unicraft ESW Series User manual

ESW 500
Operating Instructions
Electrical Cable Winch
ESW 500
ESW 800

2ESW-Series | Version 1.08
Imprint
Product identification
Electrical Cable Winch Item number
ESW 500 6199500
ESW 800 6199800
Manufacturer
Stürmer Maschinen GmbH
Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
Fax: [phone] - 55
E-Mail: [email protected]
Internet: www.unicraft.de
Indications regarding the operating instructions
Original instructions
Edition: 17.02.2021
Version: 1.08
Language: English
Author: ES/RL
Indications regarding the copyright
Copyright © 2021 Stürmer Maschinen GmbH, Hallstadt,
Germany.
The contents of these operating instructions are the sole
property of the company Stürmer.
Passing on as well as copying of this document, the use
and distribution of its content are prohibited if not explic-
itly permitted. Contraventions are liable to compensa-
tion.
Subject to technical modifications and error.
Content
1 Introduction ............................................. 3
1.1 Copyright ............................................................ 3
1.2 Customer service................................................ 3
1.3 Limitation of liability............................................. 3
2 Safety ....................................................... 3
2.1 Symbol explanation ............................................ 3
2.2 Obligations of the operating company ................ 4
2.3 Requirements to staff.......................................... 5
2.4 Personal protective equipment ........................... 5
2.5 Safety devices .................................................... 5
2.6 Safety labels ....................................................... 6
2.7 General safety regulations.................................. 6
2.8 Safety information for operating personnel......... 6
2.9 Checks................................................................ 7
3 Indended Use .......................................... 7
3.1 Foreseeable misuse ........................................... 7
3.2 Residual risks ..................................................... 7
4 Technical Data......................................... 7
4.1 Table................................................................... 7
4.2 Type plate........................................................... 7
5 Transport, Packaging, Storage .............. 8
5.1 Transport ............................................................ 8
5.2 Packaging........................................................... 8
5.3 Storage ............................................................... 8
6 Description of device.............................. 8
6.1 Illustration .......................................................... 8
6.2 Scope of delivery ................................................ 8
7 Installation ............................................... 9
8 Operation ................................................. 9
8.1 Operating conditions......................................... 11
8.2 Test run............................................................. 11
8.3 Raising a load................................................... 11
8.4 Lowering of a load ........................................... 12
8.5 Operation with pulley ........................................ 12
9 Care, Maintenance and Repair............. 12
9.1 Care by cleaning............................................... 12
9.2 Maintenance and repair ................................... 12
10 Testing the electrical Cable Winch ... 14
11 Fault finding......................................... 15
12 Disposal, recycling of used Devices. 15
12.1 Decommissioning ........................................... 15
12.2 Disposal of electrical equipment..................... 15
12.3 Disposal of lubricants...................................... 15
13 Spare Parts .......................................... 16
13.1 Ordering spare parts....................................... 16
13.2 Spare parts drawing........................................ 17
14 Electrical Circuit Diagram ................ 18
15 EU Declaration of Conformity ............ 19
16 Maintenance Schedule ....................... 20

Introduction
ESW-Series | Version 1.08 3
1 Introduction
You have made a good choice by purchasing a Unicraft
Electrical Cable Winch.
Read the operating manual thoroughly before com-
missioning the machine.
It gives you information about the proper commissioning,
intended use and safe and efficient operation and main-
tenance of your Electrical Cable Winch.
The operating manual is part of the Electrical Cable
Winch package. Always keep this operating manual in
the location where your Electrical Cable Winch is being
operated. All local accident prevention regulations and
general safety instructions for the operating range of
your Electrical Cable Winch must also be complied with.
1.1 Copyright
The contents of these instructions are copyright. They
may be used in conjunction with the operation of the
Electrical Cable Winch. Any application beyond those
described is not permitted without the written approval of
Stürmer GmbH. For the protection of our products, we
shall register trademark, patent and design rights, as this
is possible in individual cases. We strongly oppose any
infringement of our intellectual property.
1.2 Customer service
Please contact your dealer if you have questions con-
cerning your Electrical Cable Winch or if you need tech-
nical advice. They will help you with specialist informa-
tion and expert advice.
Germany:
Stürmer Maschinen GmbH
Dr.-Robert-Pfleger-Str. 26
D-96103 Hallstadt
Repair service:
Fax: [phone]-111
Email: [e-mail]
Spare part orders:
Fax: [phone]-119
Email: [e-mail]
We are always interested in valuable experience and
knowledge gained from using the application-which then
could be shared and be valuable to develop our products
even further.
1.3 Limitation of liability
All information and notes in these operating instructions
were summarised while taking applicable standards and
rules, the state-of-the-art technology and our long-term
knowledge and experiences into consideration.
In the following cases the manufacturer is not liable for
damages:
- Non-observance of the operating instructions,
- Inappropriate use
- Use of untrained staff,
- Unauthorised modifications
- Technical changes,
- Use of not allowed spare parts.
The actual scope of delivery may deviate from the expla-
nations and presentations described here in case of spe-
cial models, when using additional ordering options or
due to latest technical modifications.
The obligations agreed in the delivery contract, the gen-
eral terms and conditions as well as the delivery condi-
tions of the manufacturer and the legal regulations at the
time of the conclusion of the contract are applicable.
2 Safety
This section provides an overview of all important safety
packages for the protection of operating personnel as
well as for safe and fault-free operation. Other task-
based safety notes are included in the paragraphs of the
individual phases of life.
2.1 Symbol explanation
Safety instructions
The safety notes in these operating instructions are high-
lighted by symbols. The safety notes are introduced by
signal words which express the concern of the risk.
DANGER!
This combination of symbol and signal words indi-
cates an imminently dangerous situation which may
lead to death or severe injury if not avoided.
WARNING!
This combination of symbol and signal words indi-
cates a potentially dangerous situation which may
lead to death or severe injury if not avoided.

4ESW-Series | Version 1.08
Safety
Tips and recommendations
It is necessary to observe the safety notes written in
these operating instructions in order to reduce the risk of
personal injuries and damages to property.
2.2 Obligations of the operating com-
pany
of the operator
The operating company is the person who operates the
electrical cable winch for business or commercial rea-
sons by herself, or leaves it to a third party for use or ap-
plication, and who bears the legal product responsibility
for the protection of the user, the staff or for third parties.
Obligations of the operating company
If the electrical cable winch is used for commercial pur-
poses, the operating company the electrical cable winch
must comply with the legal working safety regulations.
Therefore, the safety notes in this operating manual, as
well as the safety, accident prevention and environment
protection regulations applying for the area of application
of the electrical cable winch must be met. The following
applies in particular:
- The operating company must be informed about
the applying industrial safety regulations and fur-
ther analyse hazards resulting from the special
working conditions at the place of use the electrical
cable winch. She must implement these in form of
operating manuals for the operation the electrical
cable winch
- During the entire lifetime of the electrical cable
winch, the operating company must verify whether
the operating manuals prepared by her correspond
to the current status of the regulations, and must
adapt these if necessary.
- The operating company must unambiguously regu-
late and determine the responsibilities for installa-
tion, operation, troubleshooting, maintenance and
cleaning.
- The operating company must ensure that all per-
sons who work with the electrical cable winch,
have read and understood this manual. Further-
more she must instruct the staff in regular intervals
and inform them about the hazards.
- The operator must provide the necessary protec-
tive equipment to the staff and order the use of the
necessary protective equipment in a binding way.
Furthermore the operating company is responsible to
keep the electrical cable winch always in a technically
flawless state. Thus, the following applies:
- The operator must ensure that the maintenance in-
tervals described in this manual are kept.
- The operator must have all safety devices checked
regularly for their good working order and their in-
tegrity.
CAUTION!
This combination of symbol and signal words indi-
cates a potentially dangerous situation which may
lead to slight or minor injury if not avoided.
ATTENTION!
This combination of symbol and signal words indi-
cates a possibly dangerous situation which may lead
to property and environmental damages if they are
not avoided.
NOTE!
This combination of symbol and signal words indi-
cates a potentially dangerous situation which may
lead to material or environmental damage if not
avoided.
Tips and recommendations
This symbol highlights useful tips and recommenda-
tions as well as information for an efficient and trou-
ble-free operation.

Safety
ESW-Series | Version 1.08 5
2.3 Requirements to staff
Qualifications
The different tasks described in this manual represent
different requirements to the qualification of the persons
entrusted with these tasks.
Only persons reliable working procedures can be ex-
pected from, are allowed to perform all works. Persons
the responsiveness of which is affected by e. g. drugs,
alcohol or medication, are not allowed to work with the
machine.
The qualifications of the personnel for the different tasks
are mentioned below:
Operator
The operator is instructed by the operating company
about the assigned tasks and possible risks in case of
improper behaviour. Any tasks which need to be per-
formed beyond the operation in the standard mode must
only be performed by the operator if it is indicated in
these instructions and if the operating company expres-
sively commissioned the operator.
Qualified electrician
Due to the electrician's specialised training, know-how,
experience and knowledge of pertinent standards and
regulations the electrician is in a position to work on the
electrical systems, and autonomously identify and avoid
potential hazards.
Qualified personnel
Due to their professional training, knowledge and experi-
ence as well as their knowledge of relevant regulations
the specialist staff is able to perform the assigned tasks
and to recognise and avoid any possible dangers them-
selves.
Manufacturer
Certain works may only be performed by specialist per-
sonnel of the manufacturer. Other personnel is not au-
thorized to perform these works. Please contact our cu-
stomer service for the execution of all arising work.
2.4 Personal protective equipment
The personal protective equipment serves to protect per-
sons against impairments of safety and health while
working. The staff member has to wear personal protec-
tive equipment while performing different tasks on and
with the machine which are indicated in the individual
paragraphs of these instructions.
The personal protective equipment is explained in the
following paragraph:
2.5 Safety devices
EMERGENCY STOP button
Fig. 1: Emergency stop button
When the EMERGENCY STOP button is pressed, the
electrical cable winch is switched off immediately.
To unlock, turn the switch in the direction of the arrow
(clockwise).
WARNING!
Danger in case of insufficient quali-
fication of the staff!
Insufficiently qualified persons cannot estimate the
risks while using the electrical cable winch and
expose themselves and others to the danger of
severe or lethal injuries.
- Have all works only performed by qualified persons.
- Keep insufficiently qualified persons out of the work-
ing area.
Head protection
The industrial helmet protects the head against
falling objects and knocks against stationary objects
items.
Protective gloves
The protective gloves provide protection for the
hands against sharp-edged components, as well as
against friction, abrasions or deeper injuries.
Safety boots
The safety boots protect the feet against crushes, fall-
ing parts and slipping over on slippery underground.
Protective clothes
Protective work clothing means tight-fitting clothing
with low tear resistance.

6ESW-Series | Version 1.08
Safety
Motor overload protection
The electrical cable winch is not suitable for continuous
operation. If the intended operating time is exceeded, the
motor overheats and the electrical cable winch witches
itself off. After a sufficient cooling phase, the motor auto-
matically switches back to operational readiness.
Upper and Lower limited position device
When the load weight is raised and makes contact with
the end switch/stop ring, the end-switch will stop the cir-
cuit for safety.
When the load weight is lowered and the steel rope is
going to be unrolled, the steel rope will then press on the
down limit brake and the brake is applied. For guaran-
teed safety, the switch contact is activated in order to in-
terrupt the circuit and stop the machine.
2.6 Safety labels
The following safety signs are applied on the device (Fig.
2), which need to be observed and followed.
Fig. 2: Safety labels
If safety labels on the machine are damaged or missing,
this can cause errors, personal injury and material da-
mage. The safety symbols attached to the machine must
not be removed. Damaged safety symbols must be re-
placed immediately.
As soon as the signs are not clearly visible and compre-
hensible at first glance, the machine must be stopped
until new signs have been attached.
2.7 General safety regulations
Setting up, retrofitting, maintenance and inspection work
may be carried out only on equipment that is not in oper-
ation. The work is allowed for trained personnel only.
It is important to point out that the making of any unau-
thorised modifications or changes to the machine is not
permitted.
Operating personnel must always ensure that the maxi-
mum load is never exceeded.
Personnel must not stand underneath a suspended load
as this could come loose and fall.
Personnel must not ride on or be lifted by the equipment.
Access to lifting equipment is not permitted.
2.8 Safety information for operating
personnel
No operational mode which could compromise the safety
of the electrical cable winch may be undertaken.
It is the responsibility of the operator to ensure that no
unauthorised personnel work on the electrical cable
winch(e.g. also by working on equipment in a manner
contrary to authorised use).
It is the responsibility of the operator to check the electri-
cal cable winch at least once before use (once a day) for
externally apparent damage or defects and to report any
changes (including to the way the machine is operating)
which are likely to compromise safety.
It is the responsibility of the operator to ensure that the
the electrical cable winch is operated only in perfect or-
der and condition.
It is the responsibility of the operator to insist that operat-
ing personnel must wear protective clothing wherever
necessary.
Under no circumstances must safety devices be re-
moved or put of operation (potential risk of serious crush-
ing, danger to life). If it is necessary to remove any safety
devices for fitting, repair or maintenance work, they must
be re-installed immediately after maintenance or repair is
complete.
NOTE!
All local regulations (the latest valid version) which
apply in the country where the device is used must be
complied with
In Germany, currently
BGV A1 - Principles of Prevention
BGV A3 (VBG 4) - Electrical systems and equipment
BGV D6 (VBG 9) - Cranes
BGV D8 - Winching, lifting and pulling equipment
BGR 500 (VBG 9a) - Load carrying devices used with
lifting equipment
BGV B3 (VBG 121) - Noise
BGG 905 (ZH 1/27) - Principles for testing cranes
EC Machine guidelines 2006/42/EC

Indended Use
ESW-Series | Version 1.08 7
2.9 Checks
Hoisting cables are classed as a load-carrying device re-
quiring inspection. For this reason, the following guide-
lines issued by the trade association central office for ac-
cident prevention regarding steel cables used in lifting
operations must be complied with: DIN 685 Part 5 Nov.
1981, UVV, BGV D8 (VBG 8 April 1997) and UVV, BGV
D6 (VBG 9 April 2001) and DIN EN 818-7 September
2002.
A record of maintenance and inspections carried out
must be entered in the crane inspection log book (e.g.
any adjustment to the brakes or clutch).
3 Indended Use
The electrical cable winch must only be used for lifting
free-moving loads weighing up to the maximum specified
load.
The electrical cable winch may be operated only by per-
sonnel who have been trained in its use.
The proper use also includes observing all indications in
these operating instructions. Any use beyond the proper
use or any other use is regarded as misuse. Under no
circumstances may personnel be lifted.
Stürmer Maschinen GmbH accepts no liability for any
constructional or technical modifications carried out on
the electrical cable winch.
Any claims due to damages because of not intended use
are excluded.
3.1 Foreseeable misuse
If the intended use is observed, any reasonably fore-
seeable misuse which could lead to hazardous situations
with personal damage is impossible with the electrical
cable winch.
3.2 Residual risks
Even if all safety regulations are observed a residual risk
in the operation of the electrical cable winch will remain,
as described below.
All persons working with the electrical cable winch must
be aware of these residual risks and follow the instruc-
tions which prevent any accidents or damage caused by
these residual risks.
- Risk of crushing of upper and lower limbs while
equipment is operating.
- During set-up and adjustment works it may be-
come necessary to remove safety devices installed
by the customer. This causes different residual
risks and hazard potentials each operator must be
aware of.
4 Technical Data
4.1 Table
4.2 Type plate
Fig. 3: Type plate ESW 800
ESW 500 ESW 800
Load lifting capa-
city with /
without deflection
pulley
250 kg
500 kg
400 kg
800 kg
Power connection 230 V / 50 Hz 230 V / 50 Hz
Fuse 10 A 10 A
Cable Ø 4,0 mm Ø 5,0 mm
Tensile strength 1870 N/mm21960 N/mm2
Lifting speed
without /
with deflection
pulley
8 m/min
4 m/min
8 m/min
4 m/min
Max. stroke
with /
without deflection
pulley
30 m
15 m
30 m
15 m
Length of cable,
control unit
5 m 5 m
Power rating 1000 W 1300 W
Sound pressure
level (LWA)
71 dB(A) 71 dB(A)
Degree of pro-
tection
IP 54 P 54
Mechanism group 1 Dm (M1) 1 Dm (M1)
W o r k d u t y S 3
20%-10min
S3
20%-10min
Dimensions
(LxWxH) [mm] 340x330x500 340x330x500
Weight 30 kg 32 kg

8ESW-Series | Version 1.08
Transport, Packaging, Storage
5 Transport, Packaging, Stor-
age
5.1 Transport
Check the electrical cable winch on delivery for any visi-
ble transportation damage. If you notice any damage to
the device please report this immediately to the carrier or
dealer.
5.2 Packaging
All used packaging materials and packaging aids are re-
cyclable and should be taken to a materials recycling de-
pot to be disposed of.
The delivery packaging is made of cardboard, so please
dispose carefully by having it chopped up and given to
the recycling collection.
The film is made of polyethylene (PE) and the cushioned
parts of polystyrene (PS). Deliver these substances to a
collection point for recyclable materials or to the waste
disposal company which looks after your region.
5.3 Storage
Clean the electrical cable winch, oil the bearings and
store them in a frost-free and dry environment (max.
+55°C). Do not place anything on the electrical cable
winch.
6 Description of Device
6.1 Illustration
Illustrations in these operating instructions may de-
viate from the original.
Fig. 4: Description of device
1 Switch box
2 Power cable
3 Down limit pole for limit stop
4 Handle connection cable
5 Emergency stop button
6 Control panel
7 Junction box
8 Uplimit assembly for limit stop
9 Load hook
10 Pulley hook with safety bar and pulley
11 Spring buffer unit
12 Limit weight
13 Steel cable
14 Hook hanging device for operation with pulley
15 Automatic rope rolling device
16 Cable drum
17 Gear box
18 Protection hook
19 Safety switch
20 Hanging hook rack
6.2 Scope of delivery
- Electrical Cable Winch
- Power cable
- Control panel
- Operating instructions
NOTE!
The electrical cable winch should be protected from
humidity.

Installation
ESW-Series | Version 1.08 9
7 Installation
- Observe mains voltage: The voltage of the power
source must match the specifications on the type
plate (Fig. 3).
- Make sure that the switch is switched off when
connected to the mains.
- The device is preferably mounted on a wall swivel
arm or on an equivalent support.
- The anchorage or the support must be of a stable
design to withstand the loads.
Step 1: Place the electrical cable winch with the suspen-
sion bracket on the carrier.
Step 2: Hook the safety hook (3, fig. 5) into the suspen-
sion bracket and insert the safety contact (2) into
the safety switch (1) (first remove the cover on
the underside of the safety switch).
Fig. 5: Insert the safety contact 2 into the safety switch 1
8 Operation
Use protective gloves!
Wear protective clothes!
DANGER!
Risk of death due to electric cur-
rent!
Contact with live components may result in immediate
danger to life due to electric shock.
- Work on the electrical system must only be carried
out by qualified electricians.
- Protect the mains cable from damage caused by
heat, oil, sharp edges, kinks and knots.
- Always pull the mains cable out of the socket by the
plug, never by the cable.
CAUTION!
Risk of crushing!
If improper work is carried out on the electrical cable
winch, there is a risk of injury to fingers and hands.
ATTENTION!
The carrier must be designed for the weight of the
device and for the maximum tractive force of 500 kg
or 800 kg!
ATTENTION!
If the safety contact has not been plugged into the
safety switch, the electrical cable winch cannot be
operated.
ATTENTION!
Never hang the electrical cable winch on the safety
hook! The safety hook is not designed for the loads
with which the electrical cable winch is operated.
DANGER!
Danger to life due to falling of the
load!
Falling loads can cause serious injury or death.
- Never stand, linger or work below a suspende load.
- Loads may only be moved under supervision.
- A load must not be lifted by the wire rope hoist if it is
slipping, falling or if its component parts are not se-
cured firmly together.
- A rusted or damaged wire rope hoist must never be
used.
- A load lifted by the wire rope hoist should not be left
unattended.
- Care should be taken during lifting that the operator
does not stand within the working range of the load.
- When leaving the workplace, lower the load.
- Unsuitable suspension points can fail and the load
may drop. The wire rope hoist load hook should
only be secured to suitable suspension points on
the load.
- Under no circumstances may a load be subjected to
a heavy blow or collision.
1
2
3

10 ESW-Series | Version 1.08
Operation
Fig. 6: Correct winding of the cable
Before starting work, make sure that the buttons are in
the OFF position and that the steel cable is not wound on
top of each other on the drum. The rope guide device en-
sures that the rope rolls up evenly. This avoids overloads
which would occur if the rope were to be wound up une-
venly. To do this, always keep the rope in tension by at-
taching a small load.
The safety hook must always be hooked into the suspen-
sion bracket, otherwise the wire rope hoist cannot be
operated!
Even when fully extended, always leave at least 5 win-
dings on the cable drum or do not bridge the lower cable
disconnection bracket mechanism in order not to da-
mage the cable.
Operation is carried out using the buttons on the control
unit, which are to be switched depending on the direction
of travel. Do not switch directly from forward to reverse,
but let the device stop in between.
When the upper end stop is reached, the machine stops
automatically.
CAUTION!
Risk of crushing!
Injuries to hands and fingers may result from
improper use of the electrical cable winch.
- Never grasp the cable while the equipment is in op-
eration.
DANGER!
Risk to life due to overload!
Beams not intended for use with the Electrical Cable
Winch and its load-bearing capacity can give way.
- The Electrical Cable Winch should always be sus-
pended from suitable equipment which has suffi-
cient load-bearing capacity to withstand the weight
of the load and the Electrical Cable Winch.
If the load-bearing capacity is exceeded, the Electri-
cal Cable Winch may fail and the load may fall.
- Only loads which do not exceed the load-bearing
capacity may be suspended.
ATTENTION!
- Do not carry people on the the electrical cable
winch.
- Do not move loads which exceed the maximum
load-bearing capacity of the the electrical cable
winch (see type plate).
- Children and other persons must be at an adequate
distance from the working area.
- Never carry out work on the winch under the influ-
ence of alcohol, drugs or medication and/or in the
event of fatigue or illnesses affecting concentration.
- Never touch the cable when the winch is in opera-
tion.
- Never use the the electrical cable winch with dam-
aged or kinked cable.
- The electrical cable winch must not be used for
moving jammed or wedged loads.
- Keep the safety distance.
- Avoid over-use of jog control (repeated short im-
pulses to the motor).
- Do not change the direction of movement suddenly.
- Never allow heavy loads to hang for long periods of
time in order to minimise the stress on the winch
and prevent accidents.
Use head protection!
Use protective gloves!
Wear safety boots!
Wear protective clothes!
NOTE!
- Operating personnel must be familiar with the oper-
ation and functions of the Electrical Cable Winch
and the safety regulations pertaining to it.
- The operator is responsible for ensuring that all op-
erating personnel have had the necessary training.
ATTENTION!
Ensure that the cable is rolled up evenly.
NO NO OK

Operation
ESW-Series | Version 1.08 11
When the unwind rope limiter switches off the electrical
cable winch, the circuit is interrupted and the machine is
stopped.
If the electrical cable winch cannot lift a weight immedi-
ately, switch off the electrical cable winch immediately to
avoid damage and accidents.
Ensure that the suspension rope is not deflected by more
than 15° and is not pulled or fastened over sharp edges!
(Risk of damage to the rope).
The direction of unwinding must always correspond to
the switch position, otherwise the electrical limit switch
will not function if it is not observed and serious damage
may be caused to the unit!
If the electrical cable winch is not in operation, it must al-
ways be disconnected from the mains supply.
8.1 Operating conditions
The working area must be dry, fire and explosion pro-
tected and free of any corrosive or poisonous sub-
stances.
The electrical cable winch must not be used to lift or
move dangerous goods such as molten, poisonous or ra-
dioactive materials.
The electrical cable winch may be used outdoors, but not
in heavy rain.
Work duty: S3-20% 10 min
Working cycle 10 minutes, of which 2 minutes operating
time and 8 minutes resting time for cooling down.
8.2 Test run
Before using the the electrical cable winch to lift a load, a
no-load test should be carried out to test all functions. In
particular, the function of the raising and lowering limits
should be tested.
8.3 Raising a load
Step 1: Check that the electrical cable winchand the rope
are in perfect and undamaged condition.
Step 2: Attach the winch load hook to a suitable load at-
tachment point and check that the hook securing
device is closed.
Step 3: Check that the load is securely attached to the
hook. Always stay away from the load and steel
cable during operation.
Step 4: First drive upwards only until the load rope is ten-
sioned.
Step 5: First lift the load only a small piece and check
that the rope and load are stable.
Step 6: Lift the load slowly and evenly.
ESW
Temperature range [°C] 0 to +50
Operating altitude max. 1000m MASL
Operating environment as closed rooms as pos-
sible, non-flammable en-
vironment, as dry and
dust-free as possible.
ATTENTION!
The electrical cable winch may only be connected to
230 V alternating current!
ATTENTION!
- Take care that no person is in vicinity or in line of
the cable behind the the electrical cable winch,
when the the electrical cable winch is under load.
- Make sure that the route of load is free from
barriers.
- Avoid swinging the load.
- The limit switches must not be approached during
operation.
NOTE!
- Do not wrap the rope around the load.
- Check the position of the centre of gravity of the at-
tachment point to prevent movement and slipping of
the load.
- Lifting equipment (eye, chain or similar) must be
loosely positioned at the bottom of the hook.
- The tip of the hook must not be loaded.
- Close the fuse.
NOTE!
- The operator must have sufficient stability and free-
dom of movement.
- The electrical cable winch must be able to swing
freely in the pulling direction.
- Limit switch-off: When the limit of the lifting travel is
reached, the power supply switches off automati-
cally and the load hook stops.
- The load hook is designed in such a way that it de-
forms when overloaded and does not break brittle.

12 ESW-Series | Version 1.08
Care, Maintenance and Repair
8.4 Lowering of a load
When lowering a load, note that the winch may still run a
few centimetres after stopping, so stop in good time.
Step 1: Lower the load smoothly and evenly.
Step 2: Place the load on a firm, safe surface.
Step 3: After lowering the load, open the safety catch on
the load hook and lower the load.
8.5 Operation with pulley
Fig. 7: Operation with pulley (left)
Step 1: Unscrew the cover from the load hook with pulley
and place the steel cable on the pulley. Screw
the cover back on. Check that the cable runs se-
curely on the pulley and that the screws are tight.
Step 2: Connect the load hook on the steel cable into the
suspension device on the housing (Fig. 7 bottom
left).
9 Care, Maintenance and Repair
9.1 Care by cleaning
The electrical cable winch must always be kept in a
clean condition.
All plastic parts and painted surfaces should be cleaned
with a soft, damp cloth and some neutral cleaner.
Remove excess grease or oil with a dry, lint-free cloth.
9.2 Maintenance and repair
If the electrical cable winch is not functioning properly,
contact a specialised dealer or our customer service.
Please find the contact data on chapter 1.2 Customer
service.
Immediately reassemble all protective and safety equip-
ment after completing the repair and maintenance of the
device.
NOTE!
The rope must not be completely unwound! At least 5
windings must remain on the drum. If the red marking
becomes visible, the winch must be stopped immedi-
ately.
CAUTION!
Risk of crushing!
When the load is lowered, the upper and lower limbs
may be crushed.
- Do not hold the upper and lower limbs between the
load and the ground when putting down the load.
ATTENTION!
The electrical cable winch must be disconnected
from the power supply system before starting any
maintenance, servicing or repair work!
Use protective gloves!
NOTE!
Never use strong cleaning agents to clean the device.
Such cleaning agents might damage or destroy the
device.
NOTE!
Oil, grease and cleaning agents are hazardous to the
environment and must not be added to waste water or
normal household waste. Dispose of these agents in
an environmentally friendly manner. The cloths
soaked in oil, grease or cleaning agents are easily
combustible. Collect the rags or the cleaning wool in a
suitable, closed container and dispose of them in an
environmentally friendly manner - do not dispose of
them with your household waste!
ATTENTION!
- Maintenance and repair works must only be per-
formed by specialists.
- Use only original spare parts in case of a repair.

Care, Maintenance and Repair
ESW-Series | Version 1.08 13
Maintenance schedule
If an increase in wear is noted during regular inspections,
the maintenance intervals should be decreased in ac-
cordance with the actual signs of wear. Contact the man-
ufacturer for further information concerning maintenance
tasks and intervals. Please find the contact data on
chapter 1.2 Customer service.
Step 1: Lubricate all moving parts of the electrical cable
winch (gears, bearings) with good quality
grease.
Step 2: Check the electrical cable winch for external da-
mage before each use.
Step 3: Ensure that all safety instructions on the electri-
cal cable winch are clearly legible.
Visual inspection
Checking the load cable for wear
The electrical cable winch is subjected to periodic main-
tenance and supervision. In many cases is the proce-
dure of monitoring regulated in norms and directives
(e.g. DIN 15020 paper 2 ,, principles of Electrical Cable
Winch, monitoring and use“).
The typical evaluation criteria described in norms with re-
gard the wire rope discard in case of e.g. wire break, wire
break nests, strand breakages, structural changes, me-
chanical wear or corrosion can be assessed by appropri-
ate qualified specialists, which are trained in mainte-
nance and assessment of cranes.
Continuous monitoring of the hoist in compliance with
DIN 685 Part 5 and UVV BGV D8 Section 27 (VBG 8
Section 27) is a compulsory requirement. The load cable
should be inspected before starting up and under normal
operating conditions after about 200 operating hours or
10,000 load cycles, under heavy operating conditions at
shorter intervals.
Particular checks should be made on the links, espe-
cially contact points, for wear, deformation, wire breaks,
structural changes, corrosion and other damage.
The cable guide should be checked when changing the
cable and replaced if necessary.
Fig. 8: Steel cable
ATTENTION!
The steel rope must not be lubricated or oiled!
Mainte-
nance
intervals
Maintenance tasks
beforeeach
operation
Check wire rope hoist for damage and
wear, look particularly at the cable and
check for deflection, stretching, fissu-
res or corrosion. If damaged, replace
the rope.
Check brake for damage and wear.
Clean the brake disc (63, Fig. 10) if
necessary and have it replaced in
case of heavy wear.
Check the hook for wear or loss of sub-
stance by grinding. If the wear exceeds
10% of the normal size on delivery, the
hook must be replaced.
Check that the retaining screws and
the mounting bracket are firmly seated
on the carrier.
following
each ope-
ration
Clean the electrical cable winch thoro-
ughly and lubricate well. Oil the load
hook well.
every 40
hours
Function check of the brake (Load
test)
every 200
hours
Wear test and wear measurement of
the brake disc
every 200
hours
Wear test of the rope. Wear test and
wear measurement of the load hook
as required Replacement of the brake disc
as required Replacement of steel cable and load
hook
annually Safety inspection: If the electrical ca-
ble winch is used in a company, it must
be inspected annually in accordance
with the Industrial Safety Regulation
and documented in accordance with §
10.
ATTENTION!
Only use original spare parts of the manufacturer or
spare parts admitted by the manufacturer.
Mainte-
nance
intervals
Maintenance tasks

14 ESW-Series | Version 1.08
Testing the electrical cable winch
Wear measurement and replacement of the load
hook
Fig. 9: Hook dimension
According to DIN 15405 Part 1, the load hook must be
replaced if the expansion is greater than 10%.
10 Testing the electrical cable
winch
The use of the electrical cable winch is possible after:
UVV "Winches, lifting and pulling equipment" BGV D8
(VBG 8), UVV "Cranes" BGV D6 (VBG 9)
Inspection by an expert prior to initial commissioning and
after major modifications when used in accordance with
BGV D8 § 23 (VBG 8 § 23).
Testing in accordance with BGV D6 § 25 (VBG 9 § 25)
by an authorised expert before initial commissioning and
after major modifications.
Periodic inspections of equipment, cranes and suppor-
ting structures by a specialist once a year. In severe ope-
rating conditions, e.g. frequent operation at full load, du-
sty or aggressive environment, high switching frequency,
high duty cycle, test distances must be shortened.
Expert for the testing of cranes, only the experts authori-
sed by the employers' liability insurance associations are
considered in addition to the TÜV experts.
Specialists are customer service fitters of the manu-
facturer or specially trained technical personnel.
The inspection shall be documented in an inspection
book.
The test is essentially a visual and functional test. It ex-
tends to the inspection of the condition of the compo-
nents and equipment, the completeness and effective-
ness of the safety equipment and the completeness of
the inspection book.
Model ESW 500 ESW 800
Cable diameter Ø 4,0 mm Ø 5,0 mm
Tensile strength 1870 N/mm21960 N/mm2
Model ESW 500 Load hook Hook on
roller
Hook length L1 [mm] 93 mm 121 mm
Hook width L2 [mm] 54 mm 73 mm
Diameter D1 [mm] 28 mm 38 mm
Thickness T1 [mm] 9,5 mm 10 mm
Thickness T2 [mm] 10,5 mm 12 mm
Thickness T3 [mm] 12 mm 13 mm
Thickness W1 [mm] 16 mm 17 mm
Thickness W2 [mm] 16 mm 17 mm
Öffnungsweite P [mm] 19 mm 24 mm
Model ESW 800 Load hook Hook on
roller
Hook length L1 [mm] 93 mm 121 mm
Hook width L2 [mm] 54 mm 73 mm
Diameter D1 [mm] 28 mm 38 mm
Thickness T1 [mm] 9,5 mm 10 mm
Thickness T2 [mm] 10,5 mm 12 mm
D
L
P
T3
T
W
WWW
T2
L1
W
W
T3
T2
Thickness T3 [mm] 12 mm 13 mm
Thickness W1 [mm] 16 mm 17 mm
Thickness W2 [mm] 16 mm 17 mm
Opening width P [mm] 19 mm 24 mm
ATTENTION!
Only use original parts from the manufacturer as
spare parts.
Model ESW 800 Load hook Hook on
roller

Troubleshooting
ESW-Series | Version 1.08 15
11 Troubleshooting
12 Disposal, Recycling of used
Devices
Please take care in your own interest and in the interest
of the environment that all component parts of the ma-
chine are only disposed of in the intended and permitted
way.
12.1 Decommissioning
Immediately decommission disused machines in order to
avoid later misuse and endangering of the environment
or personal safety.
Step 1: Eliminate all environmentally hazardous operat-
ing materials from the used device.
Step 2: If required, disassemble the machine into easy-
to-handle and usable components and parts.
Step 3: Dispose of machine components and operating
materials by the disposal channels provided.
12.2 Disposal of electrical equipment
Note that electrical equipment contains a variety of recy-
cling-capable materials and also environmentally haz-
ardous components.
Please help to separate these components and dispose
of them responsibly. In case of doubt, contact your local
waste disposal authority. Consult a specialist disposal
agent for recycling if needed.
12.3 Disposal of lubricants
Remove any leaking, used or excessive grease at the lu-
bricating points.
Disposal notes for used lubricants are available from the
manufacturer of the lubricants. If necessary, request the
product-specific data sheets.
Problem Possible cause Solution
The electrical cable winch motor is
not functioning.
1. Switch defective.
2. Motor defective.
3. Bad contact.
1. Replace switch.
2. Change motor.
3. Check contacts.
Temperature of motor too high. 1. Long service life.
2. Brake is not completely open.
1. File coolling phases
2. Contact customer service.
Motor runs with insufficient power or
too low speed.
1. Bad contact.
2. Insufficient power supply.
1. Check contacts.
2. Check the power supply, have it in-
stalled by a qualified electrician.
Motor is wet. 1. Humidity is too high or water in-
gress.
1. Drain the water. Dry the device. Af-
ter that start the motor and let it
operate for a little while. Repeat
this procedure a few times.
Brake does not work. 1. Brake disc dirty.
2. Brake disc worn.
3. Brake spring is broken.
1. Clean the brake disc
2. Contact customer service
3. Replace brake spring.

16 ESW-Series | Version 1.08
Spare Parts
13 Spare Parts
13.1 Ordering spare parts
The spare parts may be purchased with the authorised
dealer or directly with the manufacturer. Please find the
corresponding contact data in Chapter 1.2 Customer
service.
Indicate the following basic information for requests or
orders of spare parts:
- Type of device
- Item No.
- Position No.
- Year of construction:
- Quantity
- Required mode of dispatch (mail, freight, sea, air,
express)
- Address of dispatch
Spare part orders which do not include the above indica-
tions may not be taken into consideration. If the indica-
tions regarding the mode of dispatch are missing, the
product is dispatched at the discretion of the supplier.
You will find information regarding the device type, item
No. and year of manufacture on the type plate fixed to
the device.
Example
The load hook for the electrical cable winch ESW 500
must be ordered. The load hook is identified in the spare
parts drawing with the number 88.
By ordering spare parts, please send a copy of drawing
with marked part (load hook) and marked positon num-
ber (88) to your dealer or to the spare parts department
and provide the following information:
- Type of device:
Electrical Cable Winch ESW 500
- Spare part: Load Hook
- Item number: 6199500
- Position number: 88
DANGER!
Danger of injury by the use of
wrong spare parts!
Dangers may result for the user and damages as well
as malfunctions may be caused by using wrong or
damaged spare parts.
- Only use original spare parts of the manufacturer or
spare parts admitted by the manufacturer.
- Always contact the manufacturer in case of uncer-
tainties.
Tips and recommendations
The manufacturer's warranty will become null and
void if non-permissible spare parts are used.

Spare Parts
ESW-Series | Version 1.08 17
13.2 Spare parts drawing
In case of service, the following drawing shall help to identify the necessary spare parts. If necessary, send a copy of the
parts drawing with the marked components to your authorised dealer.
Fig. 10: Spare parts drawing ESW 500 and ESW 800

18 ESW-Series | Version 1.08
Electrical Circuit Diagram
14 Electrical Circuit Diagram
Fig. 11: Electrical circuit diagram ESW 500 and ESW 800

EC Declaration of Conformity
ESW-Series | Version 1.08 19
15 EC Declaration of Conformity
According to Machinery Directive 2006/42/EC Annex II 1.A
Manufacturer / distributor: Stürmer Maschinen GmbH
Dr.-Robert-Pfleger-Starße 26
D-96103 Hallstadt
hereby declares that the following product
Product group: Unicraft® Werkstatttechnik
Type of the device: Electrical Cable Winch
Designation of the device*: ESW 500
ESW 800
Item number*: 6199500
6199800
Serial number*: ______________________
Year of manufacture*: 20_____
* please fill in according to the information on the type plate
complies with all relevant regulations of the aforementioned directive as well as any other, applicable directives (subse-
quently added) – including the changes applicable at the time the declaration was made.
Relevant EU directives: 2014/30/EU EMC Directive
The following harmonized standards have been applied:
EN 14492-1:2010-06 Crane - Power-driven winching and lifting gear -
Part 1: Power-driven lifting gear
EN 60204-1:2019.06 Safety of machinery - Electrical equipment of machines -
Part 1: General requirements
DIN EN ISO 12100:2011-03 Safety of machinery - General principles for design -
Risk assessment and risk reduction
Responsible for documentation: Kilian Stürmer, Stürmer Maschinen GmbH,
Dr.-Robert-Pfleger-Str. 26, D-96103 Hallstadt
Hallstadt, 05.02.2021
______________________
Kilian Stürmer
Managing Director

20 ESW-Series | Version 1.08
Maintenance Schedule
16 Maintenance Schedule
Maintenance schedule ESW
40 h 40 h 200 h As re-
quired
200 h As re-
quired
An-
nually
Lubricate bearings, gears Functional check brake system Wear test brake disc Replacement brake disc Wear measurement load rope, hook Replacement load rope, hook Safety check Electrical Cable Winch
Data Opera-
ting
hours
Staff Signature