HADEF 240/12 User manual

5.52.145.00.01.05
Rev.05
HADEF Spur Gear Hoist
Type 240/12
with monorail push travel trolley
HR
with monorail hand geared trolley
HH
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.
Installation, Operating and
Maintenance Instructions

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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......................................................................................................5
3Transport and Storage .......................................................................6
3.1 Transport............................................................................................................................6
3.2 Safety device for transport ...............................................................................................6
3.3 Storage ...............................................................................................................................6
4Description..........................................................................................6
4.1 Areas of application ..........................................................................................................6
4.2 Design.................................................................................................................................7
4.3 Functions............................................................................................................................7
4.4 Important components......................................................................................................7
5Technical data.....................................................................................8
6Installation...........................................................................................8
6.1 Trolley.................................................................................................................................8
6.2 Adjusting the gauge..........................................................................................................8
6.3 Installation on the beam....................................................................................................9
6.4 Tools...................................................................................................................................9
7Control.................................................................................................9
7.1 Brake and pawl ................................................................................................................10
8Commissioning.................................................................................10
8.1 General .............................................................................................................................10
8.2 Load chain........................................................................................................................10
9Safety check......................................................................................11
10 Functional test..................................................................................11
10.1 Checks before the initial start-up...................................................................................11
10.2 Functional test.................................................................................................................11
11 Maintenance......................................................................................11
11.1 General .............................................................................................................................11
11.2 Monitoring........................................................................................................................11
11.3 Replacing the load chain ................................................................................................11
12 Inspection..........................................................................................12
12.1 Periodic checks ...............................................................................................................12
12.2 Checking the load chain .................................................................................................12
12.3 Checking the load hook ..................................................................................................13
12.4 Checking - pawl ...............................................................................................................13
12.5 Checking - Brake System................................................................................................14
12.6 Checking - Suspension and load hook bolt..................................................................14
13 Service...............................................................................................14
13.1 Load chain........................................................................................................................14

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13.2 Pulleys..............................................................................................................................15
13.3 Load hook ........................................................................................................................15
13.4 Gear ..................................................................................................................................15
13.5 Trolley............................................................................................................................... 15
13.6 Gear spring pressure brake ........................................................................................... 15
13.7 Lubricant - Selection.......................................................................................................15
13.8 Lubricant for food industry –Selection (as option*)....................................................16
14 Trouble .............................................................................................. 16
15 Remedy ............................................................................................. 16
16 Decommissioning ............................................................................ 16
16.1 Temporary decommissioning ........................................................................................ 17
16.2 Final decommissioning/disposal...................................................................................17
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 production of components at our work is subject to strict, intermediate checks.
After assembly, each product is subject to a final test with overload.
For the operation of hoists, the national accident prevention regulations apply in Germany, amongst others.
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.
NOTICE!
We refer to the prescribed equipment tests before initial start-up, before putting back into operation and the
regular periodic inspections.
In other countries any additional national regulations must be observed.
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.

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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.

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
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 permissible ambient temperature when operating the devices:

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Type of drive
Device classification for
Not explosive atmosphere
Explosive atmosphere
according to ATEX )* )**
Manually driven
-20°C/+50°C
-20°C/+40°C
Motor driven
-20°C/+40°C
-20°C/+40°C
) * At an atmospheric pressure range from 0.8bar to 1.1bar and an oxygen content of approx. 21%
) ** Devices of this category have been specially modified and labeled by the manufacturer
DANGER!
The permissible ambient temperature must not be exceeded!
The appropriate use of the hoists is vertical lifting and lowering of unguided loads. In combination with
trolleys, loads can also be moved horizontally.
DANGER!
The use is not allowed:
for pulling loose of stuck loads, dragging of loads and inclined pulling.
in explosive atmosphere, except the unit is especially modified for it and marked by an indication label.
in reactor containment vessels.
to transport people.
The device is not suitable for use on stages and in studios.
Persons must not stand under a suspended load.
NOTICE!
If the units are not used appropriately, it is not possible to ensure safe operation.
The owner and operator have sole liability for all personal injury and damage to property arising from
inappropriate use.
2.5 Basic safety measures

Observe installation-, operation and maintenance instruction.

Take notice of caution notes at units and in the manual

Observe safety distances.

Take care for a free view on the load.

Only use the hoists appropriately.

The equipment is to be used exclusively for movement of goods. Under no circumstances my persons be
moved.

Never load the devices beyond their working load limit.

Pay attention to the accident prevention regulations (UVV).

Should the hoist be used outside of Germany, please pay attention to the national regulations that apply.

Supporting structures and load-attached devices used in conjunction with this equipment must provide an
adequate safety factor to handle the rated load plus the weight of the equipment. In case of doubt, consult
a structural engineer.

If the equipment has not been used for a period of time, carry out visual checks of all main components
such as chains, load hooks etc. and replace any damaged parts with new, original spare parts before
putting the equipment back into operation!

Do not use a hoist that is defective, pay attention to any abnormal noise it makes during operation.

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 motion, any persons in the immediate vicinity must be informed by calling to them!

Please pay attention to the regulations for load carrying devices UVV for both positive and non-positive
methods of attaching loads.

The lifting tackle or the load must be securely attached to the hook and be seated at the bottom of the
hook.

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
The safety catch of hooks must be closed.

When charged, the housing may not be in contact somewhere.

Stop lowering the load when the bottom block or the load is being set down or is prevented from being
lowered further.
The load chain must not be twisted.
Twisted chains must be aligned before attaching the load.
The correct alignment of the chain links can be seen from the weld seams.
The chain links must always be aligned in one direction.
Don't bump against something with load or hook
Illustration 1

Motor drive is prohibited.

The devices are not suitable for continuous operation. In order to avoid too high temperatures of the
brake discs that are not permitted, the following maximum continuous operating times must not be
exceeded:
Light use (highest load is seldom lifted)
Medium use (roughly equal frequency of light, medium and heavy loads)
Heavy use (nearly always largest permissible load)
=
=
=
60 min
30 min
15 min
Let the hoist stand still at least 15 minutes afterwards to cool down the brake.
WARNING!
The following is not allowed:
to lift another load than the nominal safe working load
to manipulate the sliding clutch if units are equipped with
The use of elongated or damaged chains or wire ropes. Replace them immediately by new, original
parts.
Never loop the load chain around a load nor place or pull the chain over edges.
Never repair damaged load hooks (e.g. by hammering), but replace them by original hooks.
3 Transport and Storage
CAUTION!
Transport may only be done by qualified personnel. No liability for any damage resulting from improper
transport or improper storage.
3.1 Transport
The devices are checked and if so adequately packed before delivery.

Do not throw or drop the equipment.

Use adequate means of transport.
Transport and means of transport must be suitable for the local conditions.
3.2 Safety device for transport
NOTICE!
Should a safety device for transport exist, please remove it before commissioning.
3.3 Storage

Store the equipment at a clean and dry place.

Protect the equipment against dirt, humidity and damage by an appropriate cover.

Protect hooks, wire ropes, chains and brakes against corrosion.
4 Description
4.1 Areas of application
The devices must be as far as possible installed in a covered room.

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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!
It is not permitted to use the unit in an area at risk from explosion!
4.2 Design
HADEF Spur Gear Hoists of compact design are
monorail trolleys combined with manual hoists.
With monorail push travel trolley or
with monorail hand geared trolley
Operation by hand through hand chain.
Illustration 2
4.3 Functions
The load is lifted or lowered by pulling one of the chain falls of the endless hand chain of the hoist. A load
pressure brake prevents automatic lowering of the load after releasing the hand chain.
In combination with hand geared trolleys, the trolley is moved to the left or to the right side by pulling the
hand chain.
In combination with push travel trolleys the trolley is moved by pushing or pulling the load or, without load, by
pulling the load chain.
NOTICE!
The best protection against functional failures in case of extreme environmental impact is the regular use of
the equipment.
4.4 Important components

Gear
Gear components are made of high-quality material.

Load pressure brake
Holds the load in any position. Hardened safety pawls.

Housing
Depending on the model made from steel plate or aluminium die-casting (Not for explosion proof equipment).
In case of ex proof hoists, the housing is only made of steel plates.

Load chain
According to EN 818-7-T high quality chain. All components match precisely to each other. Therefore please
only use original chains.

Load hook
Forged steel. Rotating, this facilitates attaching the load and avoids twisting of the chain. With safety catch.

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5 Technical data
240/12 HH
Capacity
kg
500
1000
1500
2000
3000
5000
10000
Number of chain falls
1
1
1
1
2
2
4
Load chain
mm
5 x 15
6x18
8 x 24
8 x 24
8 x 24
10 x 30
10x30
Load bar size at beam flange width
from - to 1 N
mm
50-146
50-179
66-185
66-185
74-196
74-192
119-215
Load bar size at beam flange width
from - to 2 N
mm
147-302
180-310
186-310
186-310
197-310
193-310
216-310
Lifting path when reeling off
30 m hand chain
mm
921
561
522
435
320
170
84
Hand chain pull for lifting
N
260
269
375
350
390
420
426
Travel path when reeling off
30 m hand chain
m
7,8
10
9,8
9,8
6,3
6,3
6,4
Hand chain pull for travel
N
65
100
110
150
110
170
210
Approx. weight at 3 m track height
kg
19,2
25,5
47
47
71
91
235
weight per add. m lift
kg
2,8
3
3,6
3,6
5
6,6
11
240/12 HR
Capacity
kg
500
1000
1500
2000
3000
5000
10000
Number of chain falls
1
1
1
1
2
2
4
Load chain
mm
5 x 15
6x18
8 x 24
8 x 24
8 x 24
10 x 30
10x30
Load bar size at beam flange width
from - to 1 N
mm
50-146
50-179
66-185
66-185
74-196
74-192
119-215
Load bar size at beam flange width
from - to 2 N
mm
147-302
180-310
186-310
186-310
197-310
193-310
216-310
Hand chain pull for lifting
N
260
269
375
350
390
420
426
Approx. weight at 3 m track height
kg
16,7
23
44,5
44,5
68,5
78,5
223
weight per add. m lift
kg
2,8
3
3,6
3,6
5
6,6
9,6
6 Installation
The assembly and installation depends on the local environment. The hoist must be suspended in a way that
it can position itself freely.
6.1 Trolley
For assembly on a beam a travel limit must be placed at either end of the track.
This must be attached so that any elastic limitation buffer or the trolley wheels are driven against them in
their end position when moving.
Generally, additional lifting gear (e.g. fork lift, lifting platforms) will be required for the assembly. These must
take the weight of the devices securely.
6.2 Adjusting the gauge
The trolley can be adjusted to various beam flange widths. Adjustment to the relevant beam flange width “B”
depends on the type and size and is to be made as follows:
There are distance tubes (5) and/or washers
(6) situated on the load bars (2) of the trolley.
Dimension "X" is set by placing washers (6)
from the outer to the inner side ("X" increases)
or from the inner to the outer side ("X"
decreases).
Washers (6) and rubber discs (depended on
type) leave a distance for the load hook. It is
important that the load hangs in the middle
under the beam so that the two side plates are
equally loaded.
The suspension eye (9) (if existent) for bigger
load bolts must still be swivelling after it has
been secured.
Tighten the hexagon nut (3) and safety nuts (4)
again.
Check correct flange width "B" and dimension
"X". Adjustment must be repeated if necessary.
1 side plates
2 load bars
3 hexagon nut
4 safety nuts
5 distance tubes
6 washers
7 ---
8 rubber disc (depended on type)
9suspension eye

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6.3 Installation on the beam
1 Tighten the hexagon nut (3) and safety nuts (4).
2 Push on the trolley at the face of the beam flange.
3 If this is not possible, the trolley can also be mounted
on the beam from below.
4 Therefore, remove the hexagon nut (3) and the safety
nut (4) on the side without gear.
5 Pull apart the side plates (1) as far until it is possible to
push the trolley onto the beam flange from below.
Afterwards, push the trolley together to correct gauge.
6 Secure the washers (6) and distance tubes (5) by
tightening the hexagon nuts (3) and the safety nuts (4).
Illustration 3
CAUTION!
The distance “X” between the wheel flanges of the trolley wheels must be
for trolleys up to 3,2 t: 2-3 mm (1-1,5 mm each side) bigger and
for trolleys from 4 t up: 3-5 mm (1,5-2,5 mm each side) bigger than the flange width "B" of the beam
6.4 Tools
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.
Lifting and Lowering by pulling the endless hand
chain.
Lifting - pull the chain fall at the right side –
the hand chain wheel turns clockwise
Lowering - pull the chain fall at the lift side –
the hand chain wheel turns anti-clockwise
Illustration4
NOTICE!
For double lifting mechanism
Operate both lifting mechanism, synchronous resp.evenly.
Capacity/kg
Size
Tool
Use
500
1000
1500 + 2000
3000
5000
SW27
SW36
SW46
SW55
SW60
load bar
misc

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CAUTION!
Run in of chain into the chain container for hoist with double lifting mechanism
For a correct run in of chain into both chain containers, the lowering operation must be carried out, without
load, at certain intervals, until both chain container are empty.
For motorized devices with operating limit switches "lowering"
Lower until the operating limit switch is released.
Non-observance can lead to device damages!
WARNING!
The hoist must always hang centrally under the beam or under its suspension point.
Monorail push travel trolleys are moved by pushing the load.
Monorail hand geared trolleys are moved by pulling the hand chain.
7.1 Brake and pawl
The brake system needs a minimum load of 3% of the capacity.
Only this minimum load makes sure that the load-pressure-brake closes correctly. When the brake closes
correctly, the load is safely held
GEFAHR!
Working situations with no guarantee that the minimum load is charged, are forbidden!
8 Commissioning
8.1 General
Should the unit be used in Germany:
Please observe the validated, national accident prevention regulations.
For other countries:
Inspections as above. Please observe the national rules and regulations and the instructions in this manual!
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).
8.2 Load chain

Before commissioning the load chain must be aligned and oiled.

For the first commissioning of motorized hoists, chain oil is supplied with the delivery.

Move safety note and fixing wire away from the chain.