,4/5,5 1,4/5,5 1,4/5,5 --- II kW 2,2/9 2,2/9 2,2/9 2,2/9 2,2/9 2,2/9 2,2/9 2,2/9 2,2/9 2,2/9
III kW 2,5/12 2,5/12 2,5/12 2,5/12 2,5/12 2,5/12 2,5/12 2,5/12 2,5/12 2,5/12
Current consumption I A 5,6/12,5 5,6/12,5 5,6/12,5 5,6/12,5 5,6/12,5 5,6/12,5 5,6/12,5 5,6/12,5 5,6/12,5 --- II A 7,5/21
7,5/21 7,5/21 7,5/21 7,5/21 7,5/21 7,5/21 7,5/21 7,5/21 7,5/21
III A 9/28 9/28 9/28 9/28 9/28 9/28 9/28 9/28 9/28 9/28
Noise emissionl* max. approx. dB(A) 70 70 70 70 70 70 70 70 70 70
Weight without rope approx. I kg 260 305 310 415 455 685 700 815 1210 ---
II kg 300 345 400 450 495 725 740 855 1250 1320
III kg 365 410 415 515 555 785 810 915 1320 1390
*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 - 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.

12
F
P
P
W
an
B
st
sa
It
litt
ro
p
Th
fo
F



F



D
ro
u
S
6.
Th
th
A
ch
a
stening wit
h
u
sh the wire
wheel and
u
ll some cen
r
ap it compl
d place it ba
y
pulling the
u
ck into the
f
ely.
m
ay be nec
e
l
e bit into th
p
e can be lo
e retainer k
r
winches su
p
a
stening wit
h
Push the w
flanged wh
plates (1).
Pull some
c
plate.
Fasten the
a
stening wit
h
Push the w
(1).
Pull some
c
plate.
Fasten the
e
pending on
u
nd the dru
e
e chapter "I
n
4
Win
e wire rope
e
flanged wh
NO
c
cording to
o
sen so tha
h
retainer k
e
r
ope throug
h
t
hrough the
k
t
imeters out.
e
tely round t
h
ck into the k
w
ire rope, th
e
p
ocket. This
e
ssary to ins
e
e
hub with a
s
a
ded.
e
y is attache
d
p
plied witho
u
h
clamping
i
re rope thro
u
e
el and pus
h
c
entimeters
o
s
crews and
f
h
clamping
i
re rope und
e
c
entimeters
o
s
crews and
f
the directio
n
m
there are t
w
n
stallation".
d
ing up of
must alway
s
eel must ex
c
T
ICE!
v
alidated re
g
t
at least 2 r
o
e
y
h
the hub of
t
k
ey pocket.
h
e retainer k
ey pocket.
e
retainer k
locks the wi
r
e
rt the retain
s
oft tool bef
d
to the con
s
u
t wire rope.
plates on t
u
gh the hub
h
it under all
o
ut at the las
f
ix the rope
plates on t
e
r all 3 clam
p
o
ut at the las
f
ix the rope
n
the rope is
w
o wire rop
e
wire rope
s
be winded
c
eed the top
g
ulations a
o
pe layers re
t
he flanged
e
y (1)
e
y (1) gets
r
e rope
er key a
o
re the wire
s
ignment
h
e flanged
w
of the
3
clamping
t clamping
h
erewith.
h
e flanged
w
p
ing plates
t clamping
h
erewith.
w
inded
exits.
up tensione
d
layer by at l
e
n
d accident
main on the
Illust
Illust
w
heel
Illust
w
heel
Illust
Illust
d
. When the
e
ast 1 1/2 ti
prevention
drum when
r
ation 5
r
ation 6
r
ation 7
r
ation 8
r
ation 9
last wire ro
p
m
es of the w
regulations,
t
he wire rop
e
p
e layer is
w
ire rope dia
m
the wire r
e
is unwinde
5.52.262
w
inded onto
m
eter.
o
pe length
d.
.00.01.08
t
he drum,
m
ust be

5.52.262.00.01.08 13
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 10
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. at
4 wirerope
deflection
m
2000 4
3200 4,6
4000 4,4
5000 4,6
6300 4,6
8000-20000 4,5
6.6 Tools
Capacity Size Tool Use
2000-4000 kg
5000-6300 kg
8000-12500 kg
16000+20000 kg
SW19
SW24
SW32
SW36
Winch fastening
2000-20000 kg div. Rope installation
2000-20000 kg div. div.
2000-20000 kg div. div.
2000-20000 kg div. div.

14 5.52.262.00.01.08
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.
The shown control switches are only for the optical information. They can be different acc. the delivery.
Pendant control lifting/lowering
direct control
1 Emergency-Stop
2 Lifting (slow - fast)
3 Lowering (slow - fast)
Illustration 11
Pendant control – lifting/lowering
1 Emergency stop
2 Lifting (slow - fast)
3 Lowering (slow - fast)
Illustration 12
Radio control
1 Lowering (slow - fast)
2 Lifting (slow - fast)
3 no function
4 no function
5 no function
5 no function
6 no function
7 no function
8 start
9 start
10 emergency stop
Illustration 13
Push button functions
Relieved push button = stand still
push button half pushed = slow speed
push button pushed completely = fast speed
Illustration 14
Red Emergency-Stop button
button pushed = stand still
turn the button clockwise = free functions
Illustration 15

5.52.262.00.01.08 17
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.
9.7 Pressure roller (as option)
Before putting the winch into operation and after maintenance work, as well as according to necessity, check
the device in order to guarantee the correct functions of the pressure roller.
9.8 Rope guiding device (Optional)
Check correct wire rope guidance before putting the winch into operation and after any maintenance work.
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

5.52.262.00.01.08 19
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 17
Make sure that 2-3 rope layers remain on the
drum in the lowest load position.
Adjustment for "lifting" is done analogous.
Afterwards drive carefully to the end positions to
check correct adjustment.
Illustration 18
Pictures may differ from the actual design.
12.6 Pressure roller (as option)
Adjustment
Release the screw (1)
Turn the square (2) as far until the pressure
roller puts enough pressure on the wire rope.
Hold the square and tighten the screw (1)
again.
Illustration 19
12.7 Slack rope switch (as option)
12.7.1 Adjustment
Illustration - horizontally
Other versions are possible.
Insert the wire rope (1) under the guiding
pulley (4) and tighten it by the load.
Release the locking screw at the eccentric (6).
Turn the eccentric until it gets contact to the
tappet of the limit switch (3).
Secure the eccentric (6) with the locking screw.
Switch on the winch in direction "Lowering"
and relieve the wire rope (1).
Repeat this procedure if necessary until the
best switching point is found.
1 wire rope
2 rope drum
3 Spindle limit switch
4 Guiding pulleys
5 roller lever
6 eccentric
7 switching shaft
Illustration 20
NOTICE!
Connection is, normally, effected in our factory, it is shown in the diagram.