HADEF 46/21E User manual

Rev.13
5.52.262.00.01.13
Electric Wire Rope Winch
45/10E + 46/21E
Installation, Operating and
Maintenance Instructions

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5.52.262.00.01.13
NOTICE!
The installation or mounting instructions for incomplete machines you’ll find in chapter “Installation”.
o
by Heinrich de Fries GmbH
Heinrich de Fries GmbH, Gauss Str. 20, D-40235 Düsseldorf
Heinrich De Fries GmbH will be named HADEF in the following text.
Original operating- and maintenance instructions in German language.
Translation in other languages is made of the German original.
A copy may be requested in writing or is available for download on www.hadef.com
Subject to changes.
Table of Contents
1Information..........................................................................................3
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
3Transport and Storage .......................................................................7
3.1 Transport............................................................................................................................7
3.2 Safety device for transport ...............................................................................................7
3.3 Storage ...............................................................................................................................7
4Description..........................................................................................7
4.1 Areas of application ..........................................................................................................7
4.2 Design.................................................................................................................................8
4.3 Functions............................................................................................................................8
4.4 Important components......................................................................................................8
5Technical data...................................................................................11
6Installation.........................................................................................11
6.1 Winch assembly...............................................................................................................12
6.2 Selection of wire ropes ...................................................................................................12
6.3 Wire rope fastening.........................................................................................................13
6.4 Winding up of wire rope..................................................................................................14
6.5 Wire rope deflection........................................................................................................14
6.6 Toolls................................................................................................................................15
7Control...............................................................................................15
8Operation...........................................................................................16
9Commissioning.................................................................................17
9.1 General .............................................................................................................................17
9.2 Power supply ...................................................................................................................17
9.3 Gear...................................................................................................................................18
9.4 Wire rope..........................................................................................................................18
9.5 Limit switch for wire rope path (as option) ...................................................................19
9.6 Slack rope switch (as option).........................................................................................19
9.7 Pressure roller (as option)..............................................................................................19
9.8 Rope guiding device (Optional)......................................................................................19

5.52.262.00.01.13
3
10 Safety check ..................................................................................... 19
11 Functional test.................................................................................. 19
11.1 Checks before the initial start-up................................................................................... 19
12 Maintenance...................................................................................... 20
12.1 General.............................................................................................................................20
12.2 Monitoring........................................................................................................................ 20
12.3 Brake motor .....................................................................................................................20
12.4 Overload protection ........................................................................................................ 20
12.5 Limit switch for wire rope path (as option)...................................................................21
12.6 Pressure roller (as option)..............................................................................................21
12.7 Slack rope switch (as option).........................................................................................21
12.8 Rope guiding device (Optional) ..................................................................................... 22
13 Inspection ......................................................................................... 23
13.1 General Overhaul for motor-driven units......................................................................23
13.2 Periodic checks...............................................................................................................23
13.3 Wire rope..........................................................................................................................23
13.4 Gearbox oil level..............................................................................................................23
13.5 Inspection intervals.........................................................................................................24
14 Service............................................................................................... 24
14.1 Wire rope..........................................................................................................................24
14.2 Hoist gear.........................................................................................................................24
14.3 Rope guiding device .......................................................................................................25
14.4 Disengaging clutch .........................................................................................................25
14.5 Electric motor ..................................................................................................................26
14.6 Lubricant selection ......................................................................................................... 26
14.7 Lubricant for food industry –selection (as option*).................................................... 26
15 Trouble .............................................................................................. 26
16 Remedy ............................................................................................. 27
17 Decommissioning ............................................................................ 28
17.1 Temporary decommissioning ........................................................................................ 28
17.2 Final decommissioning/disposal...................................................................................28
18 Additional documents...................................................................... 28
18.1 Electric wiring diagrams.................................................................................................28
18.2 Radio control (as option)................................................................................................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 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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5.52.262.00.01.13
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.
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.

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5
Complete the operating and installation instructions by any instructions (regarding supervision or
notifications)that are important for the special kind of use of the equipment, i.e. regarding organization of
work, work flow and human resources.
In particular, the owner/user must ensure that:

The unit is only used appropriately.

The device is only operated in a fault-free, fully functional condition, and the safety components, in
particular, are checked regularly to ensure that it is functioning properly.

The required personal protective equipment for the operators, service and repair personnel is available
and is used.

The operating instructions are always available at the location where the equipment is used and that they
are legible and complete.

The unit is only operated, serviced and repaired by qualified and authorized personnel.

This personnel is regularly trained in all applicable matters regarding safety at work and environmental
protection, and that they are familiar with the operating manual and, in particular, the safety instructions it
contains.

Any safety and warning signs on the devices are not removed and remain legible.

customers equipment at site must comply with currently applicable ATEX-regulations
WARNING!
It is not allowed to make constructive changes of the equipment!
2.3 Requirements for the operating personnel
The units may only be operated by qualified persons that are appropriately trained and that are familiar with
it. They must have their employer’s authorization for operation of the units.
Before starting work, the operating personnel must have read the operating and installation instructions,
especially the chapter "Safety Instructions".
This is especially important for operating personnel that rarely uses the equipment, i.e. for installation or
maintenance work.
DANGER!
In order to avoid severe injury, please pay attention to the following when using the equipment:
Use protective clothes/equipment.
Do not wear long hair hanging down open.
Do not wear rings or other jewelry.
Do not wear clothes that are too big/wide.
Do not reach into ropes, chains, drive parts or other moving parts with your hands
2.4 Appropriate use
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.
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

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5.52.262.00.01.13
DANGER!
The ambient temperature range must not be exceeded!
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 as intended, safe operation is not guaranteed.
The operator alone is responsible for all personal injury and damage to property resulting from improper
use.
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.

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.

5.52.262.00.01.13
7
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!
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

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5.52.262.00.01.13
4.2 Design
HADEF electric wire rope winches Type 45/10 E + 46/21 E + 95/18 E EX + 96/21 E EX have been developed
for stationary use.
Serial winch with ungrooved drum. Grooved drum as option.
Type 45/10 E + 95/18 E EX
with torsion-free base frame
Type 46/21 E + 96/21 E EX
without base frame
4.2.1 Wire rope exit direction
For winches with ungrooved drum and winches without overload protection, the wire rope exit can be chosen
during assembly in nearly all directions.
The wire rope feed out direction is determined for winches with overload protection.
For winches with grooved drum, the winding direction of the wire rope is given by the grooves on the drum.
Winding direction "A" is supplied as standard.
In case of changes of the winding direction of the wire rope, electrical wiring must also be changed according
to the wiring diagram.
Wire rope exit
NOTICE!
For winches with grooved drum the direction of unwinding the wire rope cannot be changed afterwards.
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

Planetary gear
NOTICE!
As standard, the gear is filled with oil. For transport reasons, a plug screw is fitted for some winches -
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 by current cut-off
▫Serially fitted with electronic overload protection for units of 1000 kg and up.

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▫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.
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
▫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 with 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

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5.52.262.00.01.13

Disengaging clutch
The disengaging clutch separates the winch drum
from the gear in order to pull off the uncharged
wire rope.
Illustration 4
DANGER!
Disengaging of the drum may never be effected under load and/or when current is on!
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. 5
A

5.52.262.00.01.13
11
5 Technical data
FEM 9.511 group –1Bm
Wire rope speed
Rope layers
Capacity
1
kg
500
990/
1000
2000
3200
4000
5000
6300
8000
10000
12500
16000
20000
2
kg
440
880
1750
2800
3500
4400
5500
7050
8800
11000
14000
17500
3
kg
390
790
1550
2500
3100
3900
4950
6300
7800
9900
12500
15500
4
kg
360
710
1400
2250
2800
3600
4450
5700
7100
9000
11400
14000
5
kg
330
650
1300
2050
2500
3200
4050
5200
6500
8200
10400
13000
Wire rope Ø
mm
6
8
10
12
13
14
16
18
20
22
25
28
nec. min. breaking
load
kN
17
35
71
114
142
178
224
284
355
444
568
710
Wire rope storage
(for ungrooved drum)
1
m
27
25
20
23
22
25
20
22
22
22
22
22
2
m
58
56
45
52
49
55
52
50
50
52
47
50
3
m
94
90
72
84
80
88
84
84
84
87
84
84
4
m
132
128
103
120
112
126
120
120
120
122
120
120
5
m
175
169
135
160
150
165
155
155
155
160
160
160
Wire rope speed
I
1
m/min
2,7 / 0,7
3,5 / 0,9
14 / 3,5
9 / 2,2
6 / 1,5
5 / 1,2
4 / 1
3,5 / 0,9
2,5 / 0,7
2,5 / 0,6
2 / 0,5
---
II
m/min
6,2 / 1,6
8,0 / 2,0
23 / 5,5
12 / 3
11 / 2,5
8 / 2
7 / 1,7
5,5 / 1,3
4 / 1
3,5 / 0,9
2,5 / 0,6
2 / 0,5
III
m/min
18 / 4,6
19 / 5,0
35 / 8,5
19 / 4,5
14 / 3,5
12 / 3
10 / 2,5
7,5 / 1,9
6 / 1,5
5 / 1,2
3,5 / 0,9
3 / 0,8
I
2
m/min
3,1 / 0,8
3,9 / 1,0
16 / 4
10 / 2,5
7 / 1,7
6 / 1,5
5 / 1,2
4 / 1
3 / 0,8
2,7 / 0,6
2,2 / 0,5
---
II
m/min
7,0 / 1,8
9,0 / 2,3
26 / 6,5
14 / 3,4
12 / 3
9 / 2,2
8 / 2
8 / 2
5 / 1,7
4 / 1
2,8 / 0,7
2,3 / 0,6
III
m/min
20 / 5,2
22 / 5,6
10 / 40
22 / 5,5
16 / 4
14 / 3,5
12 / 3
9 / 2,2
7 / 2,3
6 / 1,5
3,8 / 0,9
3,3 / 0,8
I
3
m/min
3,4 / 0,9
4,4 / 1,1
18 / 4,5
12 / 3
8 / 2
6,5 / 1,6
5,5 / 1,4
4,5 / 1,1
3,5 / 0,9
3 / 0,7
2,5 / 0,6
---
II
m/min
7,8 / 1,9
10 / 2,5
30 / 7,5
16 / 4
14 / 3,5
10 / 2,5
8,5 / 2,1
6,5 / 1,6
5,5 / 1,3
4,5 / 1,1
3,2 / 0,8
2,7 / 0,7
III
m/min
23 / 5,7
25 / 6,2
44 / 11
24 / 6
18 / 4,5
16 / 4
13 / 3,2
10 / 2,5
7,5 / 1,8
6,5 / 1,6
4,2 / 1
3,7 / 0,9
I
4
m/min
3,7 / 0,9
4,9 / 1,2
20 / 5
13 / 3,2
9 / 2,2
7 / 1,7
6 / 1,5
5 / 1,2
4 / 1
3,2 / 0,8
2,7 / 0,6
---
II
m/min
8,6 / 2,1
11 / 2,8
32 / 8
18 / 4,5
15 / 3,7
11 / 2,7
9 / 2,2
7 / 1,7
6 / 1,5
5 / 1,2
3,6 / 0,9
3,1 / 0,8
III
m/min
25 / 6,3
27 / 6,9
50 / 12,5
28 / 7
20 / 5
18 / 4,5
14 / 3,5
11 / 2,7
8 / 2
7 / 1,7
4,6 / 1,1
4,1 / 1
I
5
m/min
4,1 / 1,0
5,3 / 1,3
22 / 5,5
14 / 3,5
10 / 2,5
8 / 2
7 / 1,7
5,5 / 1,3
4,5 / 1,1
3,5 / 0,9
3 / 0,8
---
II
m/min
9,4 / 2,3
12 / 3,0
36 / 9
20 / 5
16 / 4
12 / 3
10 / 2,5
8 / 2
7 / 1,7
5,5 / 1,3
4 / 1
3,5 / 0,9
III
m/min
27 / 6,9
30 / 7,5
54 / 13,5
30 / 7,5
22 / 5,5
20 / 5
16 / 4
12 / 2,5
9 / 2,3
7,5 / 1,8
5 / 1,2
4,5 / 1,1
Motor output
I
kW
0,9/0,2
0,9/0,2
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
5,5/1,4
---
II
kW
0,9/0,2
1,8/0,4
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
9/2,2
III
kW
1,8/0,4
4,0/1,1
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
12/2,5
Current consumption
I
A
2,3/1,1
2,3/1,1
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
12,5/5,6
---
II
A
2,3/1,1
5,3/2,5
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
21/7,5
III
A
5,3/2,5
10/6
28/9
28/9
28/9
28/9
28/9
28/9
28/9
28/9
28/9
28/9
Noise emissionl* max.
approx.
dB(A)
70
70
70
70
70
70
70
70
70
70
70
70
Weight without rope
approx.
Type 45/10E
I
kg
300
300
280
320
330
450
490
690
710
820
1250
---
II
kg
320
320
320
360
370
480
530
730
750
860
1290
1380
III
kg
340
340
380
430
440
550
590
800
810
930
1360
1430
Weight without rope
approx.
Type 46/21E
I
kg
240
240
260
280
280
390
430
600
620
750
---
II
kg
260
260
280
300
300
420
470
640
660
790
III
kg
280
280
300
350
350
490
530
720
740
850
*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.

The winch must always be aligned with the horizontally adjusted drum, regardless of the installation
position

12
5.52.262.00.01.13
6.1 Winch assembly
Type 45/10E
capacity
1st layer
fastening screws
strength class 8.8
Tightening moment
A
B
O
P
Q
R
S
T
kg
øM / Nm
number
mm
mm
mm
mm
mm
mm
mm
2000
M12 / 87
16
1450
544
70
100
700
100
480
56
3200
M12 / 87
16
1450
544
70
100
700
100
480
56
4000
M12 / 87
16
1450
544
70
100
700
100
480
56
5000
M16 / 214
16
1530
620
90
75
700
75
590
70
6300
M16 / 214
16
1530
620
90
75
700
75
590
70
8000
M22 / 530
16
1650
724
100
120
690
220
520
86
10000
M22 / 530
16
1650
724
100
120
690
220
520
86
12500
M22 / 530
16
1650
724
100
120
690
220
520
86
16000
M24 / 670
16
1850
1000
150
200
700
200
600
120
20000
M24 / 670
16
1850
1000
150
200
700
200
600
120
Illustration 6
Type 46/21E
capacity
1st layer
fastening screws
strength class 8.8
Tightening moment
A1
A2
B
O
P
Q1
Q2
R
S
T
kg
ØM / Nm
Qty.
mm
mm
mm
mm
mm
mm
mm
mm
500
M12 / 87
16
646
946
388
73
67
366
666
60
288
20
990 / 1000
M12 / 87
16
646
946
388
73
67
366
666
60
288
20
2000
M12 / 87
16
710
1035
532
73
67
430
755
60
372
20
3200
M12 / 87
16
710
1035
532
73
67
430
755
60
372
20
4000
M12 / 87
16
710
1035
532
73
67
430
755
60
372
20
5000
M16 / 214
16
710
1015
649
68
77
419
724
70
459
25
6300
M16 / 214
16
710
1015
649
68
77
419
724
70
459
25
8000
M22 / 530
16
1033
1333
800
195
100
443
743
140
460
30
10000
M22 / 530
16
1033
1333
800
195
100
443
743
140
460
30
12500
M22 / 530
16
1033
1343
800
195
100
443
753
140
460
30
16000
M24 / 670
16
*)
*)
*)
*)
*)
*)
*)
*)
20000
M24 / 670
16
*)
*)
*)
*)
*)
*)
*)
*)
Illustration 7
1Rope take-up up to 75m 2Rope take-up up to 150m *) not yet fixed at time of going to press
All 16 screws must be assembled all the time.
Acc. order are differences possible.
6.2 Selection of wire 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.

5.52.262.00.01.13
13
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 Wire rope fastening
There are three options to fasten the wire rope.
with retainer key
with clamping plates on the
flanged wheel
with clamping plates on the
drum tube (special model)
Fastening with retainer key
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 8
By pulling the wire rope, the retainer key (1) gets
stuck into the pocket. This 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.
The retainer key is attached to the consignment
for winches supplied without wire rope.
Illustration 9
Fastening with clamping plates on the flanged wheel
Push the wire rope through the hub of the
flanged wheel and push it under all 3 clamping
plates (1).
Pull some centimeters out at the last clamping
plate.
Fasten the screws and fix the rope herewith.
Illustration 10
Fastening with clamping plates on the flanged wheel
Push the wire rope under all 3 clamping plates
(1).
Pull some centimeters out at the last clamping
plate.
Fasten the screws and fix the rope herewith.
Illustration 11

14
5.52.262.00.01.13
Depending on the direction the rope is winded
round the drum there are two wire rope exits.
See chapter "Installation".
Illustration 12
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 13
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
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

5.52.262.00.01.13
15
6.6 Toolls
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 14
Arrow keys = Lifting / Lowering
Illustration 15
System start (optional)
Illustration 16
Push button functions (E)
Relieved push button = stand still
push button half pushed = slow speed
push button pushed completely = fast speed
Illustration 17
Red Emergency-Stop button
button pushed = stand still
turn the button clockwise = free functions
Illustration 18
NOTICE!
Lockable Emergency-Stop buttons must first be opened with the key before unlocking!
Capacity
Size
Tool
Use
2000-4000 kg
5000-6300 kg
8000-12500 kg
16000+20000 kg
SW19
SW24
SW32
SW36
Winch istallation
2000-20000 kg
div.
Rope installation
div.

16
5.52.262.00.01.13
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 19
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!
NOTE!
A minimum weight of approx. 20% of the rated load is necessary for lowering. This value depends on
application and ambient conditions!
Disengaging clutch (optionally)
1 Ratchet lever
2 Clutch lever
Disengage the clutch
Engage the clutch
Illustration 20
Illustration 21
Pull the clutch lever (2) until the ratchet lever
(1) locks.
Lift the ratchet lever (1).
The clutch lever (2) moves by spring tension in
direction "home position".
Move the drum slowly by hand until the clutch
locks completely and can transmit the force.
The clutch is now disengaged the the drum has
free rotation - without contact to the gear.
When the clutch is engaged again, the winch can
be put into operation again.
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.
A

5.52.262.00.01.13
17

Observe the duty cycle, i.e. intermittent operation S3-40% 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!
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).
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.

18
5.52.262.00.01.13
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.
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
kW
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.
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.

5.52.262.00.01.13
19
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.

20
5.52.262.00.01.13
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
Winch speed
Motor output
kW
Brake
Type
Brake
V DC
Nominal brake
moment
Nm
Nominal air gap
mm
Air gap
max.
mm
Min. rotor
strength
mm
I
1,4/5,5
BFK 12
180
32
0,3
0,45
8
II
2,2/9
FD 17
180
60
0,3
0,45
11,5
III
2,5/12
BFK 16
180
80
0,3
0,45
8
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.
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!
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 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 22