Huchez TRBoxter INOX 250 User manual

© 2012 by Huchez Treuils S.A.S.
Electric winch
Electric winches
TRBoxter INOX 250 to 990 kg
Instruction manual_______________________ EN
345-20.18/1

© 2012 by Huchez Treuils S.A.S.
Translation of the original instructions manual 2EN Reproduction prohibited
To ensure the constant improvement of its products,
HUCHEZ reserves the right to change the equipment as described below and, in this case,
to supply products which differ from the illustrations or specifications in this instruction manual.
Contents
1. Conditions of use ................................................................................................................................................ p. 3
2. Safety instructions .............................................................................................................................................. p. 3
3. Warranty............................................................................................................................................................. p. 4
4. Reception of the equipment............................................................................................................................... p. 5
5. Obligatory regulatory checks by the user........................................................................................................... p. 5
6. Presentation of the machines ............................................................................................................................ p. 5
6.1 Technical description
6.2 Operation
6.3 Models available
6.4 Dimensions and fastenings
6.5 Accessories
6.6 FEM classification
6.7 Variable speed drive
7. Handling – Storage ............................................................................................................................................. p. 10
8. Assembly and start-up........................................................................................................................................ p. 10
8.1 Securing the winch
8.2 Wire rope exits
8.3 Change to initial assembly
8.4 Set-up
8.5 Electrical connections
9. Servicing and maintenance................................................................................................................................. p. 19
9.1 Winches
9.2 Ropes
9.3 Hooks
9.4 Brake
10. Taking out of use ................................................................................................................................................ p. 20
11. Spare parts.......................................................................................................................................................... p. 20
12. Operating faults .................................................................................................................................................. p. 21
13. Tests.................................................................................................................................................................... p. 22
14. Declaration of conformity .................................................................................................................................. p. 22
15. Appendices ......................................................................................................................................................... p. 23

© 2012 by Huchez Treuils S.A.S.
Translation of the original instructions manual 3EN Reproduction prohibited
1 - Conditions of use
All users must read the set-up instructions carefully before using the product for the first time. These instructions
should enable the user to familiarise themselves with the winch and use it to its full capacity. The set-up instructions
contain important information about how to use the winch safely and correctly. Compliance with these instructions
helps to avoid danger, reduce repair costs, reduce stoppage time and improve the reliability and service life of the
winch. The instruction manual must always be available in the place where the winch is being used. In addition to the
set-up instructions and regulations concerning the prevention of accidents, the work safety and professional
regulations in force in each country must also be respected.
This equipment is governed by European regulations and more specifically Directive 2006/42/EC on machinery, EMC
Directive 2004/108/EC and LVD 2006/95/EC, as well as the EN 14492/1 standard.
These winches are designed to move loads using a suitable steel rope. They have been designed to perform lifting and
pulling operations within the defined load capacity limit and with safety factor 5 (static against sudden failure).
For use in lifting, the European regulation makes certain equipment obligatory, such as a limit switch system and,
for loads of 1,000 kg or more, a load limiter.
The operator must check the presence of this equipment (available as an option from the manufacturer) before
using the product for lifting purposes.
The capacity indicated on the winch corresponds to the maximum capacity of use (MCU); in no event should this
capacity be exceeded.
THIS WINCH CAN UNDER NO CIRCUMSTANCES BE USED TO LIFT PEOPLE.
Do not begin moving the load until you have attached it correctly and checked that all personnel are outside the
danger zone.
Before use, the operator must always check that the machine, rope, hook, markings and moorings are in good
working order.
The operator must check that the load is attached in such a way that the winch, the rope and the load place neither
the operator nor any other person is in danger.
The winches can be used at ambient temperatures ranging from -10°C to +50°C. Please consult the manufacturer in
the event of extreme conditions of use.
Important: In the event of an ambient temperature below 0°C, the brake must be tested to ensure that there are no
operating faults resulting from the freezing conditions.
The data concerning the heat-resistance of the steel rope and its fastenings must be available on request from the
manufacturer and must be respected.
HUCHEZ cannot accept any liability for the consequences resulting from the use or installation of equipment not
provided for in the present instructions or for the consequences of removal, modification or replacement of original
parts or components with parts or components from other sources without the written agreement of HUCHEZ.
The use of winches requires strict compliance with the accident prevention and safety measures in force in the
country where they are used.
YOU MUST ALSO RESPECT THE REGULATIONS APPLICABLE IN YOUR COUNTRY.
2 – Safety instructions
Before using the equipment, check that there are no causes of overloading such as: adhesion to the ground, suction,
jamming, etc. of the load.
As the operator of the winch, you are responsible for your own safety and the safety of your colleagues in the work
zone of the machine.
The operator must respect all the following safety information, without exception, concerning the handling and
operation of the winch as well as the references to other sections of this instruction manual. Failure to comply with
these instructions increases the level of risk.

© 2012 by Huchez Treuils S.A.S.
Translation of the original instructions manual 4EN Reproduction prohibited
•Only the people designated by the company are authorised to operate the winch
•Before using the winch for the first time, familiarise yourself with its conditions of use. To this end, read the
present instruction manual carefully and in its entirety and perform all the operations described herein one after
the other.
•Inform your departmental manager or the safety officer of any malfunction so that the fault can be repaired
immediately.
•Respect the directives of the industrial accident prevention organisations such as, in France, the Caisse Régionale
d’Assurance Retraite et de la Santé au Travail (C.A.R.S.A.T.) and the Health and Safety Committee (HSC) of your
company, if one exists.
•Scrupulously respect all information in the sections concerning the CONDITIONS OF USE (section §1) and the WORK
ROPE (section §8.5.4).
•The operator(s) must have an unimpeded view of the load.
•Please ensure that the operator is qualified to operate the machine in the conditions provided for in this manual.
This will ensure the safety of both people and the environment.
•Do not lift or transport loads when there are personnel inside the danger zone.
•Do not authorise the personnel to walk under a suspended load.
•Do not leave a load suspended or with the rope taut unsupervised.
In addition to the above instructions, we must warn you against all incorrect use or handling listed below. It is
dangerous and prohibited to:
unwind the drum completely (keep 2 to 3 residual windings).
pull at an angle.
swing the load.
use ropes of a different diameter and texture to those specified in this instruction manual (FEM 1 Am – ISO M4
for 250 and 750 kg, FEM 1 Bm – ISO M3 for500 and 990 kg).
use damaged ropes or ropes with splices.
grab or touch a moving rope or a rotating drum.
use hooks without a latch, which do not correspond to the loads indicated on the winch or which are in poor
condition.
insert objects into moving parts.
work on loaded winches or when the rope is taut.
use the winch rope as a towing chain.
drum on the control box (overheating of the motor and electrical equipment).
Place hands or clothes, etc. in contact with moving parts, in particular the areas where the rope is wound in/out.
3 – Warranty
Our electric winches are guaranteed for 2 years from the date of shipment (ex-works).
The seller undertakes to repair any operating fault resulting from a fault in the design, execution, components or
materials themselves.
The warranty does not cover wear and tear or damage resulting from a lack of regular or periodic maintenance. It does
not cover damage resulting from a lack of supervision, incorrect handling or an incorrect use of the machines, in
particular overloading, pulling at an angle, under or overvoltage or incorrect connection.
The warranty does not apply to any disassembly, modification or replacement of mechanical or electrical parts
undertaken without our agreement or by a non-approved operator. The warranty only applies to the manufacturer's
original spare parts. During the warranty period, the seller must replace or repair any parts recognised as faulty after
inspection by the qualified and approved department, all free of charge.
The warranty excludes all other services or compensation.
Repairs undertaken within the scope of the warranty are, in principle, performed in the seller's workshops or the
workshop of a representative approved by the manufacturer. When work is carried out on the equipment outside of
their workshops, the seller must cover the labour costs related to the disassembly or reassembly of these parts if these
operations are performed exclusively by their personnel or a representative approved by the manufacturer. The parts
replaced become the property of the seller and must be returned to them at their own expense.
In the case of components with a particular relative importance not manufactured by the seller themselves and which
bear the brand of a specialist manufacturer, the warranty, which may vary according to the manufacturer, is the same
as that agreed by this manufacturer.

© 2012 by Huchez Treuils S.A.S.
Translation of the original instructions manual 5EN Reproduction prohibited
4 – Reception of the equipment
Make a visual inspection of the packaging to ensure that it is in good condition.
In the event of a problem, issue the usual reserves.
Check that the winch corresponds to your order.
5 – Obligatory regulatory checks by the user
The users are required to comply with the standards in force in their country.
With regard to France:
Order of 1st March 2004 relating to the verification of lifting machines and accessories:
The modifications to the regulation relating to the use and verification of lifting machines and accessories, which came
into effect on 1st April 2005, impose new obligations on all users:
The suitability inspection that involves checking that the lifting machine is suitable for the work that the user
intends to carry out, as well as for the risks to which workers are exposed, and that the intended operations are
compatible with the conditions of use for the machine defined by the manufacturer.
The assembly and installation inspection that involves ensuring that the lifting machine is assembled and installed
safely in accordance with the manufacturer's instruction manual,
The general periodic visits that involve an inspection of the state of preservation and the operating tests.
The commissioning or recommissioning inspections in the event of a change in the place of use, the configuration
or the conditions of use on the same site; following the disassembly and subsequent reassembly of the lifting
machine; after any major replacement, repair or transformation concerning the essential components of the lifting
machine; or following any accident caused by the failure of an essential component of the lifting machine.
The maintenance booklet (order of 2nd March 2004 applicable from 1st April 2005) which must be used to record
the maintenance operations carried out in accordance with the recommendations of the manufacturer of the
machine as well as any other inspection, maintenance operation, repair, replacement or modification carried out
on the machine. For each operation, it is essential to record the date of the work, the names of the people and,
where appropriate, the companies which carried out the work, the nature of the operation and, if it is a periodic
operation, the frequency. If the operations involve the replacement of certain components of the machine, the
references of these components are indicated. The English version of the maintenance booklet for our lifting
winches can be downloaded from our website www.huchez.fr/ uk under the heading "After sales services”. A copy
is however proposed in the annexes of this manual.
The inspections must be carried out in accordance with a protocol and are intended to ensure preventive maintenance
aimed at detecting any damage or defect liable to cause a hazard.
6 – Presentation of the machines
TRBoxter INOX winches are lifting and pulling machines manufactured according to the standards and regulations in
force.

© 2012 by Huchez Treuils S.A.S.
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6.1 Technical description
All versions
Rigid steel and cast aluminium structure.
Mechanically welded stainless steel drum with wide flanges for safe and rational fastening of the rope.
Single or three phase asynchronous motors IP66.
Watertight reducer in oil bath with helical gears.
Single or three-phase standard power socket.
Emergency stop as standard.
Optional: integrated end limit switch.
Low Voltage versions only:
24 V (three-phase version) or 190 V (single-phase version) direct control electromagnetic brake.
Electrical equipment under watertight cover.
Very low voltage, 24 V remote control with socket – IP 65.
220/380 V three-phase control – IP 55 double insulation.
Speed variation versions (optional) only:
24 V direct control electromagnetic brake.
Electrical equipment under watertight cover.
Very low voltage, 24 V remote control – IP 65.
6.2 Operation
The load and winding speed of the rope on the drum are obtained by reducing the rotation movement of the electric
motor via a shaft mounted helical gear unit.
Outside the motor's operating phases, a mechanical automatic brake stops and keeps the load in position.
The brake for the speed variation and Low Voltage versions is independent and is electrically controlled.
In the Low Voltage versions, the motor is controlled on and off using a three-button wired remote control
(up/down/emergency stop).
In the speed variation version (optional), the motor rotation speed is adjusted using a potentiometer on the remote
control. The acceleration and deceleration phases are managed by the machine to prevent sudden starts and stops
(and progressive).

© 2012 by Huchez Treuils S.A.S.
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6.3 Available models
BT (Low voltage)
Type FEM
Force (kg)
Number
of layers
Rope capacity m (standard drum)
Rope
Ø mm
Speed m/min
Power kW
Weight kg
(without
rope nor
hook)
on the
upper
layer
on the
first
layer
Upper layer on the upper
layer
on the
upper
layer
on the
first
layer
TRBOXTER251BT
1Am
250
300
3
86
25
5
22
19
1.1 mono.
55
TRBOXTER253BT
1Am
250
300
3
86
25
5
22
19
1.1 tri.
55
TRBOXTER501BT
1Bm
500
500
3
65
18
7
12
10
1.1 mono.
55
TRBOXTER503BT
1Bm
500
500
3
65
18
7
12
10
1.1 tri.
55
TRBOXTER751BT
1Am
750
900
3
142
30
9
6.5
5.5
0.75 mono.
95
TRBOXTER753BT
1Am
750
900
3
142
30
9
6.5
5.5
0.75 tri.
95
TRBOXTER991BT
1Bm
990
990
3
81
23
10
5
4
1.1 mono.
95
TRBOXTER993BT
1Bm
990
990
3
81
23
10
5
4
1.1 tri.
95
*Other drum lengths (optional): please ask for more information.
Important: the above indicated rope diameter corresponds to the rope recommended in the FEM 1 Am/ISO M4
classification for 250 and 750 kg and FEM 1 Bm/ISO M3 for 500 and 990 kg. It also corresponds to the force on the last
layer.
Important: it is obligatory to check that the rope resistance coefficient complies with the load lifted (FEM 1 Am/ISO
M4 for 250 and 750 kg, FEM 1 Bm/ISO M3 for 500 and 990 kg).
6.4 Dimensions and fastenings
TRBoxter INOX Low Voltage version (BT)

© 2012 by Huchez Treuils S.A.S.
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Low voltage control, 1 speed
Models
TRBoxter INOX 250-500
TRBoxter INOX750-990
Standard Standard
A mm
According to motors, see table.
B mm
243
304
C mm
79
107,5
Ø D mm
118
140-150-160
E mm
255
318
Ø F mm
10,5
12,5
G mm
197
246
H mm
284.5
332.5
J mm
23
29
L mm
According to motors, see table.
M mm
121,5
152
N mm
121,5
152
T mm
230
290
TRBoxter INOX 250-500
Standard
Motor kW A mm
L (without/with limit switch)
mm
H mm
1,1
452
356/508
284,5
TRBoxter INOX 750-990
Standard
Motor kW A mm
L (without/with limit switch)
mm
H mm
1,1
540
456/608
332.5
6.5 Accessories
TRBoxter INOX winches can be delivered with ropes and accessories.
6.6 FEM classification
There are eight groups of mechanisms:
FEM
1 Dm
1 Cm
1 Bm
1 Am
2m
3m
4m
5m
ISO
M 1
M 2
M 3
M 4
M 5
M 6
M 7
M 8
To define the group for a lifting machine, winch or hoist, three essential parameters must be considered:
a- The maximum load to be lifted
Including the weight of the rope and any lifting accessories present (hook etc.), except if they have a total weight less
than or equal to 5% of the load to be lifted.
b- The duty factor
Indicates the extent to which the lifting machine is used at maximum load or with a reduced load. There are four
different duty factors:

© 2012 by Huchez Treuils S.A.S.
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Light
Lifting machines rarely subject to maximum load and regularly
used for very light loads.
k ≤ 0.5
Medium
Lifting machines quite often subject to maximum load and
regularly used for light loads.
0.5 < k ≤ 0.63
Heavy
Lifting machines often subject to maximum load and regularly
used for medium loads.
0.63 < k ≤ 0.8
Very
heavy
Lifting machines regularly subject to loads close to the
maximum load.
0.8 < k ≤ 1
For an exact classification, it is preferable to calculate the average cubic value using the following formula:
where:
ß= payload or partial load
rated capacity
t= operating time with payload or partial load + dead load
total operating time
Y
=dead load
maximum capacity
t
Δ= operating time with dead load only
total operating time
c- Operating class
This is the operating time per day, on the basis of 250 working days per year.
The lifting machine is considered to be in operation when it is moving; however, it is not considered to be in operation
during downtimes, for example, between lifting and lowering.
These three parameters give the FEM classification for the TRBoxter INOX:
TRBoxter INOX from 250 to 990 kg
Usage rate
Average operating time per day in hours.
30’
1 h
2 h
Light
1 Dm
1 Cm
1 Bm
Medium
1 Cm
1 Bm
1 Am
Heavy
1 Bm
1 Am
2m
Very heavy
1 Am
2m
3m
6.7. Variable speed drive
6.7.1. General
WARNING
•The electronic speed control equipement of the electric motors are connected to potentially dangerous
voltages. When connecting, performing servicing or dismantling these appliances, the greatest of precautions
must be taken to prevent electric discharges.
This appliance contains capacitors which accumulate energy. When the appliance is switched off, these
capacitors retain a dangerous voltage for a few minutes subsequent to switching off. Wait at least 5 minutes
before opening or touching live parts of the appliance.
The earth connection of the appliance must be connected to a suitable earth connector of the electrical
installation.
This appliance must be installed, adjusted and serviced by a qualified electrician. This person must be familiar
with the construction and commissioning of this appliance.

© 2012 by Huchez Treuils S.A.S.
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The variable speed controls fitted with a CEM filter and faradised motor rope may have significant leakage
currents to the earth, especially when the appliance is switched on. Differential switches could therefore be
tripped accidentally. Furthermore, the diode rectifying bridge in the input circuit could generate a direct
current in the phases of the network. You are advised to use differential switches which are not sensitive to
these transient currents and of a high tripping level. The other equipment must be protected by one or more
separate differential switches.
A differential switch upstream to a variable speed control is not adequate protection.
6.7.2. Wiring
DANGER
Make sure that the appliance is connected to a sound earth.
The wiring must be performed by a qualified electrician adhering to the safety standards of the country of
installation.
Do not perform or modify the wiring before you are personally sure that the voltage of the network is no
longer present on the appliance and that any residual voltage of the appliance has disappeared.
Check that the voltage of the network corresponds to the voltage of the variable speed.
Do not connect the phases of the network to the output terminals for the connection of the motor (U, V, W).
Tighten the screws to the suitable tightening torque. Check, before switching on, that all the connections are
securely tightened.
7 – Handling – Storage
Important: the angle formed between the hook and the two sling points must not
exceed 45°.
Lift and place the winch carefully without dropping it.
Do not forget that the centre of gravity of the winch is off-centred.
For further information on the weight of the winch, refer to section § 6.2 – Models
available.
When stored, these winches must be protected from bad weather in a clean and dry place at a temperature between -
10°C and +50°C.
8 – Assembly and start-up
8.1. Securing the winch
The flatness deviation between the 4 points of support must not exceed 1mm, in order to avoid undue strain on the
device and ensure its longevity.
The support must be able to withstand the loads to which it is subjected. An unsuitable installation site may lead to
serious accidents.
To assess the suitability of the place of installation and its resistance to loads, you must take into account any possible
overloading, the weight of the winch itself and the weight of the options and/or accessories fitted to it, including all
dynamic forces. The winch user is responsible for determining the place of installation. If in doubt with regard to the
suitability of a place of installation, contact a civil engineer or a statics specialist.

© 2012 by Huchez Treuils S.A.S.
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Calculate and check that the attachment support has a resistance that exceeds the loads to be lifted or pulled.
The fixation must be performed using 4 screws of 10 mm diameter and 8.8 class (for TRBoxter INOX 250 and 500 kg)
and 12 mm diameter and 8.8 class (for TRBoxter INOX 750/990 kg).
In all cases where this is possible, favor an assembly using special nuts supplied with the winch & shown below.
Their contour adapted to the Foundry device allow a distribution of the efforts and avoid their rotation especially
during the tightening process.
8.2. Wire rope exits
Key: Standard exit, right-hand laid wire rope
Non-standard exits, left-hand laid wire rope

© 2012 by Huchez Treuils S.A.S.
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IMPORTANT!
. Use of the standard rope clamp on the limit switch side.
. A non-standard output can be made into a standard one by using the second rope clamp, as long as this is known
when placing the order.
8.3. Change to initial assembly
(for reference numbers, refer to the exploded view in the appendix).
Remove the screws .
Disconnect the flange using a mallet.
Remove the perforated sheeting .
Identify the tie fastening .
Loosen the tie before changing place.
Screw in its new position tightening carefully.
Position the sheeting in its new position.
Fit the flange on its bearing by tightening the screws and checking that the sheeting is correctly
positioned in the grooves.
8.4. Set-up
The service life of a winch depends on its correct installation and set-up.
It is essential that you read this manual carefully before installing, using and servicing your machine.
Any use which contravenes our instructions may create hazards. In this case, the manufacturer cannot accept any
liability.
Do not use this machine before having read and understood the instruction manual in its entirety
Always keep the manual close to the machine, available to the operator and the maintenance staff
Comply and ensure compliance with the safety rules.
Connect to the power supply (see section § 8.5 - Electrical connections).
Check the rope and hook.
Ensure you are ready to press the emergency stop button at all times, with no load attached, then check that
the movement of the hook corresponds to the direction of the arrows indicated on the control unit.
Check that the brake works: with a nominal load attached, lift the load and lower it again or, in the case of
pulling, pull this load.
Check that the limit switch works.
The winch has been subjected to dynamic and static tests in the factory (cf. Test record).
To ensure correct winding of the rope, the distance between the deflecting pulley and the drum must equal to or be
greater than 20 times the length of the drum.
7
13
4
15
18
4
13
7
4

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8.5 Electrical connections
8.5.1. Identification of the winch’s electrical cables
8.5.2. Mains supply
Check that the network voltage corresponds to the one required for the machine.
Measure the real value of this voltage. There should be no more than a 5% difference between it and the
nominal value.
The machine should be connected to an electrical line with the correct protection devices: fuse/protective
circuit breaker, main circuit breaker.
Very important: the winch will only provide full power if the motor is supplied via a cable section which is suited to
this use.
Recommended power cable section:
VOLTAGE TYPE
Section of power cable
Power
Length 10 m
Length 30 m
220 V mono.
2 + T
2,5 mm²
4,0 mm²
0,75/1,1 kW
230 V tri.
3 + T
1,5 mm²
2,5 mm²
0,75/1,1 kW
3 + T
2,5 mm²
4,0 mm²
2,2/3 kW
3 + T
2,5 mm²
6,0 mm²
5,5 kW
400 V tri.
3 + T
1,5 mm²
1,5 mm²
0,75/1,1 kW
3 + T
1,5 mm²
2,5 mm²
2,2/3 kW
3 + T
2,5 mm²
4,0 mm²
5,5 kW
Power supply via a generator is possible: minimum power in kVA equal to or greater than five times the motor
power in kW.

Power supply
Remote control
Speed variation version (optional)
Power supply
Socket (remote
control)
Low Voltage version

© 2012 by Huchez Treuils S.A.S.
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8.5.3. Connection
IMPORTANT: ALWAYS ENSURE THE POWER SUPPLY IS SWITCHED OFF BEFORE CONNECTING THE WINCH (Main
circuit breaker on the cut line).
Socket connection
The appliance is systematically supplied with a power cord (length 0.5 m) equipped with a plug for connection to a wall
socket or wire socket.
The type of plug depends on the power supply voltage:
. 2P+G (domestic type) in 230 V single-phase
. 3P+G in 230 V or 400 V three-phase (in this case the plug socket is also supplied)
Connection in the unit
IMPORTANT: this type of electrical connection of the winch must be performed by a competent and qualified person.
Disconnect the power cord inside the electrical unit by accurately identifying the location of the terminals.
Pass the new cable into the unit's compression gland and reconnect it in the same way as the power cord.
A circuit breaker must be placed at a maximum of 10 m from the place of use.
After connecting the machine, check that it functions correctly.
IMPORTANT: In three-phase power supply, check in particular that the direction of rotation is correct.
In fact, in three-phase, the drum's direction of rotation depends on the allocation of the phases to each of the three
power supply connection terminals. To reverse the direction of rotation, simply switch the two phases: under no
circumstances change the direction labels in the control unit or the cabling inside the winch.
Never "shunt" the disconnecting switches, electrical switches, prevention or limitation equipment.
Never block, adjust or remove switches or end stops in order to go beyond the levels that they allow.
8.5.4. Securing the working rope
Important: in three-phase the drum's direction of rotation differs depending on the power supply connection.
Switching the two phases changes the drum's direction of rotation.
Reminder: check the maximum capacity of the winch.
Very important:
The safety regulations require that two to three whorls of rope always stay on the drum.
To comply with the legislation, the rope diameter must not exceed the recommended diameter.
If the rope and the hook used were not supplied with the machine by the manufacturer, check that they guarantee a
level of safety corresponding to table § 6.6.
IMPORTANT: even if the rope was supplied wound on to the winch, it was not tensioned during assembly. The user
must tension it using a minimum force of 1% of its breaking load.
The service life of the steel ropes used on the winch depends on a number of factors, including the type of the work
cycles (lifting height, lifting speed, number and type of deviations, etc.) and the operating mode (number of layers,
distribution of the work cycles over the length of the steel rope, etc.). The service life of steel ropes is therefore
subject to considerable variation depending on these factors.
Remember that rope must be replaced with equipment which meets the same specifications as the original rope.
This replacement must be recorded in the maintenance booklet.

© 2012 by Huchez Treuils S.A.S.
Translation of the original instructions manual15EN Reproduction prohibited
Measuring the rope diameter using sleeve callipers:
Correct measurement Incorrect measurement
Handling steel ropes
Always use suitable protective gloves when handling steel ropes.
Never use a rope with faults such as:
an unacceptable number of broken strands.
basket distortions.
broken bird-caging.
flattening.
constrictions.
strand extrusions.
broken rope cores.
slack strands.
bends or loops.
Always check the level of wear of the rope before use.
Never use steel ropes as loops.
Never expose steel ropes to angular or sharp edges.
Unwinding the rope from its reel:
CORRECT:
INCORRECT

© 2012 by Huchez Treuils S.A.S.
Translation of the original instructions manual16EN Reproduction prohibited
Fastening the rope
On the first rope clamp
On the second rope clamp
Identify using the photos above.
If necessary, remove the limit switch.
Loosen the screws.
Insert the end of the rope between the drum flange and the cable clamp.
Tighten the screws.
Check that the rope is securely clamped.
Reassemble the limit switch.
The rope should never form a loop.
Important: the direction of rotation of the drum depends on how the machine is connected.
Winding the rope on the drum:
Reminder: the maximum capacity of these winches varies on each model (see section §6.3).
Very important: The safety regulations require that 3 whorls of rope always stay on the drum. To comply with the
legislation, the rope diameter must not exceed 7 mm for the TRBoxter INOX 250/500 or 12 mm for TRBoxter INOX
750/990. If the rope and the hook used were not supplied with the machine by the manufacturer, check that they
guarantee a level of safety corresponding to coefficient 5.
Winding the rope on the drum: to do this, tension the rope and wind it with joined strands onto the drum. Check the
direction of rope winding according to the three-phase connection.
Start to wind the rope forming a spiral to the right.
The first layer must be wound in a compact manner and under tension. Take a mallet or a block of wood and knock the
turns against one another; not too hard to prevent the strands from overlapping one another, but tightly enough to
prevent the rope from moving on the drum. If the first layer is wound too loose, the next layer will form a space in the
first layer that will result in an open area. If the first layer is too tight, the subsequent layers will not have enough
space between turns.
In any case, the first layer and all the other layers must be wound onto the drum with enough pre-tension (5-10 % of
the MWL of the rope). If the rope is wound without any tension, it will suffer from crushing and premature flattening
caused by the loaded upper layers.

© 2012 by Huchez Treuils S.A.S.
Translation of the original instructions manual17EN Reproduction prohibited
Even if the first layer is wound correctly during installation, it will expand a little while in service. When the first layer
expands (loss of pre-tension) the initial procedure MUST be performed at regular intervals.
Otherwise, the "hard" turns will severely crush the base layers.
Whatever you do, DO NOT pass the rope through a clamping mechanism. For example, two blocks of wood screwed
together. THIS WILL CAUSE IRREPARABLE DAMAGE TO THE ROPE!
It is important to respect the indication below; if the rope start on the winch is at the bottom, respect the same
principle. Failure to respect this precaution will damage your rope irretrievably and it will become extremely
dangerous.
Right-hand laid rope
Wind from the left
to the right
Right-hand laid rope
Wind from the right
to the left
Left-hand laid rope
Wind from the right
to the left
Left-hand laid rope
Wind from the left
to the right
It is important to respect the "natural" winding direction of the rope (the direction of manufacture and storage)
otherwise it risks of considerably reducing its service life.
Check the direction of rope winding according to the motor connection.

© 2012 by Huchez Treuils S.A.S.
Translation of the original instructions manual18EN Reproduction prohibited
Principle of reeving:
8.5.5. Adjusting the limit switch
1. Open the limit switch by loosening the screws (1).
2. Set the trigger point for the cams; to set them properly, loosen the central screw (12) from the group of cams, set
the trigger point for each cam using their adjustment screws (11) (the screws are numbered to indicate the cams in
increasing order from the bottom of the group to the top), then tighten the central screw (12).
3. Close the limit switch using the metric screws (1).
If the limit switch is equipped with a safety cable, insert the free end of the no-drop cable into a screw (2). Ensure
the rubber seal of the cover is in the correct position and tighten the screws (1) using an 80/100 N·cm tightening
torque.

© 2012 by Huchez Treuils S.A.S.
Translation of the original instructions manual19EN Reproduction prohibited
9 – Servicing and maintenance
9.1. Winches
Respect the following instructions, in particular if your winch is used in a large number of different locations or in a
particularly dirty and damp environment:
Remove most of the dirt from the winch.
Always store the winch in a dry, clean place.
Servicing and maintenance operations on the rope must be carried out without any load on the winch.
9.1.1. - Before starting up
Check:
The electrical connections are in good working order.
The rope is correctly fastened to the drum.
The exterior appearance of the winch.
9.1.2. - When using for the first time
At the start of the installation process, it is recommended that you respect a running-in period of thirty hours at ¾ of
the load. The nominal capacity will be obtained after this running-in period.
9.1.3. - Periodic servicing
See also chapter 5: Obligatory regulatory checks by the user
Check that the mechanical components are well lubricated during each periodic general inspection.
Renew the grease every 100 hours or every three years (FUCHS Renolit CXI2 grease).
Very important:
Contact our after-sales service in the event of a change in the type of grease.
9.2. Ropes
The wire ropes must be cleaned and greased regularly using a special grease which penetrates in the rope core.
Only use appropriate and harmless cleaning products for all the components of the rope, including the core.
If lubrication is impossible for usage-related reasons, the service life of the rope will be reduced considerably and
increased monitoring of the rope will therefore be necessary.
The ropes must be checked visually every day.
Servicing and maintenance operations on the rope must be carried out without any load on the winch.
9.3. Hooks
Check the hook and its safety latch
If the rope and hook are not supplied by the manufacturer, check that the parts used guarantee a level of
safety corresponding to table in section §6.6.
Check the fastening points of the reeving on a regular basis.
9.4. Brake
The brakes cannot not be adjusted.

© 2012 by Huchez Treuils S.A.S.
Translation of the original instructions manual20EN Reproduction prohibited
10 – Taking out of use
If the equipment is in a state of disrepair likely to give rise to risks, it must not be used and must be taken out of
service:
disassemble the electrical control components
for disposal of the equipment, it should be sent to the corresponding collection centre. Make sure to
remove the grease before disposing of the equipment.
11 – Spare parts
If during maintenance operations you notice that certain parts of your winch need to be replaced, use HUCHEZ
original parts only.
For all spare parts orders, please indicate the following specifications on your order
The type and capacity of the winch (indicated on the nameplate).
The serial number and year of manufacture (indicated on the nameplate).
The designation of the desired parts (exploded views).