dynatec HiFIT HFM 21R1-S User manual

OPERATING INSTRUCTIONS
Translation of the original instructions
HiFIT device
Typ HFM 21R1-S
DYNATEC
Gesellschaft für CAE und Dynamik mbH
Adam-Opel-Straße 4
D-38112 Braunschweig
Date: 04/2021

Table of contents
1Introduction.........................................................................................................4
1.1 Type plate ..................................................................................................................6
1.2 General description....................................................................................................7
1.3 Main components....................................................................................................... 8
1.4 Scope of delivery......................................................................................................10
1.5 Operating instructions of the manufacturer...............................................................11
1.6 Operating instructions of the operator....................................................................... 12
1.7 Intended use ............................................................................................................ 13
1.8 Environmental conditions .........................................................................................14
1.9 Foreseeable misuse................................................................................................. 15
1.10 Target groups –qualifications................................................................................... 16
1.11 Operator prerequisite................................................................................................ 17
1.12 Obligation for instruction and training ....................................................................... 18
1.12.1 Sample form.............................................................................................................19
2Safety information ............................................................................................20
2.1 General notes........................................................................................................... 20
2.2 Symbols and hazard levels....................................................................................... 21
2.2.1 Requirements...........................................................................................................22
2.2.2 Notes........................................................................................................................ 22
2.3 Safety instructions....................................................................................................23
2.4 Regulations, standards.............................................................................................23
2.5 Emergency information............................................................................................. 23
2.6 Lettering, requirement signs.....................................................................................24
2.7 Specialist personnel ................................................................................................. 24
2.8 Personal protective equipment.................................................................................25
2.9 Instructions for operation, care and maintenance.....................................................26
2.10 Safety instructions for handling auxiliary and operating materials............................. 27
3Technical data...................................................................................................28
3.1 Device data ..............................................................................................................28
3.2 Operating and environmental conditions................................................................... 28
3.3 Sound and vibrations................................................................................................28
4Transport and storage......................................................................................29
4.1 Transport..................................................................................................................29
4.1.1 Transport damage.................................................................................................... 29
4.2 Storage.....................................................................................................................29
5Preparation for post-treatment........................................................................30
5.1 General notes........................................................................................................... 30
5.2 Safety instructions....................................................................................................30
5.3 General preparations................................................................................................ 31
5.3.1 Remove and insert battery........................................................................................31
5.3.2 Establishing the compressed air supply....................................................................32
5.3.3 Pin condition............................................................................................................. 33
5.3.4 LED illumination .......................................................................................................33
5.4 Intensity setting ........................................................................................................ 34
5.4.1 Setting the intensity on the device............................................................................34
5.5 Trial treatment..........................................................................................................35
5.6 Control of the intensity setting ..................................................................................36
6Post-treatment ..................................................................................................37
6.1 General notes........................................................................................................... 37
6.2 Safety instructions....................................................................................................37

6.3 Operating the device ................................................................................................ 38
7Care and maintenance......................................................................................39
7.1 General note ............................................................................................................ 39
7.2 Safety instructions....................................................................................................39
7.3 Maintenance, pin and pressure spring replacement ................................................. 40
7.3.1 Loosening the cap lock............................................................................................. 40
7.3.2 Disassembly of the wearing parts.............................................................................41
7.3.3 Cleaning and checking the wearing parts.................................................................41
7.3.4 Assembly of the wearing parts..................................................................................42
7.3.5 Pin and spike assembly............................................................................................43
7.3.6 Tightening the cap lock............................................................................................. 43
8Repair.................................................................................................................44
8.1 General notes........................................................................................................... 44
9Declaration of conformity ................................................................................45
10 Appendix ...........................................................................................................46

Operating instructions HiFIT device Type HFM21 R1-S 4 von 47
1 Introduction
These operating instructions was created to work quick
and safe with the HiFIT device. Read these operating
instructions carefully to enable safe handling of the
‘HiFIT device’.
In the further course of these operating instructions, the
term ‘device’ is used instead of the full wording ‘HiFIT
device’ for the sake of simplicity.
Operate the device properly, according to these
instructions, so that injuries and damage are avoided.
Do not operate the device based on assumptions. Keep
the operating instructions available, and consult them if
you are in doubt about the performance of a procedure.
If you still have any doubts or questions after reading
through this, do not put the device into operation. First
clarify any outstanding questions with HiFIT.
The device was designed and manufactured in
accordance with the current state of the art and the
recognised safety regulations. Nevertheless, hazards to
persons or property may arise, as not all danger points
can be avoided while maintaining effective functionality.
However, accidents due to these dangers and
malfunctions can be prevented by applying the contents
of these operating instructions and by fully conveying
the instructions contained therein to your personnel
during instruction. In addition, proper application of
these operating instructions will enable you to use the
performance of the device to the full extent possible
and avoid unnecessary malfunctions.
HINWEIS
Prior reading and understanding of these operating
instructions is a legal prerequisite for proper
commissioning and operation of the device.
Always observe the instructions and information
contained, and follow the safety instructions carefully at
all times.

Operating instructions HiFIT device Type HFM21 R1-S 5 von 47
These operating instructions apply exclusively to the
device specified on the cover sheet: HFM 21R1-S.
Compare this information with the information on the
type plate of the device.
Keep these operating instructions in a continuously
accessible filing system so that you can refer to them at
any time if you have questions.
Modification or alterations to the device are only
permitted with the written approval of the manufacturer.
In the event of unauthorised conversion, any liability on
the part of the manufacturer and the warranty shall
lapse.
Customer service:
HiFIT Vertriebs GmbH
Aitrang Branch
Adam-Opel-Strasse 4
Huttenwang 14
38112 Braunschweig
Germany
87648 Aitrang
Germany
Phone:
[phone]
Phone:
[phone]
Fax:
[phone]
Mobile:
[phone]
E-mail:
[email protected]
OPERATING INSTRUCTIONS:
HiFIT device type: HFM 21R1-S
2021 by
DYNATEC Gesellschaft für CAE und Dynamik mbH
Copyright of the operating instructions
DYNATEC retains the copyright to these operating instructions.
These operating instructions are intended for the personnel defined in Chapter 1.10, ‘Target
groups –qualification’. It contains regulations and illustrations of a technical nature which must not
be reproduced, distributed or exploited for competitive purposes without authorisation or
communicated to others, either in whole or in part.
In the event that the operating instructions are handed over in digital form and there is an internal
need for a physical printout and this project does not infringe copyright, such a printout must
generally be made in colour, as the content of some information is only complete in colour.

Operating instructions HiFIT device Type HFM21 R1-S 6 von 47
1.1 Type plate
The following information can be found on the type plate:
Manufacturer or distributor placing on the market
Address
Type designation
Device number
Year of manufacture
Voltage
For technical information and for spare parts orders,
provide all the data listed above.

Operating instructions HiFIT device Type HFM21 R1-S 7 von 47
1.2 General description
Abb. HiFIT device type HFM 21R1-S
The HiFIT device is used for the post-treatment of weld seams. It is to be regarded as a complete
machine and is subject to the EC Machinery Directive 2006/42/EC.

Operating instructions HiFIT device Type HFM21 R1-S 8 von 47
1.3 Main components
The device consists of the following main components:
Pos.
Benennung
01
Pin
02
Spike
03
LED lighting
04
Cap lock
05
Intensity setting
06
Intensity scale
07
Handle
08
On/off switch
09
Compressed air connection
10
LED light switch
11
Battery compartment
12
Air outlet
13
Side handle (optional)
01
05
04
06
07
02

Operating instructions HiFIT device Type HFM21 R1-S 9 von 47
The main components of the HiFIT device type HFM 21R1-S
03
11
08
09
12
13
10

Operating instructions HiFIT device Type HFM21 R1-S 10 von 47
1.4 Scope of delivery
Type HFM 21R1-S
The device is supplied in a case. The contents are as
follows:
1x HiFIT device type HFM21R1-S
5 x spare pins
1 x Allen key
1 x pair of pliers for circlip
1 x measuring gauge for checking
the pin geometry and the groove
depth
1 x spare battery
1 x battery charger
1 x set of operating instructions

Operating instructions HiFIT device Type HFM21 R1-S 11 von 47
1.5 Operating instructions of the manufacturer
The operating instructions of the manufacturer are an
essential aid for the correct and flawless operation of the
device.
The operating instructions are intended to help you as
the operator to keep the device at a high level of
performance during a long service life and to take the
necessary measures for accident prevention.
Read these operating instructions before operating the
device.
All illustrations are for general illustration purposes and
are not authoritative for the design.
If you still have any doubts or questions after reading
through the operating instructions, do not put the device
into operation. Clarify any outstanding questions
beforehand.
If further information is required, HiFIT staff are available
to provide service consulting.
HiFIT Vertriebs GmbH
Huttenwang 14
87648 Aitrang
Germany
Phone: [phone]
Mobile: [phone]
E-mail: [email protected]
If the device is passed on, the operating instructions
must be handed over to the new operator.
Additional copies of the operating instructions or parts
thereof are available at any time, if required, against
reimbursement of the cost price.

Operating instructions HiFIT device Type HFM21 R1-S 12 von 47
1.6 Operating instructions of the operator
The device is built according to the state of the art and
the recognised safety regulations. To the best of our
knowledge, the unit does not pose any hazards when
operated correctly.
However, even the safest appliance may pose residual
risks to the health and safety of users or third parties
during operation.
In order to achieve proper operation and safe use, it is
necessary to instruct the personnel by means of clear
usage, maintenance and other operating instructions
within the framework of training and instructions.
The place of work and the surroundings are also of
particular importance.
As an operator, you are obliged to draw up
operating instructions for your company.
Your operating instructions have the task of enabling
the safe operation and use of the device as well as
taking into account the specific characteristics of your
company, including your experience, and must be kept
up to date by you.
You are obliged to eliminate all hazards on the unit
itself and during operation. If this is not possible, you
must clearly point out the dangers in the operating
instructions you have drawn up.
Your operating instructions must be available to the
personnel at the place of work of the unit at all times
and within easy reach.
Take appropriate measures to ensure that
unauthorised persons are kept away from the unit.
The following chapters are intended to make it easier
for you to draw up your own operating instructions.

Operating instructions HiFIT device Type HFM21 R1-S 13 von 47
1.7 Intended use
The device was developed for the post-treatment of weld
seam transitions in the workshop area and for use on
construction sites.
Intended use also includes full knowledge of these
operating instructions. Be sure to observe the safety
instructions.
The device must only be operated with the original HiFIT
pins. The regrinding of worn pins by the operator is not
permitted. Without the necessary knowledge and
machinery, the shape cannot be guaranteed, which may
result in limited effectiveness of the HiFIT treatment.
The device must be operated only by compressed air.
The maximum permissible operating pressure specified
in the technical data must not be exceeded. This device
must not be operated with explosive, flammable or
harmful gases.
The device is built according to the state of the art and
the recognised safety regulations. Nevertheless,
improper use of the device may result in danger to life
and limb of the user or third parties as well as damage to
the device and other property.
Any other use is contrary to the intended use.
Unintended use, modifications to the device or the use
of parts that have not been tested and approved by the
manufacturer may result in unforeseeable damage!
NOTE
The manufacturer/supplier is not liable for damage
resulting from improper use. The operator alone bears
the risk.
NOTE
In the event of unauthorised modifications to the device,
the product liability and the liability of the
manufacturer/supplier for any resulting damage shall
lapse. The operator alone bears the risk.
NOTE
Intended use also includes compliance with the
procedure described in these operating instructions.

Operating instructions HiFIT device Type HFM21 R1-S 14 von 47
1.8 Environmental conditions
The device is designed for use in workshops and on
construction sites. Please observe the temperature
ranges specified in the technical data.
Make sure that the surface allows safe working.
The supply of compressed air to the device must be
ensured by the infrastructure of the workshop or
construction site.

Operating instructions HiFIT device Type HFM21 R1-S 15 von 47
1.9 Foreseeable misuse
Foreseeable misapplications are considered to be:
- The removal of paint or zinc.
- The removal of rust or weld spatter.
- The cleaning of workpieces.
The points mentioned represent some of the residual
risks that are possible despite the ban and can endanger
the safety of personnel.
The safety requirements defined in the Ordinance on
Industrial Safety and Health must be complied with by
the operator.
Personnel shall be continuously trained according to a
specific training plan. All activities on the device must be
carried out with maximum concentration.
The instructions in the operating instructions must be
followed.
Tampering with the device poses a great potential
danger and is strictly prohibited.
Compressed air connections are to be provided
exclusively for the operation of the device. Any deviating
use not in accordance with the intended use, e.g.
cooling your own body in summer, must be refrained
from.
It is not permitted to affix safety instructions or type
plates. In general, all components must be used as
intended. Manipulations of any kind always contradict
the intended use and are prohibited on principle.
The jamming of controls is prohibited.
In the event of unauthorised modifications to the
operating equipment or unauthorised expansion of the
device, product liability and liability for any resulting
damage shall lapse.
The maintenance intervals specified in the chapter ‘Care
and maintenance’ must be observed to the full extent
with regard to ensuring the functions.

Operating instructions HiFIT device Type HFM21 R1-S 16 von 47
1.10 Target groups –qualifications
WARNING
Risk of injury with unsuitable personnel or
insufficient qualification
Improper handling of the device can lead to considerable
personal injury or damage to property.
Have all work carried out by qualified personnel only.
The operating instructions specify the following target
groups and qualifications for different areas of activity:
Instructed personnel
These persons have been instructed in a briefing by the
operator about the tasks assigned to them and possible
dangers in the case of improper behaviour.
Specialist personnel
These persons are, due to their professional training,
expertise and experience as well as their detailed
knowledge of the relevant regulations, able to carry out
the work assigned to them and to independently
recognise and avoid possible dangers.
Only persons who can be expected to perform their work
reliably are permitted as personnel. Persons whose
ability to react is influenced, e.g. by drugs, alcohol or
medication, are not permitted.
When selecting personnel, the age- and occupation-
specific regulations applicable at the place of
employment must be observed.

Operating instructions HiFIT device Type HFM21 R1-S 17 von 47
1.11 Operator prerequisite
The operator must organise their working environment in
such a way that optimum, continuous operation is
realised.
The operator must be instructed before starting work for
the first time and recurrently once a year.
All persons who are assigned to work with the device
undertake to do the following before starting work:
Observe the basic regulations on work safety and
accident prevention, read the safety instructions and
warnings in the operating instructions and confirm by
their signature that they have understood them,
Put on personal/workplace-related protective clothing
and aids that serve occupational safety or use them
during work, insofar as this is necessary for safety
reasons.
The definitions of competences must be observed. For
example, maintenance work on the device must only be
carried out by a specially trained specialist or by an
instructed person under the direction and supervision of
such a specialist in accordance with the applicable
technical rules.

Operating instructions HiFIT device Type HFM21 R1-S 18 von 47
1.12 Obligation for instruction and training
As the operator, you are obliged to train your personnel
and inform them about existing legal and accident
prevention regulations as well as your operating
instructions.
You must ensure that these operating instructions have
been understood by your personnel and are observed.
This applies in particular to the:
Safety instructions
Meaning of the hazard symbols
Operating instructions
Maintenance instructions
Quality assurance
Regularly check the that your personnel is working in a
safety-conscious and hazard-conscious manner in
compliance with your operating instructions.
Conduct regular training for your personnel according to
a set programme.
Ensure safe resumption of work after holidays and other
work interruptions through instruction and training.
Operating the equipment requires practice.
Document the content of training sessions.
Have participants confirm that they have understood the
content of training sessions.
Keep these documents.
Create a maintenance plan tailored to your usage
conditions.
In the following chapter, Fehler! Verweisquelle konnte
nicht gefunden werden. ‘Sample form’, you will find an
example of training topics with a form to confirm the
instruction.
HiFIT offers training for the delivered device as a
service.
Ask for specific information.

Operating instructions HiFIT device Type HFM21 R1-S 19 von 47
1.12.1 Sample form
Training topics for operating personnel
HiFIT device type:
HFM 21R1-S
Example of topics to be covered:
Safety
General legislation
Accident prevention regulations
General safety instructions
Special safety instructions for the operation of the device
Safety facilities on the device
Personal protective equipment
Safety facilities in the company
Emergency measures
Operation of the device
Content of the operating instructions of the operator
Special experiences of the operator of the device since the last instruction
Special experiences with regard to the materials and tools since the last instruction
Experience with the product produced
Maintenance of the device
Cleaning, maintenance and repair of the device, the auxiliary equipment and the
operational environment
Special experience regarding cleaning, maintenance and repair of the device since the last
instruction
Confirmation of training
No.
Last name
First name
Signature
1
2
3
4
5
6
Date
Training manager
Training manager

Operating instructions HiFIT device Type HFM21 R1-S 20 von 47
2 Safety information
2.1 General notes
The basic prerequisite for safe and trouble-free
operation of the unit is complete knowledge of the safety
instructions and the safety regulations.
Therefore, read this chapter carefully before operating
the device. The safety instructions and warnings that
you will find at the appropriate places in the text of the
following chapters must also be observed. The
manufacturer cannot be held liable if the instructions and
warnings are not observed.
The operator is responsible for compliance with the
protective regulations and for the intended use of the
device.
In this respect, operation is at the operator’s own risk.
The manufacturer is not liable for damage caused during
use of the device unless this damage can be attributed
to gross negligence or intentional breach of contract on
the part of the manufacturer.
The manufacturer cannot foresee every danger. The
warnings contained in these instructions and attached to
the device may therefore not include all dangers.
In addition to the instructions in these operating
instructions, the legal regulations must be observed, in
particular the safety and accident prevention regulations.