Suspension Systems Eng

Mounting instructions

Suspension systems

Code No. 99-97-1011

Edition: 04/2012 GB

Page I

Suspension systems/ assemblyEdition: 04/2012 M 1011 GB

Overview of changes / updates in the manual

Name of chapter Type of change /

update

No. of BD

product in-

formation

Issue date Page

1.3 ”Prevention of

reasonably predictable

incorrect uses”

Section inserted 04/2012 2

2 ”Safety instructions” Chapter added 04/2012 8

3.7 ”Cable winch (GS)

for wall-mounted

system incl. hand crank”

Section completely

revised876 04/2012 31

3.11 ”Fine adjustment” Section inserted 848, 1092 04/2012 48

4 ”Suspension system

accessories”

Mounting bracket

35x45x4 added921 04/2012 50

Big Dutchman International GmbHBig Dutchman Pig Equipment GmbHP.O. Box 11 63 · 49360 Vechta · GermanyTel. +49(0)4447-801-0 · Fax [email protected] · www.bigdutchman.de

Productinformation

No. 1381 April 12, 2013

Counter plates for winch motors and wall brackets

Winch motors, pulleys and wall brackets must often be attached to walls where normal screws anddowels cannot be used (e.g. on composite boards). In this case the mounting screws are drilledthrough the wall on which a counter plate is attached outside. Until now these counter plates wereonly available as SAN-articles or just for particular winch motors and brackets.

Two multifunctional usable counter plates are available as stock articles with immediate effect:

Both counter plates have a size of 280 x 280 mm and are made of 3 mm thick stainless steelpanels.

Code No. Description83-11-2612 Counter plate SST f/winch motor CL75A/EWA

For mounting of all winch motors CL75A and all EWA 10, 12, 14 & 16.

83-11-2613 Counter plate SST f/wall bracket universalFor mounting of one or two interconnected "Bracket for idler pulley PVR" (60-60-0002) or a "Bracket universal for cable winches and pulley 3 1/2" " (83-00-0894).

Fig. 1: 83-11-2612 - Counter plate SST f/winch motor CL75A/EWA

Fig. 2: 83-11-2613 - Counter plate SST f/wall bracket universal

Heinz Südkamp Bernd Rosemeyer

- Product Manager- - Product Operator-

Climate Poultry Climate Poultry

No. 1351 January 29, 2013

Starter kit cable winch 2,000 kg with suspensions for daily "up & down"

Broiler breeder houses for hatched egg production are often equipped with suspended feedingsystems. Latter is either a chain feeding system or a Repromatic system. There are differentreasons for the suspension of feeding systems below the ceiling:

• Easy adaptation of the feeding to the development of the birds• Simplified cleaning of the house thanks to the ability to lift the feeding system below the

ceiling• No objections or equipment in the bird area outside the feeding times; this has a positive

effect on the insemination rate• Prevention of shadow casting which leads to a noticeable reduction of mislaid eggs

In order two achieve the last two mentioned aims, the feeding system is lowered every day atfeeding time and afterwards lifted again up to the ceiling.

Starter kit cable winch

Description

The starter kit cable winch for two lines and daily "up and down" consists (similar to the well knownelectric cable winches) of the cable winch with chain pin coupler (fig. 1, pos. 1) and the 5/4" tube(fig. 1, pos. 2). Furthermore, rope drums (fig. 1, pos. 3) and ball bearing plates (fig. 1, pos. 4) forthe tube are available.

Fig. 1: Starter kit cable winch 2000 kg 2lines./12m width/with intermediate ceiling for daily up & down

Pos. 1

Pos. 2

Pos. 3

Pos. 4

Big Dutchman International GmbHBig Dutchman Pig Equipment GmbHP.O. Box 11 63 · 49360 Vechta · GermanyTel. +49(0)4447-801-0 · Fax [email protected] · www.bigdutchman.de

Productinformation

PI No. 1351

Thanks to their larger diameter, the rope drums with grooves prevent the wire rope from damagesand in addition they allow for a higher winding speed. The grooves ensure that adjacent ropelayers do not rub against each other.

The ball bearing plates allow for a smoother run of the tube.

Additionally, special suspensions are available for feed trough, Repromatic feed channel, ifrequired feed cleaner and feed corner and are equipped with larger idler rollers in order to protectthe 3 mm suspension ropes.

Coding, overview of single parts

The new starter kit cable winch for daily up & down is coded as follows:

The following single parts are included:

Code-No. Description

11-32-3035Starterkit cable winch 2000kg 2l./width 12m/with interm.ceil for daily up and down

Pos. Code-No. Description Figure

1 99-50-3401Cable winch 1.10 230/400 50/60 GW80 2000kg w/limit switch

2 99-50-3415 Ball bearing plate for roller tube 5/4"

3 99-50-3414 Bracket f/winch motor GW80

4 83-08-5142Rope drum D=49mm f/tube 1 1/4" w/grooves f/max. 3.5m lifting height+halving of load

5 99-50-3411Chain bolt coupling 10B z16 5/4" for cable winch GW80

6 99-40-3814 Pipe 1 1/4"x6000 galv DIN 2440

PI-No. 1351 Page 3

Planning and installation instructions

• The maximum lifting capacity is 2,000 kg• The rope drums must have at least three wire rope winding also at uncoiled state• Maximum lifting height with load halving: 3.5 m• Maximum lifting height without load halving: 7 m• The house ceiling must be designed for the suspension system• The clearance between rope drum (fig. 2, pos. 1) and last suspension for feed trough or feed

channel (fig. 2, pos. 2) must not be smaller than 5 m• The cable winch has to be positioned at the middle of the load• The central disk of the rope drum must be aligned with the main traction rope (fig. 2)• Please also see installation and planning aids included in the manual „Suspension systems”

(Code no. 99-97-1011)!

Fig. 2: Scheme of suspension systems and rope drums

USE AND OPERATION

• Depending on the type of motor reductor the output shaft can make max. 34, 88 or 1,400rotations.

• Operating temperature: -15°C to +60°C.

ASSEMBLY

The following points must be observed during the assembly of the limit switch:

1. Position the limit switch below the black plastic cover of the motor reductor.2. For this purpose, bring the limit switch in the destined position above the selector shaft.3. Make sure that the adjusting screw (B) can press the switch spring (6) of the two operating

switches. This means that the adjusting screw (B) must always be between the switch spring (6) and the operating switches (S11 or S12).

4. Tighten the cross-head screws.

pos. 1pos. 2

pos. 2min. 5 m min. 5 m

PI No. 1351

ADJUSTMENT OF LIMIT SWITCH (see fig. 3)

In order to adjust the limit switch system the following steps must be carried out:

1. Remove the black plastic cover of the motor reductor. The limit switch is visible now.2. Check, if the adjusting rings (3) are loosely positioned on the knurled nuts (4). The knurled

nuts can thus easily be turned over the threaded rod by hand (1).3. Determine which operating switch (S11 or S12) operates the starting position and which one

the limit position. This can be achieved by a rotation of the electric motor shaft. For this purpose put a hexagon wrench key in the motor shaft. During the rotation of the shaft the switching nuts (5) move lineally along the threaded axis (1) towards one operating switch (S11 or S12). This operating switch (S11 or S12) limits the system in the selected sense of rotation (left or right) of the electric motor shaft.

• Note: for the rotation of the electric motor shaft also a drilling machine with hexagon wrenchkey can be used. In order to prevent damages of the hexagon bore inside the shaft, themaximally allowed number of revolutions of the drilling machine is 250 rpm!

• Tip: mark which operational switch limits the starting position and which the end position inorder to prevent errors!

4. Bring the system in the outer starting position by rotating the electric motor shaft.5. Turn the knurled nuts (4) hand-tight against the stopper (2) in direction of the operating

switch determined under point 3 (S11 or S12), which limits the starting position.6. Turn the adjusting ring (3) above the knurled nut (4) by means of the wrench key until the

operating switch (S11 or S12) switches. A quiet click is audible.7. Turn the adjusting ring tightly onto the wrench nut (4) by means of the wrench key by

tightening the adjusting screws (7 and 8). The adjusting ring (3) can no longer be turned over the knurled nut (4).

8. Bring the system to the outer end position by turning the electric motor shaft.9. Repeat the points 5-8 to adjust the end position.

• Note: bring the hexagon wrench key (A) back into the limit switch. Make sure that the shortside is points downwards!

10. Keep the bag with the setting instruction outside the limit-switch system.

• Note: do not keep loose parts below the black plastic cover. This might have an effect on thefunction of the system!

11. Put the black plastic cover onto the motor reductor and tighten the cross-head screws.

PI-No. 1351 Page 5

Fig. 3: Overview adjustment of limit switch

Special suspension sets for chain guidance or Repromatic and daily "up & down"

Description

The suspension kits for daily "up & down" have larger idler rollers in order to compensate theadditional load of the 3 mm suspension ropes for feed corners, feed troughs, feed channels andfeed cleaners.

The chain coupling set, with a duplex chain according to DIN chain no. 08B-2 with 12 links (including connecting link), connects the drive shaft of the GW motor gearbox with the system’s drive tube.

lick

1 2

1 2

5 ( tandard)

2

1

PI No. 1351

Coding, overview of single parts

The following suspension kits for daily "up & down" are available:

Chain feeding

Repromatic

These suspension kits include the following single parts:


10-93-3854 Suspension f/corner for daily up and down

10-93-3855 Suspension f/feed cleaner for daily up and down

10-93-3853 Suspension f/feedtrough for daily up and down


10-93-3858 Accessories for suspension RPM per circuit f/daily up & down

10-93-3857 Suspension f/Basic-unit for RPM/Challenger daily up and down

Pos. Code-No. Description Figure

1 99-50-0013 Wire rope 3mm galv

2 99-50-0120 Cable clamp 5mm galv. similar DIN 741

3 11-00-3002 Cable lock AM

4 00-00-3006 Pulley 4 1/8" 105mm plastic with split strap

5 10-93-3856Hanger for feedtrough 3000 regular/medium 1,2mm (wire)

6 15-00-1005 Hanger for corner 90/135deg

7 10-93-3876 Hanger for feed channel RPM

PI-No. 1351 Page 7

On request also alternative starter kits for daily "up & down" with lower lifting capacities arepossible. However, the lifting capacity of the winches is reduced by 30%!

For further information regarding the BD-suspension systems please see manual "Suspensionsystems" (code no. 99-97-1011).

Jörg Hurlin Rüdiger Sudhop- Product Manager - - Product Operator -Fattening Systems Fattening Systems

Page I Table of contents


1 Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.1 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.2 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.3 Prevention of reasonably predictable incorrect uses . . . . . . . . . . . . . . . . . . .2

1.4 Explaining the symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21.4.1 Safety symbols in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21.4.2 Safety symbols in the manual and on the installation . . . . . . . . . . . . . . . . . . . . .31.4.3 Safety symbols and notes on your installation . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.5 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.6 Obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.7 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.8 Disorders due to power failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1.9 First aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.10 Pollution abatement regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.11 Waste disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

1.12 Notes for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.13 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

2.2 Safety regulations for the use of electrical appliances . . . . . . . . . . . . . . . . .8

2.3 System safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92.3.1 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92.3.2 Entire system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102.3.3 Individual components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112.3.3.1 Feeding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112.3.3.2 Water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112.3.3.3 Electrical components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

2.4 Personal safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.4.1 Clothing for personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122.4.1.1 Clothing and footwear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132.4.1.2 Jewellery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132.4.1.3 Hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132.4.2 Assembly and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132.4.3 Employing external personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.5 Safety contrivances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.6 Dangers resulting from non-compliance with the safety instructions . . . . .15

3 Assembling the cable winches and the suspension system . . . . . . .16

3.1 Suspension material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

3.2 Cable winches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3.3 Cable winch 1 line with drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Table of contents Page II


3.4 Cable winch 2 lines 12 m width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213.4.1 Distance between the sliding bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223.4.2 Distance between the sliding bearings with load-halving device . . . . . . . . . . . 223.4.3 Assembly of the cable winch with two lines in houses with intermediate

ceilings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233.4.4 Assembly of the cable winch 2 lines in houses with cover = roof . . . . . . . . . . 25

3.5 Connecting the tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.6 Assembling the main pulley cable and deflection pulleys. . . . . . . . . . . . . . 293.6.1 Assembling the main pulley cable and the deflection pulleys without the

load-halving device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303.6.2 Assembling the main pulley cable and the deflection pulleys with the load-

halving device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.7 Cable winch (GS) for wall-mounted system incl. hand crank . . . . . . . . . . . 313.7.1 Assembling the brackets on the wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.7.2 Assembling the cable winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333.7.3 Fastening the cable in the cable winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.8 Cable winch 550 kg for ceiling-mounted system . . . . . . . . . . . . . . . . . . . . . 363.8.1 Assembling the 550 kg cable winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393.8.2 Assembling the 550 kg cable winch without load-halving device: . . . . . . . . . . 403.8.3 Assembling the 550 kg cable winch with load-halving device: . . . . . . . . . . . . 40

3.9 Cable winch 340 kg CH for ceiling or gable assembly . . . . . . . . . . . . . . . . . 413.9.1 Ceiling-mounted system for cable winch 340 kg CH . . . . . . . . . . . . . . . . . . . . 433.9.1.1 Assembling the 340 kg CH cable winch without load-halving device . . . . . . . . . . . 443.9.1.2 Assembling the 340 kg CH cable winch with load-halving device . . . . . . . . . . . . . 443.9.2 Gable-mounted system for cable winch 340 kg CH . . . . . . . . . . . . . . . . . . . . 453.9.2.1 Assembling the 340 kg CH cable winch without load-halving device . . . . . . . . . . . 453.9.2.2 Assembling the 340 kg CH cable winch with load-halving device . . . . . . . . . . . . . 46

3.10 Hand crank for cable winches 340 kg CH and 550 kg. . . . . . . . . . . . . . . . . . 47

3.11 Fine adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

4 Suspension system accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Basic instructions


1 Basic instructions

1.1 Basics

The Big Dutchman installation has been constructed according to the current state of

the art and all acknowledged regulations regarding technical safety. The installation is

reliable. Upon operation, however, dangers to life and limb of the user or third persons

or impairments of the system or other material property are still possible.

The system may only be mounted, attended, repaired und used:

• for due use

• in an excellent state from the safety and technical point of view

• by persons who are familiar with the safety regulations

In the event of special problems which are not described in detail in this manual, we

recommend to contact us for your own safety.

1.2 Designated use

The Big Dutchman suspension systems are intended exclusively for suspending

feeding and drinking systems and specific tiers of grating in poultry houses.

The Big Dutchman system may only be used according to its designated use.

Every other use is considered as non-designated use. The manufacturer does not

accept liability for damages resulting from other uses, the user alone has to bear the

risk. The designated use also includes the exact following of the operation,

maintenance and repair conditions as prescribed by the manufacturer.

!Please take care of this manual and always keep it in the same place

close to the installation for quick reference. All persons working with the

system, assembling, cleaning and servicing have to be familiar with the

contents of these instructions.

Please observe the contained safety instructions!

If this manual gets damaged or lost, request a new copy from Big

Dutchman.

Basic instructions Page 2


1.3 Prevention of reasonably predictable incorrect uses

The following uses of the Big Dutchman system are not permitted and qualify as

misuse:

• Moving any loads other than those for which the system is designed

• Operating the suspension system despite it having faulty components

• Use of improper detergents and disinfectants.

• Too long residence time of detergents and disinfectants.

A non-designated use will lead to a liability exclusion by Big Dutchman.

Only the user of the system takes the risk resulting from a misuse!

1.4 Explaining the symbols

1.4.1 Safety symbols in this manual

Upon reading this manual you will come across the following symbols

WARNING

This symbol indicates risks possibly leading to personal injury resulting in

death or to severe injuries.

CAUTION

This symbol indicates risks or insecure procedures possibly leading to

injuries or material damage.

NOTE

This symbol indicates notes leading to an effective, economic and

environmentally-conscious handling of the installation.

Basic instructions


1.4.2 Safety symbols in the manual and on the installation

These safety symbols illustrate remaining dangers when handling the system. They are

supplements to the above-mentioned symbols:

1.4.3 Safety symbols and notes on your installation

Depending on the type of installation you will find the following safety symbols. They

indicate technically remaining dangers when handling the system and give information

on how to avoid these dangers.

Warning against dangerous electrical voltage

Warning against the cold

Warning against slippery surface

GENERAL DANGER !

Installation automatically starts working. Before starting repair,

maintenance or cleaning work, put main switch to ”OFF”.

Danger of bruising due to rotating machine parts!

Close protective devices each time before taking the system

into operation. Opening protective devices is only allowed

when the system is in a standstill. People have to be authorised

for this.

RISK OF INJURY due to operating auger, chain or cable

discs!

Never reach into or climb into a feed container or trough while

the motor is running.



Implicitly observe the instructions attached to the installation, such as the arrow on the

motor indicating the direction of rotation.

The signs and safety instructions always have to be visible and must not be damaged.

If they are soiled by dust, manure, feed remains, oil or grease, clean them by means of

a water-detergent mixture.

1.5 Ordering spare parts

Indicate the following for ordering spare parts:

• Code No. and description of the spare part or

• Invoice No. of original invoice

• Power supply e.g. 230/400V-3Ph.- 50/60Hz

DANGER OF SKIN CORROSION due to purifying agents!

Always wear protective clothing when repairing, maintaining

and cleaning the installation. Always observe the

manufacturer’s instructions when using acids!

If a safety symbol or instruction is fixed to a part to be replaced,

ensure that it will be fixed to the new part as well.

Operational safety is the prime necessity!

For your own safety only use original Big Dutchman spare parts. For

foreign products that have not been released or recommended or for

modifications carried out (e.g. software, control units) we cannot judge

whether there is a safety risk in connection with the Big Dutchman

systems.

You can find the exact description (Code No.) of the parts for ordering

spare parts by means of the position numbers in the spare parts lists (see

appendix).

Basic instructions


1.6 Obligations

Closely adhere to the instructions in this manual.

A basic condition for safe operation and trouble-free handling of this system is the

knowledge of the basic safety instructions and regulations.

These mounting and operating instructions, particularly the safety instructions, have to

be observed by everyone working with this system. Moreover, the regulations and

instructions for the prevention of accidents valid at the respective place of use have to

be observed.

The manufacturer is not responsible for any damages to the machine resulting from

changes done by the user.

1.7 Warranty and liability

Warranty and liability claims regarding personal and material damage are excluded if

they result from one or several of the following causes:

• non-designated use of the installation

• inappropriate mounting and operating of the system

• operating the system with defective safety equipment or not duly fixed or not

functioning safety and protective devices,

• non-observance of the instructions in this manual regarding transport, stock

keeping, mounting, maintenance, operating and upgrading of the system

• unauthorised modifications on the system

• inappropriate repairs

• in the event of disasters caused by foreign matters or force majeure.

1.8 Disorders due to power failure

We recommend the installation of warning systems for a better monitoring of your

production units and the installation of an emergency power-generating set for

adequate supply with power in case of power failure. By this, you protect the animals

and thus your own economical health. For further information please contact your

property insurance.



1.9 First aid

For the case of an accident, unless specified otherwise, a first-aid kit must always be

available at the place of work. Material taken out and used is to be replaced

immediately.

If you need help, describe the accident as follows:

• where it happened

• what happened

• the number of persons injured

• what type of injury

• who is reporting the accident (your data)!

1.10 Pollution abatement regulations

All works on and with the installation have to be carried out in compliance with the legal

requirements concerning waste prevention and proper recycling / disposal of waste.

Special care has to be taken when carrying out installation, repair and maintenance

works, as water pollutants like lubricating grease and oils, as well as solvent-containing

cleaning solutions are not to pollute the soil or get into the canalisation! These materials

have to be kept, transported, collected and disposed of in appropriate containers!

1.11 Waste disposal

After finishing the assembly or repair of this installation, dispose of the packing material

and remains which do not need to be further used according to the legal provisions for

recycling. The same applies to the component parts after putting the installation out of

service.

Basic instructions


1.12 Notes for use

We reserve the right to modify the construction and technical data for reasons of further

development.

Therefore, no claims can be derived from the information, pictures, drawings and

descriptions. Subject to correction !

Get the information on mounting, adjusting, operating and maintaining before taking

the system into operation.

Apart from the safety-relevant instructions in this manual and the safety precautions

valid in the country of use, also consider the generally acknowledged technical

regulations (safe and appropriate working according to UVV, VBG, VDE etc.).

1.13 Copyright

This manual is subject to copyright. The information and drawings included in this

manual shall not be copied without the manufacturer’s consent, nor shall they be used

for anything other than the designated use. Neither shall they be given to third parties.

If you find mistakes or unclear information in this manual, please do not hesitate to let

us know.

All trade marks mentioned or shown in the text are trade marks of their respective

owners and are recognised as patented.

© Copyright 2012 by Big Dutchman

For further information please contact:

Big Dutchman International GmbH, P.O. Box 11 63, D-49360 Vechta, Germany,

Phone +49(0)4447/801-0, Fax +49(0)4447/801-237

e-mail: [email protected], Internet: www.bigdutchman.de

Safety instructions Page 8


2 Safety instructionsThese mounting and operating instructions, particularly the safety regulations, have to

be observed by all persons working on this system. Moreover the regulations for

accident prevention valid for this place have to be observed!

2.1 General safety instructions

All established safety precautions and other generally accepted safety regulations and

medical references have to be observed. Please check safety and function control

devices to ensure safe and accurate operation:

• before putting into operation

• at adequate time intervals

• after modifications and repairs.

Check the proper functioning of the system after any kind of repair works. You may only

take the device into operation, when all protective systems have been put into place

again. Follow the directions of the electric and water supply company.

2.2 Safety regulations for the use of electrical appliances

You have to ensure that the system with the electrical appliances is operated and

maintained according to the electro-technical regulations.

Installation and work on electric components/structural groups may only

be carried out by qualified personnel according to electro-technical

regulations (e.g. EN 60204, DIN VDE 0100/0113/0160).

Dangerous electric tensions are bare in case of open control equipment.

Be aware of the danger and keep workers of other professions away from

the danger zone !

Do not install control devices directly in the house, but in the service room

to prevent corrosion caused by ammonia gas.

Safety instructions


Immediately switch off the installation in the event of malfunctions of the power supply

units. Use a bipolar voltage probe to make sure that the electrical equipment is not

alive.

Check the electrical wiring and cables for recognisable damage before putting the

device into operation. Replace damaged wiring and cables before taking the device

into operation.

Only use the fuses indicated in the circuit diagram. Immediately replace damaged

fuses. Never repair or bypass the fuses!

Never cover the electrical motor. This can cause high temperatures resulting in fire and

a break-down of the equipment.

The control box as well as the terminal and connector boxes of the installation must

always be kept shut.

Let damaged or broken plugs be replaced by an electrician.

Do not pull the plug from the socket at the flexible cable.

For the respective connections please see the enclosed connecting plan of the system

parts delivered.

2.3 System safety instructions

2.3.1 Danger zone

The different areas of the Big Dutchman installations are characterised by different

types of construction.

Warning

Never repair or bypass the fuses!

Damaged fuses have to be replaced with new fuses!

Never reach into the running installation. Before reaching into the

installation, turn the system off and secure it against unintentional

actuation.

Assure yourself beforehand that the main switch is in the OFF position and

can not be put in the ON position without your knowledge.



There are several system parts that run out, rotate or slide that can increase the risk of

an accident when you are unaware of the type of construction.

There are hazard areas where a risk of injury exists

• due to rotating parts

• due to electrical current in case of non-reliable or defective switching-off of

overload current.

2.3.2 Entire system

• Parts lying about on the system or around it can cause you to stumble or fall so that

you can get injured by the constructional parts of the system.

• Ignorance of the constructional structure of the system can lead to injuries.

• Parts lying about in / on the components (e.g. in the feed trough, on the egg belt,

in the nests etc.) can severely damage the system.

After repair or maintenance work, never place any objects (e.g. spare

parts, replaced parts, tools, cleaning implements etc.) in the accessible

areas of the system or around it!

Make sure that all loose or replaced parts have been removed from the

system components before the system is taken into operation again!

Make yourself familiar with the construction of the system in sufficient

light! If this is not possible at site, get all available information on the

remaining dangers in connection with this system!

When working under the installation, always wear a safety helmet!

Safety instructions


2.3.3 Individual components

2.3.3.1 Feeding system

• Rotating or sliding parts of the feeding system can lead to injuries!

2.3.3.2 Water supply

• Leaky hoses, seals or nipple drinkers can cause water damage in the house and

destroy the installation and electrical systems.

• Danger of electric shock

• Danger of short circuits

2.3.3.3 Electrical components

Always disconnect the power supply before carrying out any work at the

feeding system, as the feeding system switches on automatically when

controlled by an automatic switch clock.

Never reach into the feed chain that runs inside the feed trough!

Never reach into the rotating feed chain drive (always keep the protecting

cover closed)!

Never touch or reach into rotating or driven parts of the installation.

First disconnect main power supply and then enter the house

compartment!

If you have to carry out maintenance, cleaning or repair work get the

information beforehand, where the main electric switch is located.

Put main switch to ”Off” and indicate maintenance or repair work by a sign

fixed to the main switch!

Immediately disconnect main water supply!



2.4 Personal safety instructions

These safety instructions are intended to make you familiar with all information

regarding the system that are important for your safety and that of the system.

Maintenance may only be carried out by specially trained and briefed users.

Keep with the safety instructions in this manual.

2.4.1 Clothing for personal safety

High electric tension!

If touching live parts, severe injuries due to electric shocks are possible!

During repair or maintenance work, live elements can be bare!

Never touch bare electrical components. Staff members must not use

machines with bare electrical components.

Missing knowledge on the structural design of the installation can lead to

injuries.

Make yourself familiar with the design and construction of the installation

Inform yourself and your colleagues about the remaining dangers in

connection with this installation!

Wear close-fitting clothes when carrying out mounting, maintenance and

cleaning work at the installtation.

Do not wear rings, chains, watches or other items which could get caught

at parts of the installation.

Never work with long hair that is not tied together. Your hair could get

caught in moving devices or system parts and thus cause serious injuries.

During all mounting, maintenance and cleaning work at the installation,

wear protective clothes and shoes as well as safety glasses and gloves if

required.

Safety instructions


2.4.1.1 Clothing and footwear

• Wide, fluttering clothes increase the risk of an accident.

• Wide pieces of clothing, ties, scarves etc. can get caught in the moving or rotating

system parts.

• High heels are a safety risk.

• If you stumble, you can knock against sharp-edged, moving or rotating system

parts and get severely injured.

2.4.1.2 Jewellery

• Loose or large jewellery increases the risk of an accident.

• The large or loose parts of jewellery can get caught in components of the

installation.

2.4.1.3 Hair

• Long hair increases the risk of an accident.

• Long hair can get caught in moving or rotating system parts.

2.4.2 Assembly and maintenance

Assembly of the installation can be carried out by the farmer himself or by an authorized

person. We assume that the operator or authorized person either have some sort of

technical training or have the necessary knowledge or practical experience that are a

main condition for a proper assembly of the installation.

Secure wide, fluttering clothes or take them off!

When working at or on the system, only wear slip-free footwear and safety

shoes when replacing heavy system parts!

Take off all jewellery, particularly necklaces, bracelets and rings!

Secure long hair by tying it back or wearing a bandanna or cap!



Repairs must only be carried out by persons who can guarantee for a proper execution

on the basis of their training or their practical knowledge and experiences. Only the

owner or the operator have the power of such a decision.

Every electrical work must only be carried out by qualified electricians according to the

respectively valid electrical regulations such as DIN, VDE, safety regulations and the

prescriptions of the local electric power supply companies or the regulations valid in the

country.

Only work with appropriate tools; in case of possible danger to hands, use protective

gloves, and safety glasses in case of danger to the eyes.

Check the proper functioning of the system after any kind of repair or maintenance. You

may only take the device into operation, when all protective systems have been put into

place again.

2.4.3 Employing external personnel

Mounting, maintenance and repair work is frequently carried out by non-operating

personnel, which is not familiar with the special circumstances and the inherent

dangers

You as operator are to survey the personnel and to define responsibilities and powers.

Inform these people in detail on the dangers of their area of work. Check their method

of working and intervene as soon as possible.

Always switch off the installation, disconnect the power supply and make

sure that the installation cannot be switched on again before carrying out

any repair, maintenance and cleaning work or before removing any

malfunction.

Secure the installation by putting a fixed sign at the main switch "Do not

activate!" and if required add the note that maintenance work is carried

out.

As supervisor, you are responsible for the safety of external personnel!

Safety instructions


2.5 Safety contrivances

2.6 Dangers resulting from non-compliance with the safety instructions

Non-observance of these instructions can cause severe danger for life and health of

people or can lead to material or environmental damages and to the forfeiture of any

claim for damages. To be precise, the non-observance of these instructions can lead to:

• Failure of vital functions of the installation

• Failure of prescribed maintenance methods

• Dangers for people owing to electrical and mechanical influences.

It is strictly forbidden to remove or put out of operation any safety

contrivances. This leads to risk of injury and danger of life! Should the

safety devices be damaged, the system has to be put out of operation

immediately. The main switch has to be locked in zero position.

Assembling the cable winches and the suspension system Page 16


3 Assembling the cable winches and the suspension system

3.1 Suspension material

The suspension material is required for hoisting feeding and drinking systems,

supplying and moving out the animals and cleaning the house. The suspension

material comprises:

• Cable winch and pulley with fastening material

• Cable with cable clamp

• Suspension material for corner, feed trough, AM/BP pipe, drinkers, feed hopper

and drive.

When choosing the suspension material see to the carrying capacity of

the support material and the admissible charges of cable winches and

fixing material.

Upon planning or before starting the assembly find out the weight of the

material to be suspended.

For the weight of the system parts refer to the manual of the system to be

mounted.

After mounting check all main traction cables, particularly in the area of the

take-up tube. The farm staff has to repeat this after each grow-out.

The fastening material for the suspension system is not included in the

system’s scope of supply and must either be provided by the customer or

purchased as an optional extra.

The suspension system should be installed according to the planning

documents and/or installation diagram.

The max. distance between the suspension points is 3 m.

If a linear suspension system is used, the frame screws must be installed

on alternate sides at a distance of approx. 5 cm from the Ø 5 mm pulley

cable.

If the cable winch is to be used for loads greater than those permissible,

a loose roller must be installed. Using a loose roller halves the load placed

on the winch and doubles the length of the cable to be wound.

Attention should be paid to the arrangement of the rollers.

Assembling the cable winches and the suspension system


3.2 Cable winches

Check for proper ratchet operation on each use of the winch. Do not use if damaged.

Seek immediate repairs.

Maintain a firm grip on the winch handle at all times, and never release the handle when

ratchet lever is in unlocked position with a load on the winch. Otherwise, handle will

spin violently, which could cause personal injury.

Never pull on the winch handle against a locked ratchet.

Never exceed rated capacity. Excess load may cause premature failure and could

result in serious personal injury.

Never apply load on winch with cable of rope fully extended. Keep at least three full

turns of cable or rope on the reel.

Do not apply any kind of motor with manual winches.

Never allow children or anyone who is not familiar with the operation of the winch to

use it.

Before starting to assemble, operate or maintain the cable winch, read the

enclosed leaflet and consider the following safety instructions!

Caution:

Ensure that the cable winches in a ceiling-mounted system are always

installed in the centre of the load.

High forces are created when using a winch, creating potential safety

hazards.

Defective cables have to be replaced immediately!

After mounting check all main traction cables, particularly in the area of the

take-up tube. The farm staff has to repeat this after each grow-out.



3.3 Cable winch 1 line with drum

The fastening material (X) for fastening the bracket at right angles (7) is

not included in the scope of supply and must either be provided by the

customer or purchased as an optional extra.



Pos. Code no. Description

X Fastening material

1 99-50-3161 Cable winch 0.09 230/400 50/60 RW45-3L 320/240kg w/limit switch

1.1 Motor 65/9/09/400-480/3/4P 763010

2 99-50-3162 Cable winch 0.09 230 50/60 RW45-3L 320/250kg w/limit switch

2.1 Motor 65/9/09/230/1/4P 701001

3 99-50-5163 Cable winch 0.37 230/400 50/60 RW245L 850/700kg w/limit switch

3.1 Motor 85/14/37/400-480/3/4P 763040

4 99-50-3164 Cable winch 0.37 230 50/60 RW245L 850/850kg w/limit switch

4.1 Motor 85/14/37/230/1/4P 701031

5 99-50-3165 Cable winch 0.55 230/400 50/60 RW405L 1400/1100kg w/limit switch

5.1 Motor 100/19/55/400-480/3/4P 763060

6 99-50-3166 Cable winch 0.55 230 50/60 RW405L 1400/1400kg w/limit switch

6.1 Motor 100/14/55/230/1/4P /OC/C 701042

7 99-50-3194 Bracket right-angle H=100mm for cable winch RW4-605

8 99-10-1068 Hexagon bolt M 10x20 DIN 558

9 99-20-1055 Lock washer A 10 DIN 127

10 99-50-3191 Drum for cable winch RW245L/405/45L

11 Drum discs large

12 Drum discs small

13 Parallel key 8x7x70 296160

14 15-40-1310 Retaining ring A16 DIN 705 296416

15 Hex bolt M 6x85 DIN 931

16 99-20-1043 Locknut M 6 DIN 985



3.4 Cable winch 2 lines 12 m width

The fastening material (X) for fastening the bracket at right angles (10) is

not included in the scope of supply and must either be provided by the

customer or purchased as an optional extra.

If the distance between the centre of the chain link pin coupling and the

center of the cable winding is > 3m, the 1 1/4"x6000 pipe must also be

supported with a “mounting plate for sliding bearing plate B 5/4” and a

“sliding bearing plate B 5/4" B55/L95”.

A distance between lines of more than 12 m requires a 6 m extension kit.

Based on the pulley principle, the load to be lifted can be halved by using

an additional loose roller. This winds double the length of cable and halves

the lifting speed.



3.4.1 Distance between the sliding bearings

At a lift height of 3 m, the sliding bearing plates must be mounted at intervals of at least

245 mm .

3.4.2 Distance between the sliding bearings with load-halving device

When using the load-halving device and there is a lift height of 3 m, the sliding bearing

plates must be mounted at an interval of at least 470 mm .

The distance between two B5/4" B55/l95 sliding bearing plates must be

large enough for all windings of the main pulley cable to sit alongside one

another on the 1 1/4"x6000 pipe.

Example:

Lift height 3 m

Circumference of the 5/4” pipe 133 mm

Diameter of the main pulley cable 5 mm

Number of initial windings 4

Lift height (m) 3m x 1000 mm/m

Number of windings (n) --------------------------------- = ------------------------ = 22,5

Circumference 5/4” pipe 133 mm

Distance from sliding

bearings = [in mm]

Number of windings x cable strength x 2 main pulley cable

+ (Number of initial windings x cable strength)

= 22.5 x 5 x 2 + (4 x 5 mm)

= 245

When using the load-halving device, ensure that double the cable length

is wound.

Distance from sleeve

bearings when using the

load-halving device (mm)

based on the example 3.4.1

=Number of windings x 2 x cable strength x 2 main

pulley cable + (Number of initial windings x cable

strength)

= 22.5 x 2 x 5 mm x 2 + (4 x 5 mm)

= 470



3.4.3 Assembly of the cable winch with two lines in houses with intermediate ceilings



1 99-50-3151 Cable winch 0.37 230/400 50/60 RW245 850/700kg w/limit switch

1.1 Motor 85/14/37/400-480/3/4P 763040

2 99-50-3152 Cable winch 0.37 230 50/60 RW245 850/850kg w/limit switch

2.1 Motor 85/14/37/230/1/4P/OC 701031


3.1 Motor 100/19/55/400-480/3/4P 763060


4.1 Motor 100/19/55/230/1/4P/OC/C 701042


5.1 Motor 100/19/110/400-480/3/eP 763080


6.1 Motor 100/19/110/230/1/4P/OC/C 701062

7 Sprocket 5/8", z 16 for shaft Ø 28, Pos. 1-4 416979

Sprocket 5/8", z 16 for shaft Ø 34, Pos. 5-6 417329

8 99-50-3909 Parallel key 8x7x35 DIN 6885 Form A for Pos. 1-2 296154

99-50-1264 Parallel key 8x7x40 DIN 6885 Form A for Pos. 3-4 296155


9 Retaining ring DIN 471 28x1.2 for Pos. 1-4 295328

Retaining ring DIN 471 34x1.5 for Pos. 5-6 295334

10 99-50-3194 Bracket right-angle H-100 mm for cable winch RW45-605


12 99-20-1055 Lock washer A 10 DIN 127

13 99-50-3171 Chain link pin coupling 5/8"/z/16/5/4" cplt. for Pos. 1-6 590014

14 Chain link sprocket 5/8"/z16/S/B5/4 417462

17 Roller chain double 5/8"x3/8" 15 links 414243

18 Chain connecting link 5/8"x3/8" double 281030

19 99-40-3814 Piper 1 1/4"x6000 DIN 2440

20 99-20-1064 Locknut M 8 DIN 985

21 99-101278 Hex bolt M 8x600 DIN 558

22 99-50-3172 Sliding bearing plate B5/4" B55/L95

23 99-50-3173 Mounting plate for sliding bearing plate B 5/4"

24 99-10-1067 Hex bolt M 6x16 DIN 558

25 99-20-1043 Locknut M 6 DIN 985

26 99-50-1420 U-bolt cadm. cplt. 8x25/W52/H69 pipe 2"

27 Pulley cable



3.4.4 Assembly of the cable winch 2 lines in houses with cover = roof




1.1 Motor 85/14/37/400-480/3/4P 763040


2.1 Motor 85/14/37/230/1/4/P/OC 701031


3.1 Motor 100/19/55/400-480/3/4P 763060


4.1 Motor 100/19/55/230/1/4P/OC/C 701042


5.1 Motor 100/19/110/400-480/3/4P 763080


6.1 Motor 100/19/110/230/1/4P/OC/C 701062

7 Sprocket 5/8", z 16 for shaft Ø 28, Pos. 1-4 416879

Sprocket 5/8", z 16 for shaft Ø 34, Pos. 1-4 417329

8 99-50-3909 Parallel key 8x7x35 DIN 6885 Form A for Pos. 1-2 296154



9 Retaining ring DIN 471 28x1.2 for Pos. 1-4 295328

Retaining ring DIN 471 34x1.5 for Pos. 5-6 295334

10 99-50-3194 Bracket right-angle H=100mm for cable winch RW45-605


12 99-20-1055 Lock washer A 10 DIN 127

21 99-10-1278 Hex bolt M 8x60 DIN 558

22 99-50-3172 Sliding bearing plate B 5/4" B55/L95

23 99-50-3173 Mounting plate for sliding bearing plate B 5/4"

24 99-10-1067 Hex bolt M 6x16 DIN 558

25 99-20-1043 Locknut M 6 DIN 985


27 Pulley cable



3.5 Connecting the tubes

The bores for connecting the 1¼"x6000 pipes (1) to the 35x3-200

couplings for the 1¼" pipe (2) must be created during the assembly

process.

The distance to the first bore at the end of the 1¼x6000 pipe (1) is 20 mm.

The distance of the second bore from the end of the 1¼"x6000 pipe (1) is

80 mm and is offset by 90º from the first bore.


1 99-40-3814 Pipe 1¼"x6000 DIN 2440

2 99-50-3174 Coupling 35x3-200 for pipe 1¼"

3 99-20-1064 Self-locking nut M8 DIN 985

4 99-10-1278 Hex bolt M 8x60 DIN 558



For your notes:



3.6 Assembling the main pulley cable and deflection pulleys


1 99-50-3700 Cable 5 mm galv. 7x19

99-50-3703 Cable 4 mm galv.

2 99-50-0013 Cable 3 mm 6x7/FE

99-50-1019 Suspension rope 3mm PES black

3 99-50-0120 Cable clamp 5 mm 3/16" galvanised DIN 741

4 00-00-3005 Pulley 3 1/2" 89 mm CH casting

5 00-00-0313 Pulley 1 7/8" 45 mm

6 10-93-1629 Frame screw galv. 80x22x7,8 to be supplied by the customer

10-93-1642 Frame screw galv. 120x22x7.8 to be supplied by the customer


99-50-3814 Hook bolt galv. 140x6.5 to be supplied by the customer

7 99-40-3814 Pipe 1¼"x6000 DIN 2440



10 99-50-1077 Thimble galv. 6 mm f/cable 5 mm DIN 6899 NG 6 RW7



3.6.1 Assembling the main pulley cable and the deflection pulleys without the load-halving device

3.6.2 Assembling the main pulley cable and the deflection pulleys with the load-halving device



3.7 Cable winch (GS) for wall-mounted system incl. hand crank

Warning:

This winch is not intended to be used for lifting, carrying or transporting

people or loads in areas in which people are located. This winch must not

be used to secure loads (e.g. vehicle transporter). Before installing,

operating or servicing this winch, carefully read all instructions contained

in the enclosed operating instructions.

Failing to follow the instructions may lead to severe or fatal injuries. Keep

these operating instructions for reference.

Code No. 99 50 3099

Cable winch 350 kg GS for wall-mounted

system incl. hand crank

Code No. 99 50 3142

Cable winch 800 kg for wall mounting incl.

hand crank



3.7.1 Assembling the brackets on the wall

The brackets are fastened to the wall, irrespective of the type of wall, using

either threaded pins or wood screws and rawlplugs.


1 83-00-0894 Bracket for cable winches and pulley 3½" (universal)

2 99-98-3783 Rawlplug universal UX 12x70 without collar

3 99-10-3710 Threaded pin M10x1000 DIN 976 galv. (pre-cut)

4 99-20-1029 Hexagon nut M10 galv. DIN 934-8

5 99-10-3823 Hex wood screw 10x120 galv. DIN 571-St

6 83-00-1043 Counter plate for bracket univ.

7 99-20-1055 Lock washer A 10 DIN 127 galv

8 99-50-1483 K washer, A 10.5x30x2.5 DIN 9021 galv.



3.7.2 Assembling the cable winch




1 83-00-0894 Bracket for cable winches and pulley 3½" (universal)

2 00-00-3005 Pulley 3½" 89mm cast iron with bearing

2.1 Pipe sleeve D13 L17 in pulley 3½"

3 99-50-3142 Cable winch 800 kg for wall mounting incl. hand crank

4 99-10-1096 Hexagon bolt M10 x 40 galv. DIN 933 8.8



7 99-50-1090 Washer B 10.5 DIN 125 galv.

8 99-50-3099 Cable winch 350 kg GS for wall-mounted system incl. hand

crank



11 37-80-2011 washer, A 8.4x25x2.0 DIN 9021 galvanised

Cable winch 350 kg Cable winch 800 kg



3.7.3 Fastening the cable in the cable winch


1 99-50-3099 Cable winch 350 kg GS for wall-mounted system incl. hand

crank

99-50-3142 Cable winch 800 kg for wall mounting incl. hand crank

2 99-50-3700 Cable 5mm galv 7x19


3 99-50-9183 Cable clamp in cable winch for wall-mounted system cplt



3.8 Cable winch 550 kg for ceiling-mounted system

Warning:

This 550 kg ceiling-mounted system cable winch is not intended to be

used for lifting, carrying or transporting people or loads in areas in which

people are located. Before installing, carefully read all instructions

contained in the enclosed operating instructions with regard to the use

and maintenance of this winch.



This 550 kg ceiling-mounted system cable winch can either be operated

manually using a crank or electrically using a crank and a special drilling

machine.




99-50-0793 Cable winch 550 kg for ceiling-mounted system

1 99-10-0771 Threaded pin 250-20x.250

2 99-10-1063 Lens head screw M 5x35 galv. DIN 7985

3 99-20-0344 Hex bolt .312-18

4 99-50-0109 Lubrication nipple

5 99-50-0298 Thimble 8mm f/cable 7 mm DIN 6899

6 99-50-9137 Cylindrical pin 1/8"x1"

7 99-50-9138 Cylindrical pin 3/16"x1"

8 99-50-9140 U-washer 1 1/16"x1½" cable winch ceiling-mounted system

9 99-50-9141 U-washer1 1/6"x 2½" cable winch ceiling-mounted system

10 99-50-9142 Spacer cable winch ceiling-mounted system

11 99-50-9143 U-washer notched 3¼" x 1 1/16" for 99500793

12 99-50-9144 U-washer fibre 1"x2½" cable winch ceiling-mounted system

13 99-50-9145 Spacer sleeve cable winch ceiling-mounted system

14 99-50-9147 Pusher for hand-operated cable winch ceiling-mounted system

15 99-50-9155 Bearing bush 7/8"x 1 1/8x3/8" cable winch ceiling-mounted

system

16 99-50-9159 Drive toothed wheel for cable winch ceiling-mounted system

17 99-50-9132 Frame for cable winch ceiling-mounted system

18 99-50-9133 Spring for cable winch ceiling-mounted system

19 99-50-9134 Locking pawl for cable winch ceiling-mounted system

20 99-50-9136 Splint 187x2.75

21 99-50-9139 U-washer 2.50 O.D. x 1.75 I.O.

22 99-50-9146 Ball bearing

23 99-50-9148 U-washer 1.5 O.D. x .75 I.D.

24 99-50-9149 U-washer .875 O.D. x .375 I.D.

25 99-50-9150 U-washer 1.062 O.D. x .500 I.D.

26 99-50-9151 Retaining ring

27 99-50-9153 Bearing bush 1/2"x5/8"x3/8" cable winch ceiling-mounted

system

28 99-50-9154 Bearing bush 3/4"x1"x3510

29 99-50-9156 Spring washer 3/16"x1" cable winch ceiling-mounted system

30 99-50-9157 Cable drum cable winch ceiling-mounted system

31 99-50-9158 Toothed wheel Z85 cable winch ceiling-mounted system

32 99-50-9160 Shaft with toothed wheel

33 99-50-9220 Dowel for tension spring .312x.750



3.8.1 Assembling the 550 kg cable winch

Fastening the inhaul cable to the ceiling-mounted system 550 kg cable winch:


1 99-50-3700 Cable 5 mm galv. 7x19


2 99-50-0013 Cable 3 mm 6x7/FE



4 00-00-3005 Pulley 3½" 89 mm CH cast

5 00-00-0313 Pulley 1 7/8" 45 mm

6 10-93-1629 Frame screw galv. 80x22x7.8 to be supplied by the customer




7 99-50-1077 Thimble galv. 6mm f/cable 5 mm DIN 6899 NG 6 RW7

8 99-50-0793 Cable winch 550 kg ceiling-mounted system



3.8.2 Assembling the 550 kg cable winch without load-halving device:

3.8.3 Assembling the 550 kg cable winch with load-halving device:



3.9 Cable winch 340 kg CH for ceiling or gable assembly

Warning:

This 340 kg CH cable winch is not intended to be used for lifting, carrying

or transporting people or loads in areas in which people are located.

Before installing, read all instructions contained in the enclosed operating

instructions with regard to the use and maintenance of this winch.



This 340 kg CH cable winch can either be operated manually using a

crank or electrically using a crank and a special drilling machine.


99-50-3095 Cable winch 340 kg CH for ceiling or gable assembly

1 Bracket for cable winch

2 Bracket for auger

3 Shaft for auger with eye Ø 15

4 Spindle for cable pulley Ø 15 with thread M 12

5 Cable pulley Ø 45x115-85

6 Auger sprocket

7 Auger

8 99-10-3922 Locking pin DIN 1481 - 4x28

9 99-50-1411 Splint 4x25 DIN 94

10 Spacer sleeve Ø 15x22-5

11 Spacer sleeve Ø 15x22-15

12 Brass press-in bearing bush Ø 15x22-15

13 U-washer Ø 15x23 (M12 bore)



14 Hex bolt M 8x12 DIN 933

15 Guide pin Ø 4x12

16 99-50-1076 U-washer B 13 DIN125

17 99-20-1158 Hex nut M12 flat DIN 936

18 Spacer sleeve Ø 15x22-16.5

19 99-10-1039 Hex bolt M 8x25 DIN 558

20 99-50-1063 Lock washer A 8 DIN 127

21 99-10-1040 Hexagon nut M 8 DIN 934

22 00-00-1117 Sticker maintenance and operating instructions hand winch




3.9.1 Ceiling-mounted system for cable winch 340 kg CH


1 99-50-3700 Cable 5 mm galv. 7x19


2 99-50-0013 Cable 3 mm 6x7/FE



4 00-00-3005 Pulley 3½ 89 mm CH cast

5 00-00-0313 Pulley 1 7/8" 45 mm

6 10-93-1629 Frame screw galv. 80x22x7,8 to be supplied by the customer




7 99-50-1077 Thimble galv. 6mm f/cable 5 mm DIN 6899 NG 6 RW7

8 99-50-3095 Cable winch 340 kg CH for ceiling or gable assembly

9 11-31-3581 Bracket for cable winch 340kg and feed hopper suspended AM/

BP

10 99-10-1095 Hex bolt M 10x30 DIN 558

11 99-20-1029 Hexagon nut M 10 DIN 555

12 99-50-1483 U-washer B 10.5 x 30 x 2.5 DIN 9021



3.9.1.1 Assembling the 340 kg CH cable winch without load-halving device

3.9.1.2 Assembling the 340 kg CH cable winch with load-halving device



3.9.2 Gable-mounted system for cable winch 340 kg CH

3.9.2.1 Assembling the 340 kg CH cable winch without load-halving device


1 99-50-3700 Cable 5 mm galv. 7x19


2 99-50-0013 Cable 3 mm 6x7/FE



4 00-00-3005 Pulley 3½" 89 mm CH cast

5 00-00-0313 Pulley 1 7/8" 45 mm

6 10-93-1629 Frame screw galv. 80x22x7.8 to be supplied by the customer




7 99-50-1077 Thimble galv. 6mm f/cable 5mm DIN 6899 NG 6 RW7

8 99-50-3095 Cable winch 340 kg CH for ceiling or gable assembly

9 83-00-0894 Bracket for cable winch and pulley 3 1/2" (universal)

10 99-10-1095 Hex bolt M 10x30 DIN 558

11 99-20-1029 Hexagon nut M 10 DIN 555



3.9.2.2 Assembling the 340 kg CH cable winch with load-halving device



3.10 Hand crank for cable winches 340 kg CH and 550 kg

99-50-0793 cable winch 550 kg ceiling-

mounted system

99-50-3095 cable winch 340 kg CH for

ceiling and gable mounted systems

99-50-9100 crank 2500-

3500 mm hand-operated,

telescopic for cable winch

ceiling-mounted system

99-50-9130 crank 1500 mm

hand-operated for cable

winch ceiling-mounted

system

99-50-9185 crank 2500 mm

hand-operated for cable

winch ceiling-mounted

system

99-50-9190

Crank 2500 mm for

drilling machine



3.11 Fine adjustment

When the drinkers are lowered, the distance A should be at least 1 m greater than the

ceiling height: A ≥ H + 1m

99-50-3097 drilling machine 300/1200 U/min for cable winch



The effect of the load-halving device is cancelled out by the larger diameter of the cable

drum. The bearing load of the winch must therefore be greater than the weight of the

drinker lines to be lifted.

There must be at least three inhaul cable windings wound on the cable

drum even when it is unwound.


1 Starting set cable winch automatic2 99-50-3099 Cable winch 350Kg GS for wall-mounted system incl. hand crank

83-00-0894 Bracket for cable winch and pulley 3 1/2" (universal)3 00-00-3005 Pulley 3 1/2" 89mm cast iron with bearing

83-00-0894 Bracket for cable winch and pulley 3 1/2" (universal)4 00-00-3005 Pulley 3 1/2" 89mm cast iron with bearing5 99-50-3172 Sliding bearing plate B5/4" B55/L95

99-50-3173 Mounting plate for sliding bearing plate B 5/4"6 83-06-7772 Cable drum D=88.9mm for 1 1/4" pipe only7 99-40-3814 Pipe 1 1/4"x6000 galvanised DIN 24408 99-50-3171 Chain link pin coupling 5/8"/Z16/ 5/4" cable winch RW9 99-10-1278 Hexagon bolt M8 x 60 galv. DIN 933 8.8

10 99-20-1064 Self-locking nut M8 DIN 985-6 galv.11 99-50-0120 Cable clamp 5 mm 3/16" galvanised DIN 741

Suspension system accessories Page 50


4 Suspension system accessories

Pos. Graphics Code no. Description

1 00-00-0313 1 7/8" 47.6 mm pulley, plastic with slinging lug

2 00-00-3006 Pulley 4 1/8"105mm plastic w/suspension strips

3 00-00-3005 Pulley 3 1/2" 89mm cast iron with bearing

4 60-10-1140 Bracket T4 with 1 cable pulley baffle master

5 99-50-3194Bracket right-angle H=100mm for cable winch RW45-605

6 83-00-0894 Bracket for cable winch and pulley 3 1/2" (universal)

7

99-50-3700

99-50-3703

99-50-0013

Wire cable 5mm galv.



8 99-50-1019 Suspension rope 3mm PES black

9 99-50-1077 Thimble galv 6mm f/cable 5mm DIN 6899 NG 6 RW7

1099-50-0120

99-50-0014

Cable clamp 5mm 3/16" galvanised like DIN 741

Cable clamp 3mm 1/8" galv. DIN 741

11

10-93-1629

10-93-1642

99-50-3834

99-50-3814

Frame screw galv. 80x22x7.8



Hook bolt galv. 140x6.5

12

83-05-7662

83-04-5049

83-05-7664

Mounting bracket 1500 35x45x4 with holes



Suspension Systems Eng

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