5.52.714.00.1.0 Edition 03.2004 GB Operating and Maintenance Manual for HADEF overhead crane as jointed crane TA Subject to changes. 1 HADEF
Table of Contents 1 General Page 3 2 Product description Page 4 3 Technical data Page 5 4 Important components Page 6 5 General safety indications Page 6 6 Transport and storage Page 8 7 Assembly Page 8 8 Bringing into service Page 9 9 Operation Page 10 10 Help with failures Page 10 11 Maintenance and repair Page 10 12 Putting out of service Page 11 13 Additional documents Page 12 Subject to changes. 2 HADEF
1 General Dear customer, You have chosen a high quality HADEF product. It meets the European Union requirements, especially the EU Machine Directive (98/37/EC). Our whole company works in line with a certified quality assurance system as per EN ISO 9001:2000 To ensure proper operation of the devices it is important that you read this manual in detail and in full before using the crane. This manual helps you to operate the devices whilst observing the applicable regulations. It contains the essential information on set up, start up, operation and maintenance, and therefore ensures safe operation and maintenance of the devices value. The production of individual parts at HADEF is subject to strict, ongoing intermediate checks. For crane operation in the Federal Republic of Germany such provisions as accident prevention regulations VBG9 and DIN 15018 apply. We refer to the compulsory crane tests before initial start up, before restarting operation and the regular repeated checks. In other countries the additional, relevant, national regulations apply. The promised performance of the devices and meeting any warranty claims require adherence to all information in these instructions. Before delivery the HADEF products were packaged properly. We would still request that you check the goods you receive for transport damage when unpacking and notify the transport company of any complaints. We wish you every success with your HADEF product Subject to changes. 3 HADEF
2 Product Description 2.1 Use in accordance with the requirements The intended use of the crane is moving loads horizontally. The cranes are suited to suspending manual or motorised lifting devices. In connection with lifting devices vertical lifting and lowering of non-guided loads is possible. For this the separate operating manual for the lifting device must be obeyed. It is not permitted to exceed the permitted load of the devices! This excludes any load test carried out before initial use by an expert certified to UW (VBG9) It is not permitted to transport people! People may not be located under a suspended load! The environmental temperature when operating the devices is -20 C to +50 C! It is not permitted to use the standard crane in environments that are subject to the risk of explosion! Use in an environment that is at risk from explosion is only permitted if the HADEF device has been delivered in an explosion-proof design (option) and the operator adheres to all the regulations applicable to the individual case. The operator is solely responsible for selecting and operating the devices. If necessary, advice is to be taken from the relevant supervisory organisation, e.g. trade association. A special instruction manual must be observed for cranes in explosion-proof design. The operator may only instruct people to set up, maintain and independently operate the crane that are suited to do so and entrusted with this task! Defective cranes may only be used again when they have been repaired! The operator may not undertake his own changes to the devices! If the crane is not used properly, safe operation can not be guaranteed. The operator and not the manufacturer is responsible for all personal injury and damage to property resulting from improper use. 2.2 Construction The HADEF jointed crane TA is available as standard with bearing loads from 250 kg to 1500 kg. 2.3 Function description Movement by pulling or pushing on the load or load attachments 2.4 Application areas These cranes are suited for use inside buildings. When set up outside a protective roof must be used or the cranes must be covered. Subject to changes. 4 HADEF
3 Technical Data Loading capacity Undercarriage type Span up to Main beam Max crane track flange width Weight without lifting device approx. Main dimensions kg mm mm kg mm H2 A2 A3 A4 B3 B4 B5 B6 C C6 250 TA10 3000 160 180 75 78 150 32 30 43 27 50 11 172 77 4000 160 90 5000 160 105 6000 160 125 7000 180 170 500 TA10 3000 160 180 75 78 150 32 30 43 27 50 11 172 77 4000 160 90 5000 180 130 6000 200 180 7000 220 240 1000 TA10 3000 180 180 110 78 150 32 30 43 27 50 11 172 77 4000 200 130 5000 220 180 6000 240 240 7000 270 320 1250 TA20 3000 220 180 125 78 170 40 30 53 35 70 13 196 11 4000 240 150 5000 240 200 6000 240 270 7000 300 360 1500* TA20 3000 220 180 125 78 170 40 30 53 35 70 13 196 11 4000 240 150 5000 240 200 6000 270 310 7000 300 360 Dimension H1 depends on the relevant type of lifting device. The information in this table refers to standard dimensions. Please refer to the test book for other spans * Not for electrical lifting devices Subject to changes. 5 HADEF
4 Important Components 4.1 Rollers With processed running surfaces and maintenance-free roller storage. The profile running surfaces permit the use of the chassis on all standard carrier profiles with sloped or parallel flanges. 4.2 Casing halves Made of steel sheets with integrated wheel break supports. 4.3 Load bolts There are various load bolt sizes for the various beam flange widths. The flange width is preset by the factory. 5 General Safety Indications 5.1 Due care required by the user The crane was designed and built using a risk analysis and after careful selection of the harmonised standards that are to be adhered to and other technical specifications. It therefore corresponds to the latest state of the art and provides the highest degree of safety. However, this safety can be achieved in the operational practice when all the required measures are taken. The responsibility for due care by the equipment operator requires these measures to be planned and their compliance checked. The user must in particular ensure that: The crane is only used for its intended purpose (for this refer to the Product Description chapter). The crane is only operated in a fault-free, fully functional condition, and the safety equipment, in particular, is monitored regularly to ensure that it is functioning properly. The required personal protection equipment for the operator, service and repair personnel is available and can be used. The operating instructions are always in a readable state and are available in full at the location of the crane. Only qualified and authorized personnel operate, service and repair the crane. This personnel is regularly instructed in all applicable questions regarding work safety and environmental protection, and they are aware of the operating manual and in particular the there safety instructions it contains. All safety and warning indications on the cranes are not removed and remain readable. Constructive modifications to the crane may only be performed after written authorization by the manufacturer! Subject to changes. 6 HADEF
5.2 Explanation of the safety symbols used The following safety symbols are used in these operating instructions. These symbols should above all make the reader aware of the text of the safety indication next to it. This symbol indicates that there is risk to people s life and health as well as to devices and materials. This symbol indicates the risks of a suspended load to the life and health of people This symbol indicates useful additional information, advice and application tips 5.3 Basic Safety Measures The crane is to be used exclusively for the movement of goods. Under no circumstances may people be moved. Please also ensure that persons do not stay unnecessarily beneath the suspended load. We refer to the relevant legal requirements of the accident prevention regulations (UW) and in case of use outside Germany to the corresponding national regulations! Before the crane is assembled and into service ensure that the building walls, ceilings or constructions on which you mount, hang or assemble the crane have sufficient stability to safely carry the weight to be handled with the device including the crane s own weight. In case of doubt, ask a structural engineer! For longer periods of standstill before re-using the device make a visible check of all important components such as rollers, bolts, suspensions etc. Do not perform changes or modifications to HADEF cranes. Extensions may affect the safety and function! Damage and flaws must be immediately reported to a supervisor. Do not use the crane until the damage has been repaired! When the equipment is put in motion, people who are close by must be warned by means of shouting! Never overload the crane beyond the permitted bearing load! Motorised operation is not permitted. Subject to changes. 7 HADEF
5.4 Requirements for the operating staff The crane may only be operated by persons that are adequate for this by means of training and that are familiar with it. They must be charged by the employer with the crane operation. The employer must ensure that the operating instructions are available and accessible to the operator personnel. 6 Transport and Storage 6.1 Transport HADEF cranes are checked before delivery. Do not throw or drop the crane. Please use adequate transport means. Ensure transport and transport means are adequate to the local conditions. Transport work may only be performed by personnel who are qualified for this purpose, whilst observing the safety indications. 6.2 Storage Should you not put the crane directly in operation or should longer operation gaps occur, then please ensure storage at a clean location and protect the crane from dirt, moisture and damages by means of an adequate cover. 7 Assembly It is essential to observe the following points in order to prevent damage or critical injuries when setting up the crane: Crane assembly and installation may only be performed by qualified personnel whilst observing the safety indications. The crane must be inspected for transport damage before the start of the assembly work. 7.1 Installation Instructions The chassis can be set for various beam flange widths. The assembly and installation of the beam depends on the local environment: 7.2 Setting and checking the gauge The chassis can be set for various beam flange widths. The setting is to be made as follows to the relevant beam flange width B. Flange width B and the X setting must be checked in all cases (dimension X ). Settings disks are located on the chassis load bolts and these are used to set dimension X by moving them from out to in ( X bigger) or vice versa ( X smaller). No setting disks may be removed! To set the limits pull the hexagonal and lock nuts (3+4) tight again. Subject to changes. 8 HADEF
7.3 Installation on the beam Pre-install the chassis lateral screens (1) with load bolts (2), setting disks (6), distance tubes (5), hexagonal (3) and lock bolts (4) on width X as per the instructions above. Tighten hexagonal and lock nuts and push the chassis onto the beam flange s front face. If this is not possible the chassis can also be Installed on the track from below. To do so unscrew the hexagonal and lock nuts. The chassis halves must be separated until the chassis can be pushed over the track beam flange. Then push the chassis together again on the right track gauge; Secure the setting disks and distance tubes by tightening the hexagonal and lock nuts. The lateral screens should not be distorted by the hexagonal nuts (3) but rather remain movable on the load bolts (2) The distance X between the rollers wheel flanges must be 2 to 3 mm. 8 Bringing into service 8.1 Bringing into service The devices must be tested by an expert before coming into service and regularly during operation at least once a year! Use in Federal Republic of Germany: Observe the accident prevention regulations in particular the regulations of the BGV D6. Use in other countries: Test as above; observe national regulations. 8.2 Environmental influences The cranes must be as far as possible installed in a covered room. When set up outside a protective roof must be used or the device must be covered. 8.3 Checks before the initial start-up Check screw connections. Move the crane without a load onto the crane track; check whether problem-free movement is possible and that there are no obstacles. Check whether the lifting device inserted is installed properly. Subject to changes. 9 HADEF
9 Control and Operation 9.1 Operation Observe the following points: Only people that are familiar with the operation of the crane may be entrusted with its operation. They must be charged by the employer with the equipment operation. The employer must ensure that the operating instructions are available at the equipment and are accessible to the operating personnel. Move the crane by pressing or pulling the load. 9.2 Operation The following important points must be observed when operating the equipments: Read the warnings and safety indications. The prescribed servicing intervals must be maintained! Do not stay under suspended loads! 10 Help with failures It is essential to observe the following points in order to prevent damage or critical injuries when repairing the equipment: Only undertake repairs if you have also the necessary qualifications. First secure the crane against unintended use by attaching a warning notice that the crane is not operational. Secure the operating area of the movable crane parts. Also read the General safety indications chapter. For the repair of failures please contact our service department. Failures that occur as a result of wear or damage to such components as axles, bearings etc. are resolved by exchanging the affected parts for original spare parts 11 Maintenance and servicing 11.1 General All test results and measures taken must be recorded! All monitoring, servicing and maintenance works are used to correctly operate the crane. The works must be performed carefully. The works must be performed by specialists. As far as possible the work should be carried out without loads. Subject to changes. 10 HADEF
11.2 Monitoring The indicated monitoring and servicing intervals are only for normal operations and one-shift operation. In case of severe usage conditions (e.g. frequent operation with full load) or special environmental conditions (e.g., heat, dust, etc.), then the intervals must be correspondingly shortened. Table: Inspection intervals Check screw connections Check suspension On startup Daily tests Check Maintenance every 3 months X X Servicing every 12 months Check rollers for wear Check buffer position (option) X X X Independently from the regulations of the individual countries, the functional safety of the HADEF devices must be checked at least once a year by an expert. In the FRG the accident prevention regulations must be observed. The tests above and national safety regulations apply in other countries. 11.3 Servicing The crane does not need any special maintenance. 12 Putting out of service It is essential to observe the following points in order to prevent damage to the crane or critical injuries when putting the machine out of service: It is mandatory to perform all work steps for putting the crane out of service in the indicated sequence: First secure the wide working area when putting out of service. Please observe the environmental disposal of the operating products. Read also the General safety indications chapter. The disassembly is performed in reverse order to the assembly. 12.1 Putting out of service temporarily Measures are as above. Also read the Transport and Storage chapter. 12.2 Putting out of service permanently / disposal Measures are as above. Ensure an environmental disposal of the equipment and any materials contained after disassembly. Subject to changes. 11 HADEF
13 Additional documents 13.1 EU Declaration of conformity or manufacturer s declaration Subject to changes. 12 HADEF