Suspension Systems Eng

Mounting instructions
Suspension systems
Code No. 99-97-1011
Edition: 04/2012 GB
Page I
Overview of changes / updates in the manual

Name of chapter
Type of change /
update
No. of BD Issue date

product information
Page
1.3 Prevention of
reasonably predictable
incorrect uses
Section inserted
04/2012
2 Safety instructions
Chapter added
04/2012
876
04/2012
31
3.7 Cable winch (GS)

Section completely
for wall-mounted
revised
system incl. hand crank
3.11 Fine adjustment
Section inserted
848, 1092
04/2012
48
4 Suspension system
accessories
Mounting bracket
35x45x4 added
921
04/2012
50
Suspension systems/ assembly

Edition: 04/2012
M 1011 GB
Product
information
No. 1381
Big Dutchman International GmbH

Big Dutchman Pig Equipment GmbH
P.O. Box 11 63 49360 Vechta Germany
Tel. +49(0)4447-801-0 Fax 801-237
big@ bigdutchman.de www.bigdutchman.de
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 and
dowels cannot be used (e.g. on composite boards). In this case the mounting screws are drilled
through the wall on which a counter plate is attached outside. Until now these counter plates were
only 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:
Code No.
Description
83-11-2612 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 universal
For 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).
Both counter plates have a size of 280 x 280 mm and are made of 3 mm thick stainless steel
panels.
Fig. 1: 83-11-2612 - Counter plate SST f/winch Fig. 2: 83-11-2613 - Counter plate SST f/wall
motor CL75A/EWA
bracket universal
Heinz Sdkamp
- Product ManagerClimate Poultry
Bernd Rosemeyer
- Product OperatorClimate Poultry
Product
information
No. 1351
Big Dutchman International GmbH

Big Dutchman Pig Equipment GmbH
P.O. Box 11 63 49360 Vechta Germany
Tel. +49(0)4447-801-0 Fax 801-237
big@ bigdutchman.de www.bigdutchman.de
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 feeding
systems. Latter is either a chain feeding system or a Repromatic system. There are different
reasons 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 at
feeding 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 known
electric 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) for
the tube are available.
Pos. 4
Pos. 1
Pos. 2
Pos. 3
Fig. 1: Starter kit cable winch 2000 kg 2lines./12m width/with intermediate ceiling for daily up & down
Thanks to their larger diameter, the rope drums with grooves prevent the wire rope from damages
and in addition they allow for a higher winding speed. The grooves ensure that adjacent rope
layers 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, if
required feed cleaner and feed corner and are equipped with larger idler rollers in order to protect
the 3 mm suspension ropes.
Coding, overview of single parts

The new starter kit cable winch for daily up & down is coded as follows:
Code-No.
Description
Starterkit cable winch 2000kg 2l./width 12m/with interm.ceil for daily
11-32-3035
up and down
The following single parts are included:

Pos.
Code-No.
99-50-3401
99-50-3415 Ball bearing plate for roller tube 5/4"
99-50-3414 Bracket f/winch motor GW80
83-08-5142
Rope drum D=49mm f/tube 1 1/4" w/grooves f/max.

3.5m lifting height+halving of load
99-50-3411
Chain bolt coupling 10B z16 5/4" for cable winch

GW80
99-40-3814 Pipe 1 1/4"x6000 galv DIN 2440
Page 2
Description
Figure
Cable winch 1.10 230/400 50/60 GW80 2000kg w/limit

switch
PI No. 1351
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)!
pos. 2
pos. 1
min. 5 m
min. 5 m
pos. 2
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 1,400
rotations.
Operating temperature: -15C to +60C.
ASSEMBLY
The following points must be observed during the assembly of the limit switch:
1.
2.
3.
4.
Position the limit switch below the black plastic cover of the motor reductor.
For this purpose, bring the limit switch in the destined position above the selector shaft.
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).
Tighten the cross-head screws.
PI-No. 1351
Page 3
ADJUSTMENT OF LIMIT SWITCH (see fig. 3)

In order to adjust the limit switch system the following steps must be carried out:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Remove the black plastic cover of the motor reductor. The limit switch is visible now.
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).
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 wrench
key can be used. In order to prevent damages of the hexagon bore inside the shaft, the
maximally 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 in
order to prevent errors!
Bring the system in the outer starting position by rotating the electric motor shaft.
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.
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.
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).
Bring the system to the outer end position by turning the electric motor shaft.
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 short
side 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 the
function of the system!
11. Put the black plastic cover onto the motor reductor and tighten the cross-head screws.
Page 4
PI No. 1351
&lick
(PHUJHQF\VZLWFK1
2SHUDWLQJVZLWFK 1
(PHUJHQF\VZLWFK 2
2SHUDWLQJVZLWFK 2
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 systems drive tube.
6SDUHSDUWV
5FDEOH FLUFXLWGLDJUDP (Vtandard)
*HQHUDO
2SHUDWLQJVZLWFK 2
(PHUJHQF\VZLWFK
2SHUDWLQJVZLWFK 1
(PHUJHQF\VZLWFK
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 the
additional load of the 3 mm suspension ropes for feed corners, feed troughs, feed channels and
feed cleaners.
PI-No. 1351
Page 5
Coding, overview of single parts

The following suspension kits for daily "up & down" are available:
Chain feeding
Code-No.
10-93-3854
10-93-3855
10-93-3853
Description
Suspension f/corner for daily up and down
Suspension f/feed cleaner for daily up and down
Suspension f/feedtrough for daily up and down
Repromatic
Code-No. Description
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
These suspension kits include the following single parts:

Pos.
Code-No.
Description
99-50-0013 Wire rope 3mm galv
99-50-0120 Cable clamp 5mm galv. similar DIN 741
11-00-3002 Cable lock AM
00-00-3006 Pulley 4 1/8" 105mm plastic with split strap
10-93-3856
15-00-1005 Hanger for corner 90/135deg
10-93-3876 Hanger for feed channel RPM
Page 6
Figure
Hanger for feedtrough 3000 regular/medium 1,2mm

(wire)
PI No. 1351
On request also alternative starter kits for daily "up & down" with lower lifting capacities are
possible. However, the lifting capacity of the winches is reduced by 30%!
For further information regarding the BD-suspension systems please see manual "Suspension
systems" (code no. 99-97-1011).
Jrg Hurlin
- Product Manager Fattening Systems
PI-No. 1351
Rdiger Sudhop
- Product Operator Fattening Systems
Page 7
Page I
Table of contents
1 Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1
1.2
1.3
1.4
1.4.1
1.4.2
1.4.3
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Prevention of reasonably predictable incorrect uses . . . . . . . . . . . . . . . . . . .2
Explaining the symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety symbols in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety symbols in the manual and on the installation . . . . . . . . . . . . . . . . . . . . .3
Safety symbols and notes on your installation . . . . . . . . . . . . . . . . . . . . . . . . . .3
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Disorders due to power failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
First aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Pollution abatement regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Waste disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Notes for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.1
2.2
2.3
2.3.1
2.3.2
2.3.3
2.3.3.1
2.3.3.2
2.3.3.3
2.4
2.4.1
2.4.1.1
2.4.1.2
2.4.1.3
2.4.2
2.4.3
2.5
2.6
General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Safety regulations for the use of electrical appliances . . . . . . . . . . . . . . . . .8
System safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Entire system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Individual components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Feeding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Electrical components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Personal safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Clothing for personal safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Clothing and footwear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Jewellery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Hair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Assembly and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Employing external personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Safety contrivances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Dangers resulting from non-compliance with the safety instructions . . . . .15
3 Assembling the cable winches and the suspension system . . . . . . .16

3.1
3.2
3.3
Suspension material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Cable winches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Cable winch 1 line with drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Edition: 04/2012
M 1011 GB
Table of contents
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.5
3.6
3.6.1
3.6.2
3.7
3.7.1
3.7.2
3.7.3
3.8
3.8.1
3.8.2
3.8.3
3.9
3.9.1
3.9.1.1
3.9.1.2
3.9.2
3.9.2.1
3.9.2.2
3.10
3.11
Page II
Cable winch 2 lines 12 m width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Distance between the sliding bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distance between the sliding bearings with load-halving device . . . . . . . . . . .
Assembly of the cable winch with two lines in houses with intermediate
ceilings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly of the cable winch 2 lines in houses with cover = roof . . . . . . . . . .
Connecting the tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling the main pulley cable and deflection pulleys . . . . . . . . . . . . . .
Assembling the main pulley cable and the deflection pulleys without the
load-halving device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling the main pulley cable and the deflection pulleys with the loadhalving device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable winch (GS) for wall-mounted system incl. hand crank . . . . . . . . . . .
Assembling the brackets on the wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling the cable winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening the cable in the cable winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable winch 550 kg for ceiling-mounted system . . . . . . . . . . . . . . . . . . . . .
Assembling the 550 kg cable winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling the 550 kg cable winch without load-halving device: . . . . . . . . . .
Assembling the 550 kg cable winch with load-halving device: . . . . . . . . . . . .
Cable winch 340 kg CH for ceiling or gable assembly . . . . . . . . . . . . . . . . .
Ceiling-mounted system for cable winch 340 kg CH . . . . . . . . . . . . . . . . . . . .
Assembling the 340 kg CH cable winch without load-halving device . . . . . . . . . . .
Assembling the 340 kg CH cable winch with load-halving device . . . . . . . . . . . . .
Gable-mounted system for cable winch 340 kg CH . . . . . . . . . . . . . . . . . . . .
Assembling the 340 kg CH cable winch without load-halving device . . . . . . . . . . .
Assembling the 340 kg CH cable winch with load-halving device . . . . . . . . . . . . .
Hand crank for cable winches 340 kg CH and 550 kg. . . . . . . . . . . . . . . . . .
Fine adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
22
22
23
25
27
29
30
30
31
32
33
35
36
39
40
40
41
43
44
44
45
45
46
47
48
4 Suspension system accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Edition: 04/2012
M 1011 GB
Page 1
Basic instructions
1 Basic instructions
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.
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.

Edition: 04/2012
M 1011 GB
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.

Edition: 04/2012
M 1011 GB
Page 3
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:
Warning against dangerous electrical voltage
Warning against the cold
Warning against slippery surface
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.
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.

Edition: 04/2012
M 1011 GB
Page 4
Basic instructions
DANGER OF SKIN CORROSION due to purifying agents!

Always wear protective clothing when repairing, maintaining
and cleaning the installation. Always observe the
manufacturers instructions when using acids!
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.
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.
1.5 Ordering spare parts

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).
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

Edition: 04/2012
M 1011 GB
Page 5
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.

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Basic instructions
Page 6
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.

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Page 7
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 manufacturers 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: big@bigdutchman.de, Internet: www.bigdutchman.de

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Safety instructions
Page 8
2 Safety instructions
These 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.

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Page 9
Safety instructions
Warning
Never repair or bypass the fuses!
Damaged fuses have to be replaced with new fuses!
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
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.
The different areas of the Big Dutchman installations are characterised by different
types of construction.

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Safety instructions
Page 10
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!

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Page 11
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!

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.
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

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!
2.3.3.3 Electrical components

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Safety instructions
Page 12
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.
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.
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!
2.4.1 Clothing for personal safety

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.

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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.
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!
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.
Take off all jewellery, particularly necklaces, bracelets and rings!
2.4.1.3 Hair
Long hair increases the risk of an accident.
Long hair can get caught in moving or rotating system parts.
Secure long hair by tying it back or wearing a bandanna or cap!
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.

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Safety instructions
Page 14
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.
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.
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
As supervisor, you are responsible for the safety of external personnel!

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.

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Safety instructions
2.5 Safety contrivances
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.
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.

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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
systems 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 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.

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3.2 Cable winches

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.
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.

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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.

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Page 19
Pos.
Code no.
99-50-3161
99-50-3162
99-50-5163
99-50-3164
99-50-3165
Cable winch 0.55 230/400 50/60 RW405L 1400/1100kg w/limit switch

Motor 100/19/55/400-480/3/4P 763060
5.1
6
Cable winch 0.37 230 50/60 RW245L 850/850kg w/limit switch

Motor 85/14/37/230/1/4P 701031
4.1
5
Cable winch 0.37 230/400 50/60 RW245L 850/700kg w/limit switch

Motor 85/14/37/400-480/3/4P 763040
3.1
4
Cable winch 0.09 230 50/60 RW45-3L 320/250kg w/limit switch

Motor 65/9/09/230/1/4P 701001
2.1
3
Cable winch 0.09 230/400 50/60 RW45-3L 320/240kg w/limit switch

Motor 65/9/09/400-480/3/4P 763010
1.1
2
Description
Fastening material
X
1
99-50-3166
Cable winch 0.55 230
50/60 RW405L 1400/1400kg w/limit switch
Motor 100/14/55/230/1/4P /OC/C 701042
6.1
7
99-50-3194
Bracket right-angle H=100mm for cable winch RW4-605
99-10-1068
Hexagon bolt M 10x20 DIN 558
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
Hex bolt M 6x85 DIN 931
15
16
Retaining ring A16 DIN 705 296416
99-20-1043
Locknut M 6 DIN 985

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Page 21
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.

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3.4.1 Distance between the sliding bearings

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
Circumference of the 5/4 pipe
Diameter of the main pulley cable
Number of initial windings
3m
133 mm
5 mm
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
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, 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
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 .

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Page 23
3.4.3 Assembly of the cable winch with two lines in houses with
intermediate ceilings
Pos.
Code no.
Fastening material
X
1
99-50-3151
99-50-3152
99-50-3153
99-50-3154
99-50-3155
Cable winch 1.10 230/400 50/60 RW605 2000/1700kg w/limit switch

Motor 100/19/110/400-480/3/eP 763080
5.1
6
Cable winch 0.55 230 50/60 RW405 1400/1400kg w/limit switch

Motor 100/19/55/230/1/4P/OC/C 701042
4.1
5

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

Motor 85/14/37/230/1/4P/OC 701031
2.1
3

Motor 85/14/37/400-480/3/4P 763040
1.1
2
Description
99-50-3156

Motor 100/19/110/230/1/4P/OC/C 701062
6.1
Sprocket 5/8", z 16 for shaft 28, Pos. 1-4 416979

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
99-50-1202
Parallel key 10x8x40 DIN 6885 Form A for Pos. 5-6 296204
Retaining ring DIN 471 28x1.2 for Pos. 1-4 295328

10
99-50-3194
Bracket right-angle H-100 mm for cable winch RW45-605
11
99-10-1068
12
99-20-1055
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
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
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

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Page 24
Page 25
3.4.4 Assembly of the cable winch 2 lines in houses with cover = roof
Pos.
Code no.
Fastening material
X
1
99-50-3151
99-50-3152
99-50-3153
99-50-3154
55-50-3155

Motor 100/19/110/400-480/3/4P 763080
5.1
6

Motor 100/19/55/230/1/4P/OC/C 701042
4.1
5

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

Motor 85/14/37/230/1/4/P/OC 701031
2.1
3

Motor 85/14/37/400-480/3/4P 763040
1.1
2
Description
99-50-3156

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

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
99-50-1202
Parallel key 10x8x40 DIN 6885 Form A for Pos. 5-6 296204

10
99-50-3194
Bracket right-angle H=100mm for cable winch RW45-605
11
99-10-1068
12
99-20-1055
21
99-10-1278
22
99-50-3172
Sliding bearing plate B 5/4" B55/L95
23
99-50-3173
24
99-10-1067
25
99-20-1043
Locknut M 6 DIN 985
26
99-50-1420
27
Pulley cable

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Page 26
Page 27
3.5 Connecting the tubes

The bores for connecting the 1"x6000 pipes (1) to the 35x3-200
couplings for the 1" pipe (2) must be created during the assembly
process.
The distance to the first bore at the end of the 1x6000 pipe (1) is 20 mm.
The distance of the second bore from the end of the 1"x6000 pipe (1) is
80 mm and is offset by 90 from the first bore.
Pos.
Code no.
1
2
3
4
99-40-3814
99-50-3174
99-20-1064
99-10-1278
Description
Pipe 1"x6000 DIN 2440
Coupling 35x3-200 for pipe 1"
Self-locking nut M8 DIN 985

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For your notes:

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3.6 Assembling the main pulley cable and deflection pulleys

Pos.
Code no.
Description
99-50-3700
99-50-3703
99-50-0013
99-50-1019
99-50-0120
00-00-3005
00-00-0313
10-93-1629
10-93-1642
99-50-3834
99-50-3814
Cable 5 mm galv. 7x19

Cable 4 mm galv.
Cable 3 mm 6x7/FE
Suspension rope 3mm PES black
Cable clamp 5 mm 3/16" galvanised DIN 741
Pulley 3 1/2" 89 mm CH casting
Pulley 1 7/8" 45 mm
Frame screw galv. 80x22x7,8 to be supplied by the customer
Frame screw galv. 120x22x7.8 to be supplied by the customer
Hook bolt galv. 140x6.5 to be supplied by the customer
99-40-3814
99-50-3173
99-50-1420
99-50-1077
Pipe 1"x6000 DIN 2440

Thimble galv. 6 mm f/cable 5 mm DIN 6899 NG 6 RW7
2
3
4
5
6
7
8
9
10

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Page 30
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

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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
Code No. 99 50 3142
Cable winch 350 kg GS for wall-mounted Cable winch 800 kg for wall mounting incl.
system incl. hand crank
hand crank

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Page 32
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.
Pos.
Code no.
Description
1
2
3
4
83-00-0894
99-98-3783
99-10-3710
99-20-1029
Bracket for cable winches and pulley 3" (universal)

Rawlplug universal UX 12x70 without collar
Threaded pin M10x1000 DIN 976 galv. (pre-cut)
Hexagon nut M10 galv. DIN 934-8
5
6
7
8
99-10-3823
83-00-1043
99-20-1055
99-50-1483
Hex wood screw 10x120 galv. DIN 571-St

Counter plate for bracket univ.
Lock washer A 10 DIN 127 galv
K washer, A 10.5x30x2.5 DIN 9021 galv.

Edition: 04/2012
M 1011 GB
Page 33
3.7.2 Assembling the cable winch

Edition: 04/2012
M 1011 GB
Pos.
1
2
2.1
3
4
5
6
7
8
9
10
11
Code no.
Page 34
Description
83-00-0894 Bracket for cable winches and pulley 3" (universal)

00-00-3005 Pulley 3" 89mm cast iron with bearing
Pipe sleeve D13 L17 in pulley 3"
99-50-3142 Cable winch 800 kg for wall mounting incl. hand crank
99-10-1096 Hexagon bolt M10 x 40 galv. DIN 933 8.8
99-20-1029 Hexagon nut M10 galv. DIN 934-8
99-50-1090 Washer B 10.5 DIN 125 galv.
99-50-3099 Cable winch 350 kg GS for wall-mounted system incl. hand
crank
99-10-1040 Hexagon nut M8 galv. DIN 934-8
37-80-2011 washer, A 8.4x25x2.0 DIN 9021 galvanised
Cable winch 350 kg

Edition: 04/2012
M 1011 GB
Cable winch 800 kg
Page 35
3.7.3 Fastening the cable in the cable winch
Pos.
1
2
3
Code no.
Description
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
99-50-3700 Cable 5mm galv 7x19
99-50-3703 Cable 4 mm galv.
99-50-9183 Cable clamp in cable winch for wall-mounted system cplt

Edition: 04/2012
M 1011 GB
Page 36
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.

Edition: 04/2012
M 1011 GB
Page 37
Pos.
Code no.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
99-50-0793
99-10-0771
99-10-1063
99-20-0344
99-50-0109
99-50-0298
99-50-9137
99-50-9138
99-50-9140
99-50-9141
99-50-9142
99-50-9143
99-50-9144
99-50-9145
99-50-9147
99-50-9155
Cable winch 550 kg for ceiling-mounted system

Threaded pin 250-20x.250
Lens head screw M 5x35 galv. DIN 7985
Hex bolt .312-18
Lubrication nipple
Thimble 8mm f/cable 7 mm DIN 6899
Cylindrical pin 1/8"x1"
Cylindrical pin 3/16"x1"
U-washer 1 1/16"x1" cable winch ceiling-mounted system
U-washer1 1/6"x 2" cable winch ceiling-mounted system
Spacer cable winch ceiling-mounted system
U-washer notched 3" x 1 1/16" for 99500793
U-washer fibre 1"x2" cable winch ceiling-mounted system
Spacer sleeve cable winch ceiling-mounted system
Pusher for hand-operated cable winch ceiling-mounted system
Bearing bush 7/8"x 1 1/8x3/8" cable winch ceiling-mounted
16
17
18
19
99-50-9159
99-50-9132
99-50-9133
99-50-9134
system
Drive toothed wheel for cable winch ceiling-mounted system
Frame for cable winch ceiling-mounted system
Spring for cable winch ceiling-mounted system
Locking pawl for cable winch ceiling-mounted system
20
21
22
23
24
25
26
27
99-50-9136
99-50-9139
99-50-9146
99-50-9148
99-50-9149
99-50-9150
99-50-9151
99-50-9153
28
29
30
31
32
33
99-50-9154
99-50-9156
99-50-9157
99-50-9158
99-50-9160
99-50-9220
Splint 187x2.75
U-washer 2.50 O.D. x 1.75 I.O.
Ball bearing
U-washer 1.5 O.D. x .75 I.D.
U-washer .875 O.D. x .375 I.D.
U-washer 1.062 O.D. x .500 I.D.
Retaining ring
Bearing bush 1/2"x5/8"x3/8" cable winch ceiling-mounted
system
Bearing bush 3/4"x1"x3510
Spring washer 3/16"x1" cable winch ceiling-mounted system
Cable drum cable winch ceiling-mounted system
Toothed wheel Z85 cable winch ceiling-mounted system
Shaft with toothed wheel
Dowel for tension spring .312x.750

Edition: 04/2012
M 1011 GB

Edition: 04/2012
M 1011 GB
Page 38
Page 39
3.8.1 Assembling the 550 kg cable winch
Pos.
Code no.
Description
99-50-3700
99-50-3703
99-50-0013
99-50-1019
99-50-0120
00-00-3005
00-00-0313
10-93-1629
10-93-1642
99-50-3834
99-50-3814
99-50-1077
99-50-0793

Cable 4 mm galv.
Cable 3 mm 6x7/FE
Pulley 3" 89 mm CH cast
Pulley 1 7/8" 45 mm
Thimble galv. 6mm f/cable 5 mm DIN 6899 NG 6 RW7
Cable winch 550 kg ceiling-mounted system
2
3
4
5
6
7
8
Fastening the inhaul cable to the ceiling-mounted system 550 kg cable winch:

Edition: 04/2012
M 1011 GB
Page 40
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:

Edition: 04/2012
M 1011 GB
Page 41
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.
Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
Code no.
Description
99-50-3095 Cable winch 340 kg CH for ceiling or gable assembly

Bracket for cable winch
Bracket for auger
Shaft for auger with eye 15
Spindle for cable pulley 15 with thread M 12
Cable pulley 45x115-85
Auger sprocket
Auger
99-10-3922 Locking pin DIN 1481 - 4x28
99-50-1411 Splint 4x25 DIN 94
Spacer sleeve 15x22-5
Spacer sleeve 15x22-15
Brass press-in bearing bush 15x22-15
U-washer 15x23 (M12 bore)

Edition: 04/2012
M 1011 GB

Pos.
14
15
16
17
18
19
20
21
22
Code no.
99-50-1076
99-20-1158
99-10-1039
99-50-1063
99-10-1040
00-00-1117
Description
Guide pin 4x12
U-washer B 13 DIN125
Hex nut M12 flat DIN 936
Spacer sleeve 15x22-16.5
Hexagon nut M 8 DIN 934
Sticker maintenance and operating instructions hand winch

Edition: 04/2012
Page 42
M 1011 GB
Page 43
3.9.1 Ceiling-mounted system for cable winch 340 kg CH
Pos.
Code no.
99-50-3700
99-50-3703
99-50-0013
99-50-1019
99-50-0120
00-00-3005
00-00-0313
10-93-1629
10-93-1642
99-50-3834
99-50-3814
99-50-1077
99-50-3095
11-31-3581
2
3
4
5
6
7
8
9
10
11
12
Description

Cable 4 mm galv.
Cable 3 mm 6x7/FE
Pulley 3 89 mm CH cast
Pulley 1 7/8" 45 mm
Frame screw galv. 80x22x7,8 to be supplied by the customer
Thimble galv. 6mm f/cable 5 mm DIN 6899 NG 6 RW7
Cable winch 340 kg CH for ceiling or gable assembly
Bracket for cable winch 340kg and feed hopper suspended AM/
BP
99-10-1095 Hex bolt M 10x30 DIN 558
99-20-1029 Hexagon nut M 10 DIN 555
99-50-1483 U-washer B 10.5 x 30 x 2.5 DIN 9021

Edition: 04/2012
M 1011 GB
Page 44
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

Edition: 04/2012
M 1011 GB
Page 45
3.9.2 Gable-mounted system for cable winch 340 kg CH
Pos.
Code no.
Description
99-50-3700
99-50-3703
99-50-0013
99-50-1019
99-50-0120
00-00-3005
00-00-0313
10-93-1629
10-93-1642
99-50-3834
99-50-3814

Cable 4 mm galv.
Cable 3 mm 6x7/FE
Pulley 3" 89 mm CH cast
Pulley 1 7/8" 45 mm
Hook bolt galv. 140x6.5
to be supplied by the customer
2
3
4
5
6
7
8
9
99-50-1077 Thimble galv. 6mm f/cable 5mm DIN 6899 NG 6 RW7

99-50-3095 Cable winch 340 kg CH for ceiling or gable assembly
83-00-0894 Bracket for cable winch and pulley 3 1/2" (universal)
10
11
99-10-1095 Hex bolt M 10x30 DIN 558

99-20-1029 Hexagon nut M 10 DIN 555
3.9.2.1 Assembling the 340 kg CH cable winch without load-halving device

Edition: 04/2012
M 1011 GB

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

Edition: 04/2012
M 1011 GB
Page 46
Page 47
3.10 Hand crank for cable winches 340 kg CH and 550 kg
99-50-0793 cable winch 550 kg ceilingmounted system
99-50-9100 crank 25003500 mm hand-operated,

telescopic for cable winch
ceiling-mounted system
99-50-3095 cable winch 340 kg CH for

ceiling and gable mounted systems
99-50-9130 crank 1500 mm

hand-operated for cable
winch ceiling-mounted
system
99-50-9190
Crank 2500 mm for
drilling machine
99-50-9185 crank 2500 mm

hand-operated for cable
winch ceiling-mounted
system

Edition: 04/2012
M 1011 GB
Page 48
99-50-3097 drilling machine 300/1200 U/min for cable winch
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

Edition: 04/2012
M 1011 GB
Page 49
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.
Pos.
1
2
3
4
5
6
7
8
9
10
11
Code no.
99-50-3099
83-00-0894
00-00-3005
83-00-0894
00-00-3005
99-50-3172
99-50-3173
83-06-7772
99-40-3814
99-50-3171
99-10-1278
99-20-1064
99-50-0120
Description
Starting set cable winch automatic
Cable winch 350Kg GS for wall-mounted system incl. hand crank
Bracket for cable winch and pulley 3 1/2" (universal)
Pulley 3 1/2" 89mm cast iron with bearing
Sliding bearing plate B5/4" B55/L95
Cable drum D=88.9mm for 1 1/4" pipe only
Pipe 1 1/4"x6000 galvanised DIN 2440
Chain link pin coupling 5/8"/Z16/ 5/4" cable winch RW
Hexagon bolt M8 x 60 galv. DIN 933 8.8
Self-locking nut M8 DIN 985-6 galv.

Edition: 04/2012
M 1011 GB
Page 50
Suspension system accessories
4 Suspension system accessories

Pos.
Graphics
Code no.
Description
00-00-0313
1 7/8" 47.6 mm pulley, plastic with slinging lug
00-00-3006
Pulley 4 1/8"105mm plastic w/suspension strips
00-00-3005
60-10-1140
Bracket T4 with 1 cable pulley
99-50-3194
Bracket right-angle H=100mm for cable winch RW45605
83-00-0894
99-50-3700
Wire cable 5mm galv.
99-50-3703
99-50-0013
99-50-1019
99-50-1077
Thimble galv 6mm f/cable 5mm
99-50-0120
Cable clamp 5mm 3/16" galvanised like DIN 741
99-50-0014
Cable clamp 3mm 1/8" galv. DIN 741
10-93-1629
Frame screw galv. 80x22x7.8
10-93-1642
99-50-3834
99-50-3814
Hook bolt galv. 140x6.5
83-05-7662
Mounting bracket 1500 35x45x4 with holes
83-04-5049
83-05-7664
10
11
12

Edition: 04/2012
M 1011 GB
baffle master
DIN 6899 NG 6 RW7

Suspension Systems Eng

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Suspension Systems Eng

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Mounting instructions

Overview of changes / updates in the manual

No. of BD Issue date

3.7 Cable winch (GS)

Suspension systems/ assembly

Big Dutchman International GmbH

April 12, 2013

Big Dutchman International GmbH

January 29, 2013

Starter kit cable winch 2,000 kg with

Easy adaptation of the feeding to the development of the birds

Starter kit cable winch

Coding, overview of single parts

The following single parts are included:

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

99-50-3414 Bracket f/winch motor GW80

Rope drum D=49mm f/tube 1 1/4" w/grooves f/max.

Chain bolt coupling 10B z16 5/4" for cable winch

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

Cable winch 1.10 230/400 50/60 GW80 2000kg w/limit

Planning and installation instructions

The maximum lifting capacity is 2,000 kg

Fig. 2: Scheme of suspension systems and rope drums

USE AND OPERATION

ADJUSTMENT OF LIMIT SWITCH (see fig. 3)

5FDEOH FLUFXLWGLDJUDP (Vtandard)

Fig. 3: Overview adjustment of limit switch

Coding, overview of single parts

These suspension kits include the following single parts:

99-50-0013 Wire rope 3mm galv

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

11-00-3002 Cable lock AM

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

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

10-93-3876 Hanger for feed channel RPM

Hanger for feedtrough 3000 regular/medium 1,2mm

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

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

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

Suspension systems/ assembly

Cable winch 2 lines 12 m width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Suspension systems/ assembly

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

1.2 Designated use

Suspension systems/ assembly

1.3 Prevention of reasonably predictable incorrect uses

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.

1.4 Explaining the symbols

Suspension systems/ assembly

1.4.2 Safety symbols in the manual and on the installation

Warning against dangerous electrical voltage

Warning against the cold

Warning against slippery surface

1.4.3 Safety symbols and notes on your installation

Suspension systems/ assembly

DANGER OF SKIN CORROSION due to purifying agents!

5FDEOH FLUFXLWGLDJUDP (Vtandard)