HADEF 24/12 Assembly instructions

5.52.196.00.01.02 Rev.02
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HADEF Spur Gear Hoist
Type 24/12
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with monorail push travel trolley HR
with monorail hand geared trolley HH
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Installation,- Operating and
Maintenance Instructions

Information
2 5.52.196.00.01.02
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NOTICE!
The installation or mounting instructions for incomplete machines you’ll find in chapter “Installation”
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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.
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Table of Contents
1Information..........................................................................................4
2Safety...................................................................................................5
2.1Warning notice and symbols............................................................................................5
2.2Duty of care of the owner..................................................................................................5
2.3Requirements for the operating personnel.....................................................................6
2.4Appropriate use.................................................................................................................6
2.5Basic safety measures......................................................................................................7
3Transport and Storage.......................................................................8
3.1Transport............................................................................................................................8
3.2Safety device for transport...............................................................................................8
3.3Storage ...............................................................................................................................8
4Description..........................................................................................9
4.1Areas of application ..........................................................................................................9
4.2Design.................................................................................................................................9
4.3Functions............................................................................................................................9
4.4Important components....................................................................................................10
5Technical data...................................................................................11
6Installation.........................................................................................12
6.1Adjusting the gauge........................................................................................................12
6.2Installation on the beam..................................................................................................12
6.3Tools.................................................................................................................................13
7Operation...........................................................................................14
8Commissioning.................................................................................15
8.1General .............................................................................................................................15
8.2Load chain........................................................................................................................15
9Safety check......................................................................................16
10Functional test..................................................................................17
10.1Checks before the initial start-up...................................................................................17
10.2Functional test.................................................................................................................17
11Maintenance......................................................................................18

Information
5.52.196.00.01.02 3
11.1General.............................................................................................................................18
11.2Monitoring........................................................................................................................18
11.3Replacing the load chain................................................................................................18
12Inspection ......................................................................................... 19
12.1Periodic checks...............................................................................................................19
12.2Checking the load chain.................................................................................................19
12.3Checking the load hook..................................................................................................20
12.4Checking - pawl...............................................................................................................20
12.5Checking - Brake System ............................................................................................... 20
12.6Checking - Load and suspension hook bolt................................................................. 21
13Service............................................................................................... 22
13.1Load chain .......................................................................................................................22
13.2Pulleys..............................................................................................................................22
13.3Load hook ........................................................................................................................23
13.4Gear ..................................................................................................................................23
13.5Trolley...............................................................................................................................23
13.6Gear spring pressure brake ...........................................................................................23
13.7Overload protection ........................................................................................................ 24
13.8Lubricant - Selection.......................................................................................................24
13.9Lubricant for food industry – Selection (as option*)....................................................24
14Trouble .............................................................................................. 25
15Remedy ............................................................................................. 26
16Decommissioning ............................................................................ 27
16.1Temporary decommissioning ........................................................................................ 27
16.2Final decommissioning/disposal...................................................................................27
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Information
4 5.52.196.00.01.02
1 Information
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The products meet European Union requirements, in particular the EU Machine Directive (2006/42/EG).
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 accident prevention regulations BGV D8, BGV D6 and BGR 500 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.
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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.
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Safety
5.52.196.00.01.02 5
2 Safety
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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.
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2.2 Duty of care of the owner
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.
Devices for use in area prone to explosion must (from customer's side) be earthed with a shunting
resistor of < 106Ωagainst earth.
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WARNING!
It is not allowed to make constructive changes of the equipment!
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Safety
6 5.52.196.00.01.02
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 authorisation 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 jewellery.
Do not wear cloths that are too big/wide.
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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, carried out by a licensed qualified person in accordance with the accident prevention regulations
UVV BGV D6 before initial operation.
The permitted environmental temperature during equipment operation is –20°C up to +40°C!
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!
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The appropriate use of the hoists is vertical lifting and lowering of unguided loads. In combination with
trolleys, loads can also be moved horizontally.
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DANGER!
It is not allowed:
pulling loose of stuck loads, dragging of loads and inclined pulling is not allowed.
in explosive atmosphere, except the unit is especially modified for it and marked by an indication label
to transport people
persons must not stand under a suspended load
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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.
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Safety
5.52.196.00.01.02 7
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 BGR500 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.
The safety catch of hooks must be closed.
When charged, the housing may not be in contact somewhere.
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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.
Illustration 1
When charged, the housing may not be in contact somewhere.
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Motor drive is prohibited.
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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.
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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.
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Transport and Storage
8 5.52.196.00.01.02
3 Transport and Storage
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CAUTION!
Transport may only be done by qualified personnel. No liability for any damage resulting from improper
transport or improper storage.
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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.
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Description
5.52.196.00.01.02 9
4 Description
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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.
Ambient temperature: - 20°C up to + 40°C. Humidity: 100 % or less but not under water
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DANGER!
It is not permitted to use the unit in an area at risk from explosion!
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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
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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.
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NOTICE!
The best protection against functional failures in case of extreme environmental impact is the regular use of
the equipment.
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Description
10 5.52.196.00.01.02
4.4 Important components
4.4.1 Gear
Gear components are made of high-quality material.
4.4.2 Load pressure brake
Holds the load in any position. Hardened safety pawls.
4.4.3 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.
4.4.4 Load chain
According to EN 818-7-T high quality chain. All components match precisely to each other. Therefore please
only use original chains.
4.4.5 Load hook
Forged steel. Rotating, this facilitates attaching the load and avoids twisting of the chain. With safety catch.
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4.4.6 Overload protection
Hoists with overload protection protects the hoist by a slipping clutch from damage by overload. When the
slipping clutch operates, lifting of the load is stopped. Lifting is only possible again after the load has been
lowered and reduced to nominal load.
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Technical data
5.52.196.00.01.02 11
5 Technical data
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24/12 HH
Capacity kg 500 1000 1500 2000 3000 5000 10000 20000
Number of chain falls 1 1 1 1 2 2 4 2x4
Load chain mm 5 x 15 6x18 8 x 24 8 x 24 8 x 24 10 x 30 10 x 30 10 x 30
Load bar size at beam flange width
from - to 1 N mm 50-146 50-135 66-185 66-185 74-196 74-192 119-215 160-310
Load bar size at beam flange width
from - to 2 N mm 147-302 136-220 186-310 187-310 197-310 193-310 216-310 --
Lifting path when reeling off
30 m hand chain mm 921 561 522 435 320 170 85 2x85
Hand chain pull for lifting N 260 269 375 350 390 420 450 2x450
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 6,5 10 11 15 11 17 21 (*)
Approx. weight at 3 m track height kg 19,2 25,5 47 47 71 91 170 (*)
weight per add. m lift kg 2,8 3 3,6 3,6 5 6,6 11 21
(*) not yet fixed at the time the document was made out
24/12 HR
Capacity kg 500 1000 1500 2000 3000 5000
Number of chain falls 1 1 1 1 2 2
Load chain mm 5 x 15 6x18 8 x 24 8 x 24 8 x 24 10 x 30
Load bar size at beam flange width
from - to 1 N mm 50-146 50-135 66-185 66-185 74-196 74-192
Load bar size at beam flange width
from - to 2 N mm 147-302 136-220 186-310 187-310 197-310 193-310
Hand chain pull for lifting N 260 269 375 350 390 420
Approx. weight at 3 m track height kg 16,7 23 44,5 44,5 68,5 78,5
weight per add. m lift kg 2,8 3 3,6 3,6 5 6,6
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Installation
12 5.52.196.00.01.02
6 Installation
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6.1 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)
9 suspension eye
Pos: 10.2.2 /1_HADEF/ 6--MONTAGE/Fahrwerke 19/ 90 bis 28/ - 29/... - 209/05/19/90 bis 28/ - 209/05/2. Montage auf Träger - Fahrw.+ H-Züge @ 0\mod _1182781260523_52.doc x @ 6580 @ @ 1
6.2 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
Pos: 10.2.3 /1_HADEF/ 6--MONTAGE/Fahrwerke 19/ 90 bis 28/ - 29/... - 209/05/19/90 bis 28/ - 209/05/3. Montage_Feststellring @ 1\mod _1267104431334_52.doc x @ 13089 @ @ 1

Instal
l
5.52.19
6
6.2.1
Securin
g
safety s
c
In or
d
dism
a
side.

A
fter
insta
l
scre
w
(4).
Whe
n
drive
To d
o
stern
the s
i
Pos:10.2.4 /1_HADEF/---ALLGEMEIN/Hinweise/Kettenzüge/VORSICHT - Maß X
=
C
The dist
a
for trolle
y
for trolle
y
Pos: 10.3 /1_HADEF/6- -MONTAGE/Werkzeuge/ 24/24/12 @ 3\mod_13624705 267
8
6.3
Pos: 11.1 /1_HADEF/7- -BEDIENUNG/*Ü1*/#. Kapitel - Bedienung @ 0\mod_1172
6
Cap
a
5
1
0
1500
3
0
5
0
1
0
2
0
5
100
0
l
ation
6
.00.01.02
Bolt secu
r
g
the load b
o
c
rews (3).
d
er to adjust
a
ntle the saf
e
adjustment
o
l
lation on th
e
w
s (3) again
n
pulling ap
a
shaft will al
s
o
this, loose
n
tube bearin
g
ide plates h
a
=
2-3mm und 3-5mm @ 0\mod_1184767195 881_52.docx @ 6813 @ @ 1
C
AUTIO
N
a
nce “X” bet
w
y
s up to 3,2
y
s from 4 t
u
8
2_52.docx @ 26110 @ @ 1
Tools
6
47408811_52.doc x@ 398 @ @ 1
a
city/kg
5
00
000
+ 2000
000
000
0
000
0
000
5
00
0
-20000
r
ing with co
o
lts with set
c
the beam fl
a
e
ty screws (
3
o
f dimensio
n
e
beam, inst
a
and secure
t
a
rt the side p
s
o be move
d
n
the safety
s
g
and secur
e
a
ve been pu
s
N
!
w
een the w
h
t: 2-3 mm (1
u
p: 3-5 mm (
1
Size
SW27
SW36
SW46
SW55
SW60
SW75
SW24
size 1
size 2
misc.
misc.
lla
r
c
ollars (1) a
n
a
nge width
3
) at one tro
l
n
"X" and
a
ll the safety
t
hem with a
n
lates, the tr
o
.
s
crews at th
e
e
them agai
n
s
hed togeth
e
h
eel flanges
o
-1,5 mm ea
c
1
,5-2,5 mm
e
Tool
n
d
lley
n
ut
o
lley
e
n
after
e
r.
of the trolle
y
c
h side) bigg
e
ach side) b
i
l
Illustration
1 set coll
a
2 load ba
3 safety
s
4 hexago
5 washer
y
wheels mu
s
er and
i
gger than th
Use
load ba
r
load bolt
w
set colla
Overloa
d
protectio
n
misc.
misc.
4
a
r
r
s
crew
n
nu
t
s
t be
e flange wid
t
r
w
ith
r
d
n
th "B" of the beam
13

Operation
14 5.52.196.00.01.02
7 Operation
Pos: 11.2 /1_HADEF/7--BEDIENUNG/Allgemei n/01.Bedienung - Alle @ 0\mod_117 3087534915_52.doc x @ 440 @ @1
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.
Pos: 11.3.1 /1_HADEF/7--BEDIENUNG/Hand/Ke ttenzug + Fahrwerke/Al le H@ 0\ mod_1182339959857_52. docx @ 6276 @ @ 1
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
Illustration5
Pos: 11.3.2 /1_HADEF/7--BEDIENUNG/Hand/Ke ttenzug + Fahrwerke/ Alle H + Zusatz b.Fahrwerk @ 0\ mod_1182783208251_52. docx @ 6601 @ @ 1
Monorail push travel trolleys are moved by pushing the load.
Monorail hand geared trolleys are moved by pulling the hand chain.
Pos:11.3.3 /1_HADEF/---ALLGEMEIN/Hinweise/Kettenzüge/WARNUNG- Hebezeugimmer mittig hä ngen @ 0\mod_117732307955 0_52.docx @ 5150 @ @ 1
WARNING!
The hoist must always hang centrally under the beam or under its suspension point.
Pos: 12.1 /1_HADEF/9-- INBETRIEBNAHME/*Ü1*/ #. Kapitel - Inbetriebnahm e @ 0\mod_1177486166685_52. docx @ 5393 @ @ 1

Commissioning
5.52.196.00.01.02 15
8 Commissioning
Pos: 12.2.1.1 /1_HADEF/ 9--INBETRIEBNA HME/Allgemein/Allge mein/01.Allgemein @ 0\ mod_1172504961658_52. docx @ 355 @ @ 1
8.1 General
Should the unit be used in Germany, please observe the accident prevention regulations, in particular BGV
D8, BGV D 6 and BGR 500 (VBG 9a).
For other countries: Inspections as above. Please observe the national rules and regulations and the
instructions in this manual!
Pos:12.2.1.2/1_HADEF/---ALLGEMEIN/Hinweise/Prüfungen/HINWEIS- Prüfung durch befähigte Pesonen @ 0\ mod_1177339966681_52 .docx @ 5319 @ @ 1
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. To BGV D6 II§25(4) 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).
Pos: 12.2.2.1 /1_HADEF/ 9--INBETRIEBNA HME/Allgemein/Lastke tte/06.Lastkette @ 0\ mod_1178195068515_52. docx @ 5681 @ @ 1
8.2 Load chain
Before commissioning the load chain must be aligned and oiled.
Move safety note and fixing wire away from the chain.
Pos:12.2.2.2/1_HADEF/---ALLGEMEIN/Hinweise/Ketten/VORSICHT- Ketten: Kein Fett, ohne Schmierung kei ne Haftung @ 0\mod_117 7481784104_52.docx @ 5349 @ @ 1
CAUTION!
Do not use grease for lubrication of load chain.
Without lubrication, manufacturer's warranty and/or liability will be void.
Pos:12.2.2.3/1_HADEF/---ALLGEMEIN/Hinweise/Ketten/HINWEIS- Kettenlebensdauererhöhung durch Schmierung @ 0\ mod_1177481941192_52. docx @ 5355 @ @ 1
NOTICE!
Continuous, thorough lubrication will increase the life of the chain considerably.
Pos: 13.1 /1_HADEF/10- SICHERHEITSPRÜFUNG/* Ü1*/#. Kapitel - Si cherheitsprüfung @ 0\mod_117 2647514342_52.doc x @ 401 @ @1

Safety check
16 5.52.196.00.01.02
9 Safety check
Pos: 13.2 /1_HADEF/10- SICHERHEITSPRÜFUNG/A llgemein/01.Sic herheitsprüfung Al le@ 0\ mod_1178197796463_52. docx @ 5700 @ @ 1
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.
Pos: 13.3 /1_HADEF/10- SICHERHEITSPRÜFUNG/A llgemein/Sicher heitsprüfung Ketten @ 0\ mod_1172661092232_52. docx @ 429 @ @ 1
The chains are correctly placed, oiled and in good condition.
Pos: 14.1 /1_HADEF/11- FUNKTIONSPRÜFUNG/*Ü 1*/#. Kapitel - Funktiospr üfung @ 0\mod_11764468 80639_52.docx @ 4028 @ @ 1

Functional test
5.52.196.00.01.02 17
10 Functional test
Pos: 14.2.1 /1_HADEF/ 11-FUNKTIONSPRÜFUNG/Fun ktionsprüfung/ HKe ttenzug @ 1\mod_1267020 857717_52.doc x@ 12950 @ @ 1
10.1 Checks before the initial start-up
Lifting gear
Load chains must not be twisted.
Lubricate the load chain with gear oil or suitable chain lubricant before first loading.
Trolley drive
The open-lying teeth of the trolley drive must be lubricated.
Hand gear for hand geared trolley
Ensure correct fit of the hand chain, it must not be twisted and must hang freely.
10.2 Functional test
Lifting gear
Check lifting and lowering functions, initially without a load.
Then check the brake function under load. The load must be securely held.
Trolleys
Carefully move the trolley to the end positions and check the positions of the end stops.
Pos: 15.1 /1_HADEF/12- INSTANDSETZUNG/*Ü1* /#. Kapitel - Instandha ltung @ 0\mod_117264760313 9_52.docx @ 405 @ @ 1

Maintenance
18 5.52.196.00.01.02
11 Maintenance
Pos: 15.2.1 /1_HADEF/ 12-INSTANDSETZUNG/A llgemein/01.Allge mein @ 0\mod_1173251926256_ 52.docx @ 469 @ @ 1
11.1 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.
Pos: 15.2.2 /1_HADEF/ 12-INSTANDSETZUNG/A llgemein/02.Über wachung @ 0\mod_11732545034 20_52.docx @ 472 @ @ 1
11.2 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
Pos: 15.3.1 /1_HADEF/ 12-INSTANDSETZUNG/La stkette wechseln/03. Alle @ 0\mod_117327544 8587_52.docx @ 533 @ @ 1
11.3 Replacing the load chain
CAUTION!
If there is any visible damage and when the conditions for replacement are reached (i.e. one or several
dimensions in the table have been reached, there is corrosion or elongation), the chain must be replaced.
When replacing the chain, also check the chain wheels.
Procedure:
Only insert new chains in an unloaded state and as the chains that are currently in the device – i.e. not
twisted.
Remove chain from its fastening at the end and attach a chain link which is open at the side.
A chain link which is open at the side, can
easily be produced by grinding out a small
piece. The opening must have the same
thickness as the chain link.
Illustration 6
Hang a new original chain (same size and oiled) in the side opened chain link and insert it.
Make sure the chain is not installed twisted.
Make sure the chain links are aligned in one direction.
Assemble the chain to the end fastening.
Pos: 16.1 /1_HADEF/13- PRÜFUNG/*Ü1*/#. Kapi tel - Prüfung @ 0\mod_117326 4087196_52.doc x@ 507 @ @ 1

Inspection
5.52.196.00.01.02 19
12 Inspection
Pos: 16.2 /1_HADEF/13- PRÜFUNG/Wieder kehrende Prüfung/01.W iederkehrende Prüfung @ 0\ mod_1175675257580_52. docx @ 3164 @ @ 1
12.1 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.
In Germany it is necessary to observe the accident prevention regulations BGV D6, BGV D8, BGR 500 as
well as DIN 15020 (Basics for cable drives). In other countries, the above mentioned tests and the national
safety regulations apply.
Pos: 16.3.1.1 /1_HADEF/ 13-PRÜFUNG/Ketten zug/Allgemein/01. Zupr üfende Teile @ 0\mod_ 1173259827552_52.doc x@ 481 @ @ 1
12.1.1 Components to be checked
The following must be checked:
Dimensions of load chain, load hooks, pawls, bolts, ratchet wheels, brake linings.
The dimensions must be compared to the dimensions in the tables.
A visual inspection for deformations, cracks and corrosion must be carried out.
Pos:16.3.1.2/1_HADEF/---ALLGEMEIN/Hinweise/Prüfungen/VORSICHT- Verschleißgrenzen@ 1\mod_1260457845218_52.doc x@ 11380 @ @ 1
CAUTION!
When the wear limit is reached, the part must be exchanged by a new, original part.
Pos: 16.3.2.1 /1_HADEF/ 13-PRÜFUNG/Ketten zug/Tabelle-Inspek tionsinterval le/02.Alle H m. Fahrw. + Ratschz üge @ 0\mod_118284212 7821_52.docx @ 6620 @ @ 1
on
commissioning daily checks 1st mainte- nance
after
3 months
Inspection
Maintenance
every
3 months
Inspection
Maintenance
every
12 months
Check screw connections X X
Check lifting, lowering functions. X X
Check brake function X X
Check free-wheeling of chain
(only applicable for ratchet lever hoists with free-wheeling
mechanism) X X
Brake - check the brake disc thickness X
Check sprocket wheels, ratchet wheels, pawls, bolts X
Clean and lubricate the load chain X X X
Check the load chain for elongation and wear X
Check the load hook for cracks and deformation X
Load hook - check the safety latch X X
Check and lubricate the bearing of the chain pulleys X X
Check the chain pulleys X X
Check the rubber end stops X X X
Check the trolley wheels for wear X
Check lubrication of the trolley driving pinion X X X
Have the equipment checked by a qualified person
(periodic inspection) X
Pos:16.3.2.2/1_HADEF/---ALLGEMEIN/Hinweise/Kettenzüge/WARNUNG - Inspektion: Über,-unterschreiten Maße-Ketten,Haken @ 0\mod_11775044566 74_52.docx @ 5496 @ @ 1
WARNING!
If one or several of the dimensions fall below or exceed the dimensions in the table, or if cracks or
corrosion are found, the parts must be replaced with original spare parts.
Pos: 16.3.3.1 /1_HADEF/ 13-PRÜFUNG/Ketten zug/Lastkette/Las tkette - Maßerklärung @ 0\ mod_1173261324103_5 2.docx @ 492 @ @ 1
12.2 Checking the load chain
acc. DIN 685-part 5
L11 = pitch increase over 11 chain links
L1 = pitch increase over 1 chain link
dm = detected link thickness
Illustration 7
Pos: 16.3.3.2 /1_HADEF/ 13-PRÜFUNG/Ketten zug/Lastkette/Tabe lle - Ketten 5x15 - 6x18 - 8x24- 10x30 @ 3\ mod_1338367889898_52. docx @ 21711 @ @ 1
Chain dimension
Dimension
mm Chain dimension
5x15 6X18 8x24 10x30
L11 170,6 203,94 272,1 340,7
L1 15,7 18,9 25,3 31,8
dm 4,5 5,4 7,2 9,0

Inspection
20 5.52.196.00.01.02
Pos:16.3.3.3/1_HADEF/---ALLGEMEIN/Hinweise/Ketten/WARNUNG - Ketten: Bei Erreic hen der Tabellenmaße durc h Verschleiß oder Verfor mung die Ke @ 0\mod_1178705158 838_52.docx @ 5763 @ @ 1
WARNING!
When the dimensions listed in the table are reached due to wear or deformation, the chain must be
replaced!
Pos: 16.3.4.1 /1_HADEF/ 13-PRÜFUNG/Ketten zug/Lasthaken/Las thaken - Maßerklärung - X-Y-H@ 0\mod_1182346659653_52.doc x@ 6 318 @ @ 1
12.3 Checking the load hook
Load hook
X = measuring distance hook mouth width
Y = measured length from hook no. 6
H = thickness of hook saddle
Illustration 8
Pos: 16.3.4.2 /1_HADEF/ 13-PRÜFUNG/Ketten zug/Lasthaken/ Tabelle - Hakenmaße - 9/+ 24/12 @ 3\mod_1338381630953_ 52.docx @ 21777 @ @ 1
Table 1
Dimension
mm
Capacity
500 kg 1000 kg 1500 kg 2000 kg 3000 kg 5000 kg 10000 kg 20000 kg
X or Y 27/35 33/45 33,5/47 37/52 43,5/62.5 51/79 64/- 82/-
H 16,8 21 25,5 28,3 35,6 43,2 60,4 84,8
Dimensions in the tables are theoretical values without tolerances.
Please fill in the measured
values before putting into
operation:
Capacity kg
X or Y mm
H mm
Pos:16.3.4.3/1_HADEF/---ALLGEMEIN/Hinweise/Haken/VORSICHT- Hakenbei Verformung....@ 0\mod_1177582461489 _52.docx @ 5510 @ @ 1
CAUTION!
When the dimension of hook opening width is deformed more than 10% or when the dimension of the hook
bottom thickness is fallen short of by 5% due to wear, the hook must be replaced.
Pos: 16.3.5 /1_HADEF/ 13-PRÜFUNG/Kettenzug/ Sperrklinke/ Tabelle - 8/+9/+24/ +240/Tabelle - 8/+9/+ 24/+240/12 @ 3\mod_13383769896 92_52.docx @ 21726 @ @ 1
12.4 Checking - pawl
A Vmin
kg mm mm
500 14,5 13,5
1000 25 23,5
1500-3000 30 27,5
5000-20000 35 33,5
Pos: 16.3.6 /1_HADEF/ 13-PRÜFUNG/Kettenzug/ Sperrrad+Br emsbelag/Tabelle 8/+9/ +24/+240/Tabelle 8/+ 9/+24/+240/12 @ 3\mod_1338 377339751_52.doc x @ 21731 @ @ 1
12.5 Checking - Brake System
Ratchet wheel (A) and brake linings (B)
D Vmin tn tvmin
A 2x B
kg mm mm mm mm
500 45 44 2,5 2
1000 68 67 2 1,5
1500-3000 80 78 2 1,5
5000-20000 100 98 2,5 2
Pos: 16.3.7 /1_HADEF/ 13-PRÜFUNG/Kettenzug/ Bolzen/Tabelle - 9/ +24/Tabelle - 9/+ 24/12 @ 3\mod_1338382507619_ 52.docx @ 21782 @ @ 1