HADEF 20/94 AF Series Assembly instructions

5.52.692.00.01.06 Rev.06

HADEF Monorail Trolley

Type 20/94 AF

as monorail push travel trolley AFR

as monorail hand geared trolley AFH

as monorail electric trolley AFE

as monorail pneumatic trolley AFP

Installation, Operating and

Maintenance Instructions

5.52.692.00.01.06

NOTICE!

The installation or mounting instructions for incomplete machines you’ll find in chapter “Installation”







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

Information......................................................................................... 3

Safety ................................................................................................. 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

Transport and Storage ...................................................................... 6

3.1 Transport..........................................................................................................................6

3.2 Safety device for transport..............................................................................................6

3.3 Storage .............................................................................................................................6

Description......................................................................................... 6

4.1 Areas of application.........................................................................................................6

4.2 Design ..............................................................................................................................7

4.3 Functions .........................................................................................................................7

4.4 Important components ....................................................................................................7

Technical data ................................................................................... 8

Installation ......................................................................................... 8

6.1 Trolley...............................................................................................................................8

6.2 Adjusting the gauge ........................................................................................................8

6.3 Installation on the beam..................................................................................................9

6.4 Tools...............................................................................................................................10

Operation ......................................................................................... 10

Operation ......................................................................................... 11

Commissioning ............................................................................... 11

9.1 General ...........................................................................................................................11

9.2 Power supply .................................................................................................................12

Safety check .................................................................................... 12

Functional test................................................................................. 12

11.1 Checks before the initial start-up .................................................................................12

11.2 Functional test ...............................................................................................................12

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Maintenance .................................................................................... 13

12.1 General ...........................................................................................................................13

12.2 Monitoring......................................................................................................................13

12.3 Brake motor ...................................................................................................................13

Inspection ........................................................................................ 14

13.1 Periodic checks .............................................................................................................14

Service ............................................................................................. 14

14.1 Electric motor ................................................................................................................14

14.2 Pneumatic motor ...........................................................................................................14

Trouble............................................................................................. 15

Remedy ............................................................................................ 15

Decommissioning ........................................................................... 16

17.1 Temporary decommissioning.......................................................................................16

17.2 Final decommissioning/disposal..................................................................................16

Additional documents..................................................................... 16

18.1 Electric wiring diagrams ...............................................................................................16

18.2 Radio control (as option) ..............................................................................................16

18.3 Pneumatic connections diagram..................................................................................16

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.

5.52.692.00.01.06

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.

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 < 10

Ωagainst earth.

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.

5.52.692.00.01.06

DANGER!

In order to avoid severe injury, please pay attention to the following when using the equipment:

Use protective clothes/equipment.

Do not wear long hair hanging down open.

Do not wear rings or other jewelry.

Do not wear clothes that are too big/wide.

Do not reach into ropes, chains, drive parts or other moving parts with your hands

2.4 Appropriate use

The permitted safe working load of the devices must not be exceeded! An exception can be made during the

load test before initial operation, carried out by a licensed qualified person.

The permissible ambient temperature during operation of manual driven devices is -20 °C / + 50 °C and

at all power driven devices -20 °C / + 40 °C!

Defective devices and load suspension devices must not be used until they have been repaired! Only

original spare parts must be used. Non-compliance will result in any warranty claims becoming void.

Liability and warranty will become void if unauthorized modifications of the units are made by the user!

Moving horizontally on beams.

DANGER!

It is not allowed:

pulling loose of stuck loads, dragging of loads and inclined pulling is not allowed.

in explosive atmosphere, except the unit is especially modified for it and marked by an indication label

In reactor containment vessels.

to transport people

The device is not suitable for use on stages and in studios

persons must not stand under a suspended load

NOTICE!

If the units are not used appropriately, it is not possible to ensure safe operation.

The owner and operator have sole liability for all personal injury and damage to property arising from

inappropriate use.

2.5 Basic safety measures

Observe installation-, operation and maintenance instruction.

Take notice of caution notes at units and in the manual

Observe safety distances.

Take care for a free view on the load.

Only use the hoists appropriately.

The equipment is to be used exclusively for movement of goods. Under no circumstances my persons be

moved.

Never load the devices beyond their working load limit.

Pay attention to the accident prevention regulations (UVV).

Should the hoist be used outside of Germany, please pay attention to the national regulations that apply.

Supporting structures and load-attached devices used in conjunction with this equipment must provide an

adequate safety factor to handle the rated load plus the weight of the equipment. In case of doubt, consult

a structural engineer.

If the equipment has not been used for a period of time, carry out visual checks of all main components

such as chains, load hooks etc. and replace any damaged parts with new, original spare parts before

putting the equipment back into operation!

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Do not use a hoist that is defective, pay attention to any abnormal noise it makes during operation.

Stop working immediately in case of disturbances and remedy failures.

Any damage and faults must be reported to a responsible supervisor immediately.

If the unit is put into motion, any persons in the immediate vicinity must be informed by calling to them!

Please pay attention to the regulations for load carrying devices UVV for both positive and non-positive

methods of attaching loads.

The lifting tackle or the load must be securely attached to the hook and be seated at the bottom of the

hook.

The safety catch of hooks must be closed.

When charged, the housing may not be in contact somewhere.

3 Transport and Storage

CAUTION!

Transport may only be done by qualified personnel. No liability for any damage resulting from improper

transport or improper storage.

3.1 Transport

The devices are checked and if so adequately packed before delivery.

Do not throw or drop the equipment.

Use adequate means of transport.

Transport and means of transport must be suitable for the local conditions.

3.2 Safety device for transport

NOTICE!

Should a safety device for transport exist, please remove it before commissioning.

3.3 Storage

Store the equipment at a clean and dry place.

Protect the equipment against dirt, humidity and damage by an appropriate cover.

Protect hooks, wire ropes, chains and brakes against corrosion.

4 Description

4.1 Areas of application

The devices must be as far as possible installed in a covered room.

If they are used in the open, protect the units against the effects of weather such as rain, hail, snow, direct

sunshine, dust, etc. - we recommend to use a cover in parking position. If the device is set up in a

continuously humid environment with strong temperature fluctuations, the correct functionings are

endangered by the forming of condensation.

Ambient temperature -20°C up to +50°C. Power-operated units -20 up to +40°C. Humidity 100 % or less but

not under water

During longer periods of standstill, corrosion may reduce the function of the brake.

DANGER!

It is not permitted to use the unit in an area at risk from explosion!

5.52.692.00.01.06

4.2 Design

HADEF trolleys with 2 load bolts.

Type 20/94 AFR, with push travel trolley

Type 20/94 AFH, with hand geared trolley

Type 20/94 AFE, with electric trolley

Type 20/94 AFP, with pneumatic trolley

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.

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 roller 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

Hoist with 2 load bolts. Different bolt lengths are available for different beam flange widths.

Motors

▫Type AFE - Standard 3-phase current motor 400V/50Hz – IP55 – F – max. above sea level.

▫Type AFP - pneumatic motor, 6 bar

Control

▫Type AFE - control by pendant control switch for direct control or low voltage control

▫Type AFP - control by precision direct control or indirect control

5.52.692.00.01.06

5 Technical data

Travel speed:

electric trolley 16/4 m/min

pneumatic trolley 8 m/min

Operating pressure:

pneumatic trolley 6 bar

air comsumption per motor 1,2m³/min

500kg

3, t

6,3t

7,5t

10t

15t

AFR

159

164

AFH*

165

170

AFE

174

178

AFP

186

100

190

*without hand chain, **on request

3-phase current motor 400V/50Hz - IP55 – F – max. 1000 m above sea level.

Order-related Special data, refer to the motor nameplate.

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

load bar size

for beam flange width

from - to

output

current

1 N

AFE

AFP

AFE

500kg 50-146 147-30 -- -- --

1t 50-179 180-310 0,06/0, 5 0,75 0,45/0,8

t 66-185 186-310 0,06/0, 5 0,75 0,45/0,8

3, t 74-196 197-310 0,06/0, 5 0,75 0,45/0,8

4t 74-196 197-310 0,06/0, 5 0,75 0,45/0,8

5t 74-19 193-310 0,1/0,4 0,75 0,8/1, 5

6,3t 119- 15 16-31 0,1/0,4 0,75 0,8/1, 5

7,5t 119- 15 16-31 0,1/0,4 0,75 0,8/1, 5

10t 119- 15 16-31 0,1/0,4 0,75 0,8/1, 5

1 t 119- 15 16-31 0,1/0,4 0,75 0,8/1, 5

15t 160-310 --- x 0,18/0,55 x 0,75 x 1,3/1,5

0t 160-310 --- x 0,18/0,75 x 0,75 x 1,3/1,5

5t 160-310 --- x 0, 5/1 x 0,75 x 1,4/ ,7

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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

6.3.1 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 2

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

5.52.692.00.01.06

6.4 Tools

7 Operation

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.

The shown control switches are only for the optical information. They can be different acc. the delivery.

Monorail push travel trolleys are moved by pushing the load.

Monorail hand geared trolleys are moved by pulling the hand chain.

Pendant control lifting/lowering

direct control

1 Emergency-Stop

2 Lifting (slow - fast)

3 Lowering (slow - fast)

Illustration 3

Pendant control – lifting/lowering

1 Emergency stop

2 Lifting (slow - fast)

3 Lowering (slow - fast)

Illustration 4

Capacity

Size

Tool

Use

0,5t

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.

This manual suits for next models

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