HADEF 20/94AF-EX User manual

Rev.06
5.52.692.01.01.06
Monorail Trolley
20/94AF-EX
as monorail push travel trolley
AFR
as monorail hand geared trolley
AFH
as monorail pneumatic trolley
AFP
Explosion proof design
II 2G Ex h IIB T4 Gb or II 2D Ex h IIIA T135°C Db
II 2G Ex h IIB T3 Gb or II 2D Ex h IIIA T200°C Db
DANGER!
Not to be used with IIC gases and IIB gases hydrogen sulphide and ethylene oxide and light metal
and shock sensitive dusts.
It is not allowed to use the equipment in area at risk from explosion where gas AND dust does both
exist at the same time!
Installation, Operating and
Maintenance Instructions

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5.52.692.01.01.06
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..................................................................................................4
2.3 Requirements for the operating personnel.....................................................................4
2.4 Appropriate use.................................................................................................................5
2.5 Basic safety measures......................................................................................................5
2.6 Explosion protection.........................................................................................................7
3Transport and Storage .....................................................................10
3.1 Transport..........................................................................................................................10
3.2 Safety device for transport .............................................................................................10
3.3 Storage .............................................................................................................................10
4Technical data...................................................................................10
5Installation.........................................................................................11
5.1 Trolley...............................................................................................................................11
5.2 Adjusting the gauge........................................................................................................11
5.3 Installation on the beam..................................................................................................11
5.4 Tools.................................................................................................................................12
6Control...............................................................................................12
7Operation...........................................................................................13
8Commissioning.................................................................................13
8.1 General .............................................................................................................................13
8.2 Compressed air connection ...........................................................................................14
9Safety check......................................................................................15
10 Functional test..................................................................................15
10.1 Checks before the initial start-up...................................................................................15
10.2 Functional test.................................................................................................................15
11 Maintenance......................................................................................15
11.1 General .............................................................................................................................15
11.2 Monitoring........................................................................................................................15
12 Inspection..........................................................................................15
12.1 Periodic checks ...............................................................................................................15
13 Service...............................................................................................16

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13.1 Lubricant - Selection....................................................................................................... 16
13.2 Lubricant for food industry –Selection (as option*)....................................................16
14 Trouble .............................................................................................. 16
15 Remedy ............................................................................................. 17
16 Decommissioning ............................................................................ 17
16.1 Temporary decommissioning ........................................................................................ 17
16.2 Final decommissioning/disposal...................................................................................18
17 Additional documents...................................................................... 18
17.1 Pneumatic connections diagram...................................................................................18
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 EN ISO 9001.
The production of components at our work is subject to strict, intermediate checks.
After assembly, the products are subject to a final test with overload.
For the operation of hoists, the national accident prevention apply in Germany, amongst others.
Lifting equipment for use in areas prone to explosion complies with current legislation, standards and
regulations and is classified in the applicable Ex-protection class.
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 serves for safe and efficient use of this hoist. Illustrations serve to explain something and may
differ from the illustration of the existing unit as they only serve as an example.
Documentation of component manufacturers that may be supplied additionally, must be observed, in case of
differences between these documentation and our manuals, the specification of the our manual must be
observed.
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
DANGER!
To assess the intended use of the devices correctly, the user must carry out an Ex-zone
classification.
The classification must be carried out in accordance with all current legislation, standards and
regulations for areas prone to explosion!
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.

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5.52.692.01.01.06
Danger from explosive area.
2.2 Duty of care of the owner
DANGER!
Failure to follow the instructions of this manual can lead to unpredictable hazards.
For any resulting damage or personal injury, HADEF assumes no liability.
The unit was designed and built following a risk analysis and careful selection of the harmonized standards
that are to be complied with, as well as other technical specifications. It therefore represents state-of-the-art
technology and provides the highest degree of safety.
Our delivery includes the hoist supplied beginning at its suspension and ending at the load hook and if
supplied with control, the control line/hose that leads to the hoist. Further operating material, tools, load
attaching devices as well as main energy supply lines must be assembled according to the valid rules and
regulations. For explosion-proof equipment, all these parts must be approved for use in area prone to
explosion, or they must be suitable for use in area prone to explosion. The owner is responsible for this.
However, in everyday operation this degree of safety can only be achieved if all measures required are
taken. It falls within the duty of care of the owner/user of the devices to plan these measures and to check
that they are being complied with.
Complete the operating and installation instructions by any instructions (regarding supervision or
notifications)that are important for the special kind of use of the equipment, i.e. regarding organization of
work, work flow and human resources.
In particular, the owner/user must ensure that:

The unit is only used appropriately.

The device is only operated in a fault-free, fully functional condition, and the safety components, in
particular, are checked regularly to ensure that it is functioning properly.

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

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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!

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.
DANGER!
It’s only allowed to use the unit in the EX-classification which is named on the type plate; or in lower
classes.
2.5 Basic safety measures

Observe installation-, operation and maintenance instruction.

Take notice of caution notes at units and in the manual

Observe safety distances.

Take care for a free view on the load.

Only use the hoists appropriately.

The equipment is to be used exclusively for movement of goods. Under no circumstances my persons be
moved.

Never load the devices beyond their working load limit.

Pay attention to the accident prevention regulations (UVV).

Should the hoist be used outside of Germany, please pay attention to the national regulations that apply.

Supporting structures and load-attached devices used in conjunction with this equipment must provide an
adequate safety factor to handle the rated load plus the weight of the equipment. In case of doubt, consult
a structural engineer.

If the equipment has not been used for a period of time, carry out visual checks of all main components
such as chains, load hooks etc. and replace any damaged parts with new, original spare parts before
putting the equipment back into operation!

Do not use a hoist that is defective, pay attention to any abnormal noise it makes during operation.

Stop working immediately in case of disturbances and remedy failures.

Any damage and faults must be reported to a responsible supervisor immediately.

If the unit is put into motion, any persons in the immediate vicinity must be informed by calling to them!

Please pay attention to the regulations for load carrying devices UVV for both positive and non-positive
methods of attaching loads.

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5.52.692.01.01.06

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.
DANGER!
Special safety measures for use in areas prone to explosion.
No use in zone 0 or zone 20
Not to be used with IIC gases and IIB gases hydrogen sulphide, ethylene oxide and light metal and shock
sensitive dusts!
No use in temperature class T5 or T6.
It is not allowed to use the equipment in area at risk from explosion where gas AND dust does both exist
at the same time!
During assembly and operation of explosion-proof equipment, the relevant regulations of i.e. BG-Chemie
about the use of equipment in area at risk from explosion, must be adhered to by the user/owner.
Please make sure that external ventilation is sufficient.
Please wear conductive shoes. Gloves should have a shunt resistance of < 108.
It is not allowed to take off clothes.
The surface temperature of the devices could increase by a variety of external circumstances. For this
reason, the surface temperature is to be monitored.
Avoid ignitable dust deposits.
Remove dust deposits daily before commencing work and ensure that dust cannot settle between moving
parts.
Never remove dust with compressed air - remove it with a wet bolt of cloth.
Defective units or units that show abrasion of its surface rust on chains, hooks, or suspension devices,
must be taken out of service.
Please observe the prescribed intervals.
Assembly and maintenance work must only be carried out in an atmosphere not prone to explosion.
Check the grease level of the bearings regularly
Exchange friction surfaces in time and (an exception to this are electric units - maintenance of the brakes
must only be effected by HADEF).
Protect the device from impact, friction, rough handling and moisture.
DANGER!
The operator is responsible for professional equipotential bonding (earthing) for power-operated
devices!
Special scope
Use of different EX-zones is depended from the EX-classification of the unit. Find the EX-classification on its
type plate.
Unit classified
in EX-classification
No use
in EX-zone
3G
0,20,1,21,22
3D
0,20,1,21,2
2G
0,20,21,22
2D
0,20,1,2

5.52.692.01.01.06
7
2.6 Explosion protection
The EX classification of the unit is indicated on a
separate plate, situated on the unit.
Illustration 1
Example of ATEX classification:
II
2
G
Ex h
IIB
T4
Gb
CE-marking
European Union
explosion-proof operating material
II
device group / application
I
II
danger of mine damp
other areas prone to explosion
2
device category
1
2
3
for use in zone 0
for use in zone 1
for use in zone 2
G
EX atmosphere
G
D
...caused by gas, steam, fog
...caused by dust
Ex h
type of protection
for mechanical devices, including e. g.
“c” construction safety
“k” encapsulation of liquids
IIB
explosion group II (gases)
IIA
IIB
IIC
limit gap widths (MESG) > 0,9 mm
limit gap widths (MESG) ≤0,9 to ≥0,5 mm
limit gap widths (MESG) < 0,5 mm
T4
Temperature class - gases
(for dust only the temperature in °C
is stated)
T1
T2
T3
T4
T5
T6
limit temperature 450 °C
limit temperature 300 °C
limit temperature 200 °C
limit temperature 135 °C
limit temperature 100 °C
limit temperature 85 °C
Gb
EPL (equipment protection level)
Ga
Gb
Gc
e.g. Group II (for gases, vapours, mist):
level of protection: very high (complies with zone 0)
level of protection: high (complies with zone 1)
level of protection: enhanced (complies with zone 2)
2.6.1 EX-Category
EX - Zone
1+21
2+22
1+21
2+22
Device category
2
2
Expl.-group of gases
Expl.-group of dust
IIB
IIIA
IIB
IIIA
Temperature class - gases
Temperature class - dust
T4
T135°C
T3
T200°C
DANGER!
The classification for the device can be found on the EX-type plate on the unit.
The device must only be used in the classification stated or in a lower classification.

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2.6.2 Surface temperature of the devices
DANGER!
The temperature class mentioned on the EX-type plate on the unit must be observed, - make sure
that the max. surface temperature is even fallen short of.
DANGER!
The maximum surface temperature of the equipment must always be lower than the ignition
temperature of the gas/vapour/dust/air mixture. Equipment which has been classified in higher
temperature classes is, of course, also approved for use in applications with lower temperature
classes. As gas/air mixtures for T5 do not occur with normal use, and only very rarely occur for T6,
for specific gas/air mixtures such as carbon disulphide (IIC), our hoists are not rated for these
temperature classes and must not be used for these classes.
Temperature
class
Ignition tem-
perature of gas
°C
max. surface
temperature of the
operating material in
°C
T1
>450
450
T2
>300 <450
300
T3
>200 <300
200
T4
>135 <200
135
T5
>100 <135
100
T6
>85 <100
85
2.6.3 EX zone classification
Areas that are prone to explosion are classified into zones. The owner must determine the zone that exists.
Information on the zone classification can be found in IEC 60079-10 and in national standards. The following
table contains an overview of the zone classification in combination with the device category.
Gases
Vapours
Mist
device category
(Gases)
Dust
device category
(dust)
explosive
atmosphere
is present
Zone 0
1G
Zone 20
1D
continuously, long-term or
frequently
Zone 1
2G
Zone 21
2D
occasionally
Zone 2
3G
Zone 22
3D
rarely or short-term

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9
2.6.4 Explosion hazards … recognizing and preventing!

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3 Transport and Storage
CAUTION!
Transport may only be done by qualified personnel. No liability for any damage resulting from improper
transport or improper storage.
3.1 Transport
The devices are checked and if so adequately packed before delivery.

Do not throw or drop the equipment.

Use adequate means of transport.
Transport and means of transport must be suitable for the local conditions.
3.2 Safety device for transport
NOTICE!
Should a safety device for transport exist, please remove it before commissioning.
3.3 Storage

Store the equipment at a clean and dry place.

Protect the equipment against dirt, humidity and damage by an appropriate cover.

Protect hooks, wire ropes, chains and brakes against corrosion.
DANGER!
Units that show corrosion must be taken out of service!
4 Technical data
Travel speed:
Pneumatic trolley 8 m/min
Operating pressure:
Pneumatic trolley 6 bar
Air comsumption per motor 1,2m³/min
Weights
500kg
1t
2t
2,5t
3,2t
4t
5t
6,3t
7,5t
10t
12t
15t
20t
25t
AFR
N1
8
13
29
29
58
58
71
159
--
--
--
--
--
--
N2
10
14
31
31
62
62
73
164
--
--
--
--
--
--
AFH*
N1
9
17
34
34
64
64
76
165
165
165
165
**
**
**
N2
11
18
36
36
68
68
80
170
170
170
170
**
**
**
AFP
N1
--
39
55
55
84
84
97
186
186
186
186
**
**
**
N2
--
40
58
58
89
89
100
190
190
190
190
**
**
**
*without hand chain, **on request
Capacity
Load bar size
for beam flange
width
from - to
Output
1N
mm
2N
mm
AFP
kW
1t
50-179
180-310
0,75
2t
66-185
186-310
0,75
2,5t
66-185
186-310
0,75
3,2t
74-196
197-310
0,75
4t
74-196
197-310
0,75
5t
74-192
193-310
0,75
6,3t
119-215
216-312
0,75
7,5t
119-215
216-312
0,75
10t
119-215
216-312
0,75
12t
119-215
216-312
0,75
15t
160-310
---
2x 0,75
20t
160-310
---
2x 0,75
25t
160-310
---
2x 0,75

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11
5 Installation
DANGER!
Assembly, disassembly and maintenance operations must only be carried out in an atmosphere not
prone to explosion!
The assembly and installation depends on the local environment. The hoist must be suspended in a way that
it can position itself freely.
5.1 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.
5.2 Adjusting the gauge
The trolley can be adjusted to various beam flange widths. Adjustment to the relevant beam flange width “B”
depends on the type and size and is to be made as follows:
There are distance tubes (5) and/or washers
(6) situated on the load bars (2) of the trolley.
Dimension "X" is set by placing washers (6)
from the outer to the inner side ("X" increases)
or from the inner to the outer side ("X"
decreases).
Washers (6) and rubber discs (depended on
type) leave a distance for the load hook. It is
important that the load hangs in the middle
under the beam so that the two side plates are
equally loaded.
The suspension eye (9) (if existent) for bigger
load bolts must still be swivelling after it has
been secured.
Tighten the hexagon nut (3) and safety nuts (4)
again.
Check correct flange width "B" and dimension
"X". Adjustment must be repeated if necessary.
1 side plates
2 load bars
3 hexagon nut
4 safety nuts
5 distance tubes
6 washers
7 ---
8 rubber disc (depended on type)
9 suspension eye
5.3 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 2

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5.52.692.01.01.06
5.3.1 Bolt securing with collar
Securing the load bolts with set collars (1) and safety
screws (3).
In order to adjust the beam flange width dismantle
the safety screws (3) at one trolley side.
After adjustment of dimension "X" and installation on
the beam, install the safety screws (3) again and
secure them with a nut (4).
When pulling apart the side plates, the trolley drive
shaft will also be moved.
To do this, loosen the safety screws at the stern tube
bearing and secure them again after the side plates
have been pushed together.
Illustration 3
1 set collar
2 load bar
3 safety screw
4 hexagon nut
5 washer
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
5.4 Tools
6 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.
Control buttons
Control symbols shown are for optical information only and can vary depending on the control module.
Emergency stop
Illustration 4
Capacity
Size
Tool
Use
0,5t
1t
to 2t
to 3,2t
to 6,3t
to 10t
SW27
SW36
SW46
SW55
SW60
SW75
Load bar
12,5t
to 60t
SW22
SW24
Load bar
with
fixing ring
diff.

5.52.692.01.01.06
13
Arrow keys = drive left / right
Illustration 5
System start (optional)
Illustration 6
Push button functions (E)
Relieved push button = stand still
push button half pushed = slow speed
push button pushed completely = fast speed
Illustration 7
Push button functions (P)
Relieved push button = stand still
push button pushed = respective movement
Illustration 8
Red Emergency-Stop button
button pushed = stand still
turn the button clockwise = free functions
Illustration 9
NOTICE!
Lockable Emergency-Stop buttons must first be opened with the key before unlocking!
7 Operation
The following, important points must be observed when operating the equipment:

Read the safety instructions.

Never load the devices beyond their working load limit.

The prescribed maintenance intervals must be adhered to.
DANGER!
In particular, use is not permitted:
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
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.

14
5.52.692.01.01.06
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).
8.2 Compressed air connection
Before commencing work on the equipment, the main air supply line must be closed and secured against
inadvertent opening!
8.2.1 Main connection
The connections must be made according to the pneumatic connection diagram.
Connect to the existent hose nozzle.
The hose must be secured with a hose clamp.
Nominal width of the air connection hose
0,52-0,75 kW - NW 13 mm
1,5 kW - NW 19 mm
2,5 kW - NW 25 mm
If hose length exceeds 15 m, a larger cross section must be selected.
8.2.2 Control hose connection
Control switches with hoses are connected at the factory, unless otherwise agreed.
8.2.3 Maintenance unit
It is important that an automatic maintenance unit, consisting of oiler, filter ,water separator and air pressure
reducer is installed in the main air supply - if not assembled by the manufacturer this must be assembled by
the customer.
It serves for the necessary preparation of the operation air so that the pneumatic motor can work trouble-
free. Installation must be as close as possible to the motor; - in no cases should the distance to the motor
exceed 10 m.
Should higher pressure occur in the supply net, it will be reduced to the operating pressure of 6 bar by the
pressure reducing valve. The oiler enriches the air with oil. Setting of oil addition: approx. 2 drops of oil must
be added per minute.
NOTICE!
HADEF does not assume any responsibility for damage caused by non-observance of the instructions.
CAUTION!
Should the unit be assembled at the customer, the maintenance unit is supplied without oil.
Before putting the unit into operation, the main air supply line must be cleaned and the oiler of the
maintenance unit must be filled with oil. Should this not be done the unit may be severely damaged.

5.52.692.01.01.06
15
CAUTION!
The maintenance units are not approved for use with synthetic oil.
They must not be connected to compressed air systems which are supplied by compressors with synthetic
lubricants.
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.

The oil levels in the gear boxes are sufficient.

All movements of the load comply with the symbols on the control switch.
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
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
Have the equipment checked by an expert
(periodic inspection)
X
*as far as applicable
remove dust (do not use compressed air to do so)
X
Check device for corrosion
X
X
check lubrication/ grease - bearings
X
X
check lubrication/ grease - driving pinion
X
X
name plates - check for existence and legibility
X

16
5.52.692.01.01.06
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
DANGER!
Assembly, disassembly and maintenance operations must only be carried out in an atmosphere not
prone to explosion!
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.

5.52.692.01.01.06
17
15 Remedy
Problem*
Unit
Cause
Remedy
Unit cannot be switched on
Electric trolley
No main power
Check connection to mains supply
Phase sequence not correct (with low voltage control)
Exchange 2 phases
(see wiring note at the plug)
Motor runs in opposite direction
Electric trolley
Phase sequence / rotating field wrong
(with three-phase direct control)
Exchange 2 phases
(see wiring note at the plug)
Motor does not run
Electric trolley
Fuse burnt out
Replace the fuse
Defective switching unit in the control button switch
Replace the switching unit
Interruption in the control cable
Check control cable and replace if necessary.
Defect of capacitor (only for one-phase alternating
current)
Replace the capacitor
Overheat protection has tripped*
Allow engine to cool
Defective coil - mechanic or electric overload
Motor must be repaired by a specialist
If the unit is suitable for explosive atmospheres, the
motor must be returned to the manufacturer for repair!*
Pneumatic
trolley
Operation pressure / quantity of air is too low
Check connection to mains supply
After prolonged standstill
See maintenance - pneumatic motor
Motor runs –trolley does not move
Motor driven
trolley
No or incorrect power transmission
Check driving pinion and repair if necessary,
check condition of trolley wheels / contact to main
beam surface and repair / adjust if necessary
If the unit is suitable for explosive atmospheres, please
clarify with the manufacturer what to do!*
Motor hums and uses excessive current
Electric trolley
Defective coil
Motor must be repaired by a specialist
If the unit is suitable for explosive atmospheres, the
motor must be returned to the manufacturer for repair!*
Rotor is rubbing
(Optional) brake does not release
See problem “(Optional) brake does not release”
Defect of capacitor
(only for one-phase alternating current)
Replace the capacitor
Defect of starter relay
(only for one-phase alternating current)
Replace the starter relay
Phase failure (only three-phase direct control)
Find the cause and repair
Motor does not brake or has excessive afterrunning.
Electric trolley
Switching error after intervention in the electric circuit
Check the electric connection of the brake acc. to
the wiring diagram
Motor driven
trolley
Brake linings are worn or dirty.
Brake lining carrier must be changed completely
If the unit is suitable for explosive atmospheres, the
motor must be returned to the manufacturer for repair!*
Air gap is too large
Re-adjust the air gap
If the unit is suitable for explosive atmospheres, the
motor must be returned to the manufacturer for repair!*
(Optional) brake does not release
Electric trolley
Brake rectifier defective
Replace the brake rectifier
If the unit is suitable for explosive atmospheres, the
motor must be returned to the manufacturer for repair!*
Brake current relay defective
Replace the brake current relay
If the unit is suitable for explosive atmospheres, the
motor must be returned to the manufacturer for repair!*
Brake coil is defective
Replace the brake coil
If the unit is suitable for explosive atmospheres, the
motor must be returned to the manufacturer for repair!*
Permissibe air gap is exceeded due to worn out brake
lining
Re-adjust the air gap and exchange the brake lining
if necessary
If the unit is suitable for explosive atmospheres, the
motor must be returned to the manufacturer for repair!*
Power drop in the mains power line > 10%
Provide correct power supply voltage
Pneumatic
trolley
Operation pressure / quantity of air is too low
Check connection to mains supply
Fuses burnt out or motor contactor is triggered
Electric trolley
Short circuit in component
Eliminate the short circuit
Motor has a short circuit in the body or windings
Correct the problem by a specialist
If the unit is suitable for explosive atmospheres, the
motor must be returned to the manufacturer for repair!*
Motor is switched incorrectly
Correct the switching
Wrong type of fuse
Replace the fuse with correct one
Trolley runs very slowly or not at all
All trolleys
Driving pinion dirty or blocked.
Clean the driving pinion and lubricate it, if necessary,
exchange worn parts
Hand geared
trolley
Hand chain is twisted or blocked
Place the hand chain correctly
*) as far as applicable
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”.

18
5.52.692.01.01.06
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.
17 Additional documents
17.1 Pneumatic connections diagram
The pneumatic connections diagram is attached to the consignment.