HADEF DIN 7355 Assembly instructions

5.52.210.00.01.01 Rev.01
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HADEF Steel Jack
DIN 7355
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Installation,- Operating and
Maintenance Instructions

Information
2 5.52.210.00.01.01
Internet Download: www.doc.hadef.de/b7355_gb.pdf
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NOTE!
The installation or mounting instructions for incomplete machines you’ll find in chapter “Installation”
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©by Heinrich de Fries GmbH
Heinrich de Fries GmbH, Gauss Str. 20, D-40235 Düsseldorf
Heinrich de Fries GmbH wird im Weiteren als
HADEF bezeichnet. Heinrich De Fries GmbH will be named HADEF in the following text.
Originalbetriebsanleitung in deutscher Sprache. Translation of the original operating and
maintenance instructions
Eine Kopie kann bei HADEF schriftlich
angefordert werden. A copy is available from HADEF on request.
Änderungen vorbehalten. Subject to changes.
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Table of Contents
1Information..........................................................................................4
2Safety...................................................................................................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
3Transport and Storage.......................................................................8
3.1 Transport............................................................................................................................8
3.2 Safety device for transport...............................................................................................8
3.3 Storage ...............................................................................................................................8
4Description..........................................................................................9
4.1 Areas of application ..........................................................................................................9
4.2 Design.................................................................................................................................9
4.3 Functions............................................................................................................................9
4.1 Important components......................................................................................................9
5Technical data...................................................................................10
5.1 Main dimensions..............................................................................................................10
6Installation.........................................................................................11
7Operation...........................................................................................12
8Commissioning.................................................................................13
8.1 General .............................................................................................................................13
9Functional test..................................................................................14

Information
5.52.210.00.01.01 3
10 Maintenance...................................................................................... 15
10.1 General.............................................................................................................................15
10.2 Monitoring........................................................................................................................15
11 Inspection ......................................................................................... 16
11.1 Periodic checks............................................................................................................... 16
11.2 Inspection intervals......................................................................................................... 16
12 Service............................................................................................... 17
12.1 Gear ..................................................................................................................................17
12.2 Safety crank and load pressure brake ..........................................................................17
12.3 Lubricant selection ......................................................................................................... 17
13 Trouble .............................................................................................. 18
14 Remedy ............................................................................................. 19
15 Decommissioning ............................................................................ 20
15.1 Temporary decommissioning ........................................................................................ 20
15.2 Final decommissioning/disposal...................................................................................20
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Information
4 5.52.210.00.01.01
1 Information
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HADEF 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 HADEF is subject to strict, intermediate checks.
After assembly, each HADEF 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 HADEF 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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NOTE!
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
5.52.210.00.01.01 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 5.52.210.00.01.01
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 HADEF spare parts must be used. Non-compliance will result in any warranty claims on HADEF
becoming void.
Liability and warranty will become void if unauthorized modifications of the units are made by the user!
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Vertical lifting and lowering of loads with short lifting heights, that do not require special safety measures.
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NOTE!
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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DANGER!
If the units are not used appropriately, it is not possible to ensure safe operation.
It is not allowed:
The use in an area at risk from explosion. Exception is made when the unit is modified to be
explosion-proof and this is shown on special type plates it carries for this purpose.
To transport people with the equipment.
Persons must not stand under a suspended load.
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Safety
5.52.210.00.01.01 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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Motor drive is prohibited.
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Transport and Storage
8 5.52.210.00.01.01
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
HADEF 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
NOTE!
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
5.52.210.00.01.01 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 functioning of the motor
and the brake 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 Steel jacks acc. DIN 7355 are winches
with stationary pinion rack and movable housing.
They are constructed for mobile use to lift and
lower load vertically with small lifting heights or
horizontally and tilt angle as supporting winch.
The load must always be in right angle (90°) to the
winch foot surface.
Optional with a safety crank or a ratchet safety
crank, load pressure brake included. The load will
hold in each position, safety.
Variations:
Steel jack with reduced total height
Steel jack with adjustable lifting claw foot
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4.3 Functions
The load is lifted/ lowered, by turning the winch handle. The incorporated load-pressure-brake prevents
automatic lowering of the load after release of the winch handle. Little after run of the load or turn of the
winch handle is due to the system and not a mistake.
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4.1 Important components
4.1.1 Housing
The housing is made of steel plate.
4.1.2 Brake
Load pressure brake inside the crank.
4.1.3 Gear
Rack and pinion drive
4.1.4 Crank
SIKU = Safety crank with load pressure brake
RAKU = Ratchet safety crank with load pressure brake and switching lever
4.1.5 Load contact
Head = upper load contact
Lifting claw = bottom load contact
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Technical data
10 5.52.210.00.01.01
5 Technical data
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Capacity lifting
height crank pressure lift per crank turn weight approx.
kg mm kN mm Kg
1500 350 250 14 13
3000 350 250 8 20
5000 300 250 4 27
10000 300 500 4 42
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5.1 Main dimensions
dimensions
mm 1500 kg 3000 kg 5000 kg 10000 kg
A 725 725 725 800
B 265 265 265 320
C 65 70 75 80
D 140 140 170 170
E 130 130 150 150
F 60 65 75 85
G 85 90 110 124
H 50 60 67 76
J 350 350 300 300
Illustration 1
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Installation
5.52.210.00.01.01 11
6 Installation
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Please observe the following points in order to avoid any damage to equipment or injury of person:
Wear safety gloves.
Install the winch on a stable ground.
Make sure attachment surface is flat and that installation is made stress-free, - use shim parts if
necessary.
The winch must be set up and attached in such a way that it cannot change position neither by the load
nor by other influences.
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The load must only be lifted with the head or the lifting claw of the device.
The load must always contact the surface of the winch feet right-angled (90°).
CAUTION!
Do not push inclined as this may lead to accidents, this is not allowed.
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Operation
12 5.52.210.00.01.01
7 Operation
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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.
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Lifting and lowering by turning the hand crank.
Lifting load – turn clockwise. ¬
Hold load – release hand crank. The load holds
automatically. Acc. The different types, the crank
can removed in each position or the crank grip
can fold back.
Ù
Lowering load – turn anti clockwise. «
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Winch with safety crank
Crank with integrated load pressure brake.
Lifting or lowering by change of turning direction.
Winch with ratchet safety crank
Crank with integrated load pressure brake.
Switching lever for ratchet function
Depending on the turning function selected only lifting or
lowering is possible. This makes it possible to lift or lower
by continuous crank movement (ratching) in area where
there is little space available.
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Commissioning
5.52.210.00.01.01 13
8 Commissioning
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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!
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NOTE!
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 quality 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).
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Functional test
14 5.52.210.00.01.01
9 Functional test
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Function must be tested with capacity load, which is shown on the type plate.
Test brake by lifting and lowering the load. The load must be hold safety.
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Maintenance
5.52.210.00.01.01 15
10 Maintenance
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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.
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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
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Inspection
16 5.52.210.00.01.01
11 Inspection
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11.1 Periodic checks
Independently from the regulations of the individual countries, HADEF 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.
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11.2 Inspection intervals
on commissioning daily checks 1st service after 3
months inspection, service every 3 months inspection, service every 12
months
Inspection of the equipment by a qualified person (periodic
inspection) X
Check screw connections X X
Check brake function X X
check brake air gap (only for electric devices) X
check overload protection if existent X
clean and lubricate the wire rope X X X
check wire rope and wire rope end fastenings for damage
and wear X
check the load tackle and load hook for cracks and
deformation X
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Service
5.52.210.00.01.01 17
12 Service
Pos: 17.2.1 /14-W ARTUNG/Winde + Seilzug/Getr iebe/03.Getriebe 7355 @ 1\mod_126683316529 0_52.doc @ 12735 @ @ 1
12.1 Gear
The gear is lubricated with high-quality long-time grease by the manufacturer.
Due to short operation periods renewal of lubrication is only necessary after one year.
After removal of the crank (A) and the ratchet pawls (B) ,
the front-side housing plate (C) can be removed. There is
now access to the gear parts and the rack and pinion drive,
they can be dismantled now.
Lubricate all gear parts, rack and pinion drive and bearing.
Recommended lubricant: Shell fat Alvania EP2
or similar product.
Illustration 2
In case of severe operating conditions, i.e. dust, humidity etc. shorter lubrication intervals may be necessary.
It is possible to re-lubricate the rack and pinion drive more than once a year (annual maintenance intervals)
without dismantling it when it is totally moved out in uncharged condition. The bearing points can be
lubricated with some drops of oil when the winch is placed down on its side. This makes it possible that the
lubricant penetrates between the bearing pin and the hole.
Pos: 17.2.2 /14-W ARTUNG/Winde + Seilzug/Si cherheitskurbel/260/ 76 + 7355 @ 1\mod_12663266 79410_52.doc @ 12331 @ @ 1
12.2 Safety crank and load pressure brake
Winches which are fitted with safety cranks have a load pressure brakes installed in the crank.
The abrasion of brake rings must be checked. Gap max. >30°.
Caution!
Change of worn brake rings and repair of cranks only by manufacturer.
Brake linings should be free of oil, grease, dirt and dampness, because of an increased abrasion.
If lowering will work slowly, let drip some drops oil
in the gap of crank nave.
Grease the rotating parts of crank grip, slightly.
Illustration 3
Pos: 17.3 /14-WARTUN G/Schmierstoffe/Sc hmierstoff-Auswahl_ H@ 1\ mod_127167018300 2_52.doc @ 13442 @ @ 1
12.3 Lubricant selection
FUCHS SHELL ESSO ARAL MOBIL KLÜBER
Renolit FEP 2 Alvania EP 2 Unirex EP 2 -- Mobilux EP 2 --
Pos: 18.1 /15-STÖRUNG/*Ü1*/#. Kapitel - Störung @ 0\mod_117264829 5608_52.doc @ 413 @ @1

Trouble
18 5.52.210.00.01.01
13 Trouble
Pos: 18.2.1 /15-STÖRUNG/Allgemein/01.St örung @ 0\mod_1173250229044 _52.doc @ 460 @ @ 1
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.
Pos: 18.2.2 /--- ALLGEMEIN/Hinweise/V ORSICHT - Störung beseitigen b ei Verschleißteilen @ 0\ mod_1177594576085_5 2.doc @ 5572 @ @ 1
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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Remedy
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14 Remedy
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Trouble Cause Remedy
Brake is worn or defective
Rack and pinion drive is deformed, gear is stuck.
The winch or the crank must be repaired by the manufac-
turer.
Check the gear and replace rack and pinion drive or gear
parts if necessary.
Load is not lifted or it is difficult to lift the load.
Brake discs are humid or oiled The winch or the crank must be repaired by the manufac-
turer.
The load pressure brake does not open. Brake mechanism or brake discs are locked. Loosen the brake by slightly pushing the winch handle by
hand (in direction lowering).
No loading in right-angle possible. Deformation of the lifting claw, the head or the rack and pinion
drive. The winch must be repaired by the manufacturer
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Decommissioning
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15 Decommissioning
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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:
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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.
=== Ende der Liste für Textmarke Inhalt ===