HADEF 108/99 User guide

Rev.01
5.52.624.00.01.01
Pedestal
108/99 - 108/22
Installation, Operating and
Maintenance Instructions

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5.52.624.00.01.01
NOTICE!
The installation or mounting instructions for incomplete machines you’ll find in chapter “Installation”.
o
by Heinrich de Fries GmbH
Heinrich de Fries GmbH, Gauss Str. 20, D-40235 Düsseldorf
Heinrich De Fries GmbH will be named HADEF in the following text.
Original operating- and maintenance instructions in German language.
Translation in other languages is made of the German original.
A copy may be requested in writing or is available for download on www.hadef.com
Subject to changes.
Table of Contents
1Information..........................................................................................3
2Safety...................................................................................................3
2.1 Warning notice and symbols............................................................................................3
2.2 Duty of care of the owner..................................................................................................3
2.3 Requirements for the operating personnel.....................................................................4
2.4 Appropriate use.................................................................................................................4
2.5 Basic safety measures......................................................................................................4
3Transport and Storage .......................................................................5
3.1 Transport............................................................................................................................5
3.2 Storage ...............................................................................................................................5
4Description..........................................................................................5
4.1 Areas of application ..........................................................................................................5
4.2 Design.................................................................................................................................6
4.3 Functional description......................................................................................................6
4.4 Important components......................................................................................................6
5Technical data.....................................................................................6
6Installation...........................................................................................6
6.1 Wire rope deflection..........................................................................................................7
6.2 Rope exit.............................................................................................................................7
6.3 Tools...................................................................................................................................7
7Control.................................................................................................8
8Commissioning...................................................................................8
8.1 General ...............................................................................................................................8
9Safety check........................................................................................8
10 Maintenance........................................................................................9
10.1 General ...............................................................................................................................9
10.2 Monitoring..........................................................................................................................9
11 Inspection............................................................................................9
11.1 Periodic checks .................................................................................................................9
11.2 Inspection intervals...........................................................................................................9
11.3 Inspection...........................................................................................................................9
12 Service.................................................................................................9
13 Trouble.................................................................................................9

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14 Remedy ............................................................................................. 10
15 Decommissioning ............................................................................ 10
15.1 Temporary decommissioning ........................................................................................ 10
15.2 Final decommissioning/disposal...................................................................................10
1 Information
The products meet European Union requirements, in particular the valided EU Machine Directive.
The entire company works acc. to a certified quality assurance system as per ISO 9001.
The stated performance of the devices and meeting any warranty claims require adherence to all instructions
in this manual.
Before delivery, all products are packed properly. Check the goods after receipt for any damage caused
during transport. Report any damage immediately to the forwarding agent.
This manual allows a safe and efficiently use of equipment. Images of this manual are for a principle
understanding and can be different from the real design.
2 Safety
2.1 Warning notice and symbols
Warnings and notice are shown as follows in these instructions:
DANGER!
This means that there is a high risk that leads, if it is not avoided, to death or severe injury.
WARNING!
This means that there is a risk that could lead, if it is not avoided, to death or severe injury.
CAUTION!
This means that there is little risk that could lead, if it is not avoided, to slight injury or damage to
the device or its surrounding.
NOTICE!
Gives advice for use and other useful information.
Danger from electricity.
Danger from explosive area.
2.2 Duty of care of the owner
DANGER!
Failure to follow the instructions of this manual can lead to unpredictable hazards.
For any resulting damage or personal injury, HADEF assumes no liability.
The unit was designed and built following a risk analysis and careful selection of the harmonized standards
that are to be complied with, as well as other technical specifications. It therefore represents state-of-the-art
technology and provides the highest degree of safety.
Our delivery includes the hoist supplied beginning at its suspension and ending at the load hook and if
supplied with control, the control line/hose that leads to the hoist. Further operating material, tools, load
attaching devices as well as main energy supply lines must be assembled according to the valid rules and
regulations. For explosion-proof equipment, all these parts must be approved for use in area prone to
explosion, or they must be suitable for use in area prone to explosion. The owner is responsible for this.
However, in everyday operation this degree of safety can only be achieved if all measures required are
taken. It falls within the duty of care of the owner/user of the devices to plan these measures and to check
that they are being complied with.
Complete the operating and installation instructions by any instructions (regarding supervision or
notifications)that are important for the special kind of use of the equipment, i.e. regarding organization of
work, work flow and human resources.
In particular, the owner/user must ensure that:

The unit is only used appropriately.

The device is only operated in a fault-free, fully functional condition, and the safety components, in
particular, are checked regularly to ensure that it is functioning properly.

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
The required personal protective equipment for the operators, service and repair personnel is available
and is used.

The operating instructions are always available at the location where the equipment is used and that they
are legible and complete.

The unit is only operated, serviced and repaired by qualified and authorized personnel.

This personnel is regularly trained in all applicable matters regarding safety at work and environmental
protection, and that they are familiar with the operating manual and, in particular, the safety instructions it
contains.

Any safety and warning signs on the devices are not removed and remain legible.

customers equipment at site must comply with currently applicable ATEX-regulations
WARNING!
It is not allowed to make constructive changes of the equipment!
2.3 Requirements for the operating personnel
The units may only be operated by qualified persons that are appropriately trained and that are familiar with
it. They must have their employer’s authorization for operation of the units.
Before starting work, the operating personnel must have read the operating and installation instructions,
especially the chapter "Safety Instructions".
This is especially important for operating personnel that rarely uses the equipment, i.e. for installation or
maintenance work.
DANGER!
In order to avoid severe injury, please pay attention to the following when using the equipment:
Use protective clothes/equipment.
Do not wear long hair hanging down open.
Do not wear rings or other jewelry.
Do not wear clothes that are too big/wide.
Do not reach into ropes, chains, drive parts or other moving parts with your hands
2.4 Appropriate use
Devices are intended for deflecting a wire rope in all directions.
The permitted safe working load of the devices must not be exceeded! An exception can be made during the
load test before initial operation, carried out by a licensed qualified person.

Defective devices and load suspension devices must not be used until they have been repaired! Only
original spare parts must be used. Non-compliance will result in any warranty claims becoming void.

Liability and warranty will become void if unauthorized modifications of the units are made by the user!

The permitted environmental temperature during equipment operation is –20°C up to +50°C.
DANGER!
The ambient temperature range must not be exceeded!
NOTICE!
If the units are not used as intended, safe operation is not guaranteed.
The operator alone is responsible for all personal injury and damage to property resulting from improper
use.
2.5 Basic safety measures

Observe installation-, operation- and maintenance instruction.

Pay attention to caution notes at units and in the manual.

Observe safety distances.

Take care for a free view on the load.

Only use this devices appropriately.

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
The equipment is to be used exclusively for movement of goods. Under no circumstances persons may
be moved.

Never load the devices beyond their working load limit.

Observe the relevant national accident prevention regulations.

Building walls, ceilings, floors or constructions - on which the units are mounted or suspended - must be
checked by a structural engineer for sufficient stability.

After the unit has been standing for a longer period of time, visually inspect all components that are
important for its function and replace damaged components with new original spare parts.

Do not use a defective device.

Stop working immediately in case of disturbances and remedy failures.

Any damage and faults must be reported to a responsible supervisor immediately.

If the unit is put into operation, any persons in the immediate vicinity must be informed by calling to them!

Observe the provisions for load suspension equipment in accordance with the relevant national
regulations for the positive and non-positive slinging of loads.

The lifting tackle or the load must be securely attached to the device.
3 Transport and Storage
3.1 Transport
The goods are checked and adequately packed before delivery.

Do not throw or drop the accessories

Use adequate means of transport
Transport and means of transport must be suitable for the local conditions.
3.2 Storage

Store the accessories at a clean and dry place

Protect the accessories against dirt, humidity, corrosion and damage by an appropriate cover
4 Description
4.1 Areas of application
The devices must be as far as possible installed in a covered room.
If they are used in the open, protect the units against the effects of weather such as rain, hail, snow, direct
sunshine, dust, etc. - we recommend to use a cover in parking position. If the device is set up in a
continuously humid environment with strong temperature fluctuations, the correct functionings are
endangered by the forming of condensation.
NOTICE!
Use only in the intended atmosphere with a humidity of up to 100%, but not under water!
DANGER!
In particular, use is not permitted:
for tearing loose fixed loads, dragging of loads as well as diagonal pulling
for pulling against a fixed point without additional safety and/or measuring equipment against exceeding
the nominal load
in potentially explosive atmospheres, unless the equipment has been modified for this purpose and
this is shown on special type plates it carries for this purpose.
in reactor containments
for transporting persons
for holding lifted loads
for scenic use
when persons are under suspended loads

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4.2 Design
Pedestal with wire rope pulley and roller bearing
4.3 Functional description
Free insertion as well as deflection of wire rope in all directions.
NOTICE!
The best protection against functional failures in case of extreme environmental impact is the regular use of
the equipment.
4.4 Important components
Rope pulley with machined groove
Maintenance-free roller bearing
Side plates made of bended steel plate
Rope slip off guard (only 108/22)
5 Technical data
108/99
capacity
kg
rope pulley diameter
max. rope diameter
mm
weight
outer Ø mm
groove base Ø mm
250
85
60
6
1,4
500
125
90
9
3,7
1000
180
135
13
10,2
2000
240
185
18
23,8
3200
300
230
23
44
5000
360
280
27
75
12500
530
420
38
195
20000
645
510
46
360
108/22
capacity
kg
rope pulley diameter
max. rope diameter
mm
weight
outer Ø mm
groove base Ø mm
250
85
65
4
1,9
500
118
100
6
5,1
1000
178
145
9
14,3
2000
238
200
12
32,4
3200
305
255
16
57
5000
348
290
18
90
12500
465
390
24
199
20000
530
450
28
313
6 Installation
Fixing screws on site. Rope diameter acc. duty classification1Em.
The installation surface must be plan.
Install strainless.
108/99
Size
Rope
Ø
max.
A
A1
B
B1
D5
Schraube
8.8
mm
mm
mm
mm
mm
mm
M
025
6
80
60
86
66
9
8
05
9
110
80
127
97
13
12
10
13
170
130
162
127
17
16
20
18
210
160
216
166
21
20
32
23
270
210
252
192
25
24
50
27
320
260
294
234
32
30
125
38
450
380
323
263
32
30
200
46
570
480
370
300
32
30
Illustration 1

5.52.624.00.01.01
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108/22
Size
Rope
Ø
max.
A
A1
B
B1
D5
Schraube
8.8
mm
mm
mm
mm
mm
mm
M
025
4
110
90
86
66
9
8
05
6
160
130
127
97
13
12
10
9
220
180
162
127
17
16
20
12
250
200
216
166
21
20
32
16
310
250
247
187
25
24
50
18
360
260
294
234
32
30
125
24
470
400
323
263
32
30
200
28
570
480
370
300
32
30
Illustration 2
6.1 Wire rope deflection
maximum wire rope deflection angle
4° for standard wire ropes
2° for non-twisting resp. twist-resistant wire
ropes
The minimum dimension (M) from the centre of
the drum to the centre of the sheave, or from
sheave to sheave, must be observed.
Illustration 3
NOTICE!
Skewed running and non-compliance with the minimum distances of deflection points can result in
increased wear and lead to premature rope discard!
6.2 Rope exit
Rope exit is possible in all directions.
108/22
For rope exits at certain angles, individual rope slip off guard can be moved or removed.
up to 1000kg
from 2000kg
To prevent the rope from slipping off when slack, the rope must be guided under at least one rope slip off
guard.
6.3 Tools
108/99
capacity
tool
size
usage
250kg –1000kg
M6
axial securing
2000kg –5000kg
M8



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108-22
7 Control
Only people that are familiar with the operation of the lifting devices and cranes may be entrusted with their
operation. They must be authorized by the employer for the operation of the equipment. The employer must
ensure that the operating instructions are available near the equipment and that they are accessible for the
operating personnel.

Only use wire ropes, that do not exceed the maximum permitted diameter.

Put the wire rope properly on the pulley and ensure that the rope rests on the groove base.

Check screw connections.
8 Commissioning
8.1 General
The operator of the unit is responsible for the entire system.
According to the Ordinance on Industrial Safety and Health, a hazard analysis must be carried out by the
operator.
Observe the respective national standards, regulations and directives of the responsible bodies at the place
of operation.
NOTICE!
Hoists up to 1000 kg capacity and without motor-driven trolleys of hoisting unit must be tested by a
“qualified person” before putting into operation for the first time.
Hoists of 1000 kg capacity and up or with more than one motor-driven hoist movement; i.e. lifting and
trolley movement, must be tested by a “licensed qualified person” before putting in operation.
An exception is “hoists ready for operation” acc. validated national regulations with EU-declaration of
conformity.
Definition “qualified person” (former expert)
A “qualified person” has learned, due to occupational training and experience and the job that the person has
done, the skills needed to tests the material for one’s work.
Definition “licensed qualified person” (former approved expert)
A “licensed qualified person” has, due through special occupational training, knowledge about testing of the
material for one’s work and knows the national accident prevention regulations and other prescriptions and
technical regulations. This person must test the material for one’s work regularly with regard to design and
kind of use. The license will be given to qualified person be the approved supervision authorities (ZÜS).
9 Safety check
Before putting into service initially or when putting back into service, it must be checked whether:

All fastening screws (if existent), socket pins, flap socket and safety devices are tightened and secured.
capacity
tool
size
usage
250kg –500kg
M6
axial securing
Rope slip off guard
1000kg
M8
2000 - 5000kg
M10
12500kg
M16
20000kg
M20

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10 Maintenance
10.1 General
All monitoring, servicing and maintenance operations are to ensure correct functioning of the equipment;
they must be effected with utmost care.

Only “qualified persons” may do this work.

Servicing and maintenance work must only be done when the hoist is not loaded.

Records must be kept of all test results and measures taken.
10.2 Monitoring
The monitoring and servicing intervals stated are valid for operation under normal conditions and single-shift
operation. In case of severe operating conditions (e.g. frequent operation with full load) or special
environmental conditions (e.g., heat, dust, etc.), the intervals must be shortened correspondingly
11 Inspection
11.1 Periodic checks
Independently from the regulations of the individual countries, lifting devices must be checked at least yearly
by a qualified person or licensed qualified person regarding its functional safety.
11.2 Inspection intervals
daily
checks
inspection,
service every
3 months
inspection,
service every
12 months
check screw connections
X
check wear and tear of rope pulley
X
check smooth running of rope pulley
X
check smooth running of rope within pulley
X
equipment check by a qualified person (periodic inspection)
X
11.3 Inspection

Examine for bearing damage.
The rope pulley should have a firm seating on ist axle and should turn smoothly.

Check for wear and tear.
The wire rope must not stick in the groove and has to be liftable effortlessly.
12 Service
The wire rope pulley and the ball bearings are maintenance-free.
13 Trouble
Please pay attention to the following in case of problems:

Troubles with the equipment must only be repaired by qualified personnel.

Secure the unit against unintended operation start.

Put up a warning note indicating that the unit is not to be used.

Secure the working area of moving parts of the unit.

Please read the chapter "Safety instructions".
Notes on the repair of faults are found in the following table.
For the repair of failures please contact our service department.
CAUTION!
Trouble caused by wear or damage to parts such as wire ropes, chains, chain wheels, axes, bearings,
brake parts, etc., must be remedied by replacing the parts with original spare parts.

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14 Remedy
trouble
cause
remedy
loud noise while turning rope pulley
ball bearing worn or defective
replace ball bearing
loose seating or sluggishness of rope pulley
Rope pulley does not turn
rope sticking in pulley groove
rope pulley worn or deformed
replace rope pulley
15 Decommissioning
WARNING!
It is essential that the following points are observed in order to prevent damage to the equipment or critical
injury when the device is being decommissioned:
It is mandatory that all steps for decommissioning the machine are carried out in the indicated sequence:

First secure the working area for decommissioning, leaving plenty of space.

Read the chapter "Safety instructions".

Disassembly is carried out in reverse order to the assembly.

Please make sure that all operating material is disposed of in accordance with environmental regulations.
15.1 Temporary decommissioning

Measures are as above.

Also read the chapter “Transport and storage”.
15.2 Final decommissioning/disposal

Measures are as above.

After disassembly, ensure that the disposal of the equipment and any materials it contains is carried out
in accordance with environmental regulations.