HADEF 208/05 User manual

Rev.04
5.52.695.00.01.04
Monorail Trolleys
as monorail push travel trolley
208/05
as monorail hand geared trolley
209/05
with threaded bold
G
208/05
209/05
208/05G
209/05G
Installation, Operating and
Maintenance Instructions

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

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13 Service............................................................................................... 10
13.1 Lubricant - Selection....................................................................................................... 10
13.2 Lubricant for food industry –Selection (as option*).................................................... 10
14 Trouble .............................................................................................. 10
15 Remedy ............................................................................................. 10
16 Decommissioning ............................................................................ 11
16.1 Temporary decommissioning ........................................................................................ 11
16.2 Final decommissioning/disposal................................................................................... 11
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.
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.

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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
Horizontal movement on beams up to the maximum rated load.
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!

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The permissible ambient temperature when operating the devices:
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 ambient temperature range must not be exceeded!
NOTICE!
If the units are not used as intended, safe operation is not guaranteed.
The operator alone is responsible for all personal injury and damage to property resulting from improper
use.
2.5 Basic safety measures
Observe installation-, operation and maintenance instruction.
Take notice of caution notes at units and in the manual
Observe safety distances.
Ensure good visibility during operations
Use the equipment only for its intended purpose
The equipment is only intended for moving goods. Persons must not be moved under any circumstances.
Never load the equipment beyond the specified permissible load capacity.
Observe the relevant national accident prevention regulations.
Should the hoist be used outside of Germany, please pay attention to the national regulations that apply.
Building walls, ceilings, floors or constructions - on which the units are mounted or suspended - must be
checked by a structural engineer for sufficient stability.
After the unit has been standing for a longer period of time, visually inspect all components that are
important for its function and replace damaged components with new original spare parts.
Do not use a defective unit; listen for abnormal operating noises.
In case of malfunctions, stop the operation immediately and rectify the fault.
Report damage and defects immediately to a responsible person
When working with the unit, warn persons in the immediate vicinity.
Observe the provisions for load suspension equipment in accordance with the relevant national
regulations for the positive and non-positive slinging of loads.
The sling or load must be securely attached to the load hook and rest on the bottom of the hook.
The safety latches of hooks must be closed.
The housing must not be in contact with anything.
Motor drive is prohibited.
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.

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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.
If they are used in the open, protect the units against the effects of weather such as rain, hail, snow, direct
sunshine, dust, etc. - we recommend to use a cover in parking position. If the device is set up in a
continuously humid environment with strong temperature fluctuations, the correct functionings are
endangered by the forming of condensation.
NOTICE!
Use only in the intended atmosphere with a humidity of up to 100%, but not under water!
DANGER!
In particular, use is not permitted:
for tearing loose fixed loads, dragging of loads as well as diagonal pulling
for pulling against a fixed point without additional safety and/or measuring equipment against exceeding
the nominal load
in potentially explosive atmospheres, unless the equipment has been modified for this purpose and
this is shown on special type plates it carries for this purpose.
in reactor containments
for transporting persons
for holding lifted loads
for scenic use
when persons are under suspended loads
4.2 Design
Type 208/05 as push travel
Type 209/05 as hand geared trolley
Type 208/05G with threaded load bolt
Type 209/05G with threaded load bolt
4.3 Functions
Push travel trolley:
The trolley is moved by pushing the load.
Hand geared trolley:
Hand geared trolleys are moved by pulling one of the two
stands of the endless hand 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.
4.4 Important components
Trolley wheels
Machined trolley wheels with maintenance-free roller bearings. Profiled wheel surfaces for the use on all
standard beams with inclined and parallel flanges.
Side plates
Made of steel plate with integrated wheel fracture supports.
Load bolts
Device with 1 load bolt. Different bolt lengths are available for different beam flange widths.
Variation: with thread load bolt
5 Technical data
(..) Type „G< with threaded load bar
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:
Capacity
Beam flange width
from - to
at load bar size
Manual
hand chain
force
Travel path
when reeling
off 30 m of
hand chain
with
tread load bar
kg
1N
2N
G 1N
G 2N
209/05
209/05
208/05
209/05
mm
mm
mm
mm
~N
m
--
Without hand-
chain
500
64-152
153-310
50-220
90-305
--
--
7 (5)
--
1000
64-190
191-310
58-220
90-305
60
9,5
14 (9)
18 (13)
2000
88-190
191-310
66-220
90-305
110
10,8
21 (14)
26 (19)
3000
102-190
191-310
74-220
90-305
120
10
35 (24)
41 (28)
5000
114-185
186-310
90-305
--
140
8
48 (41)
54 (45)
10000
125-300
--
--
--
170
6,6
--
113
20000
136-305
--
--
--
190
3,45
--
258

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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
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 1
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
Version with thread load bar:
By turning the thread load bar the site plates will
be moved together or apart.
Caution!
When using the trolley you must permanently pay attention on the load bar that it not moves out and the
distance between wheel flange and girder section is always correct adjusted.
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.
Monorail push travel trolleys are moved by pushing the load.
Monorail hand geared trolleys are moved by pulling the hand chain.

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8 Commissioning
8.1 General
The operator of the unit is responsible for the entire system.
According to the Ordinance on Industrial Safety and Health, a hazard analysis must be carried out by the
operator.
Observe the respective national standards, regulations and directives of the responsible bodies at the place
of operation.
NOTICE!
Hoists up to 1000 kg capacity and without motor-driven trolleys of hoisting unit must be tested by a
<qualified person= before putting into operation for the first time.
Hoists of 1000 kg capacity and up or with more than one motor-driven hoist movement; i.e. lifting and
trolley movement, must be tested by a <licensed qualified person= before putting in operation.
An exception is <hoists ready for operation= acc. validated national regulations with EU-declaration of
conformity.
Definition <qualified person= (former expert)
A <qualified person= has learned, due to occupational training and experience and the job that the person has
done, the skills needed to tests the material for one’s work.
Definition <licensed qualified person= (former approved expert)
A <licensed qualified person= has, due through special occupational training, knowledge about testing of the
material for one’s work and knows the national accident prevention regulations and other prescriptions and
technical regulations. This person must test the material for one’s work regularly with regard to design and
kind of use. The license will be given to qualified person be the approved supervision authorities (ZÜS).
9 Safety check
Before putting into service initially or when putting back into service, it must be checked whether:
All fastening screws (if existent), socket pins, flap socket and safety devices are tightened and secured.
10 Functional test
10.1 Checks before the initial start-up
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
Trolleys
Carefully move the trolley to the end positions and check the positions of the end stops.
11 Maintenance
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.
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

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12 Inspection
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.
at
commissioning
daily
checks
1st maintenance
after
3 months
Inspection
Maintenance
every
3 months
Inspection
Maintenance
every
12 months
check screw connections
X
X
check the bearings
X
check the trolley wheels
X
check lubrication of the driving pinion
X
X
buffers - check correct position and wear
X
X
electric motor* - check the brake lining
X
electric motor* - check the brake
X
X
pneumatic motor*
X
X
X
Have the equipment checked by an expert
(periodic inspection)
X
*as far as applicable
13 Service
Maintenance must be effected by lubricating the driving pinions (for hand geared trolleys) and by checking
the rubber end stops.
13.1 Lubricant - Selection
FUCHS
SHELL
ESSO
MOBIL
TOTAL
CASTROL
KLÜBER
Renolit FEP 2
Alvania EP 2
Unirex EP 2
Mobilux EP 2
MULTIS EP2
--
--
Stabylan 5006
--
--
--
--
Optimol Viscoleb 1500
Klüberoil 4UH 1-1500
--
--
--
--
--
--
Wolfracoat 99113
Chain lubricant OKS 451
13.2 Lubricant for food industry –Selection (as option*)
SHELL
MOBIL
CASTROL
KLÜBER
Gearing
FM Grease HD2
Mobilgrease FM 222
--
Klüberoil 4UH 1-1500 N
Load chain
--
Lubricant FM 100
Optimol Viscoleb 1500
--
Load hook;
Pulleys
Gear rim;
Drive pinion
FM Grease HD2
Mobilgrease FM 222
--
--
* must be mentioned by order
14 Trouble
Please pay attention to the following in case of problems:
Troubles with the equipment must only be repaired by qualified personnel.
Secure the unit against unintended operation start.
Put up a warning note indicating that the unit is not to be used.
Secure the working area of moving parts of the unit.
Please read the chapter "Safety instructions".
Notes on the repair of faults are found in the following table.
For the repair of failures please contact our service department.
CAUTION!
Trouble caused by wear or damage to parts such as wire ropes, chains, chain wheels, axes, bearings,
brake parts, etc., must be remedied by replacing the parts with original spare parts.
15 Remedy
Problem
Cause
Remedy
Trolley runs very slowly or not at all
Driving pinion dirty or blocked.
Clean the driving pinion and lubricate it, if necessary,
exchange worn parts
Place the hand chain correctly
Hand chain is twisted or blocked*)
*) as far as applicable

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16 Decommissioning
WARNING!
It is essential that the following points are observed in order to prevent damage to the equipment or critical
injury when the device is being decommissioned:
It is mandatory that all steps for decommissioning the machine are carried out in the indicated sequence:
First secure the working area for decommissioning, leaving plenty of space.
Read the chapter "Safety instructions".
Disassembly is carried out in reverse order to the assembly.
Please make sure that all operating material is disposed of in accordance with environmental regulations.
16.1 Temporary decommissioning
Measures are as above.
Also read the chapter <Transport and storage=.
16.2 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.