Installation, Operating and

Maintenance Instructions

HADEF Monorail Trolley

Type 18/16VA
as push travel trolley R
as hand geared trolley H
Stainless steel design

5.52.122.00.01.02 Rev.02
 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
1  Information .......................................................................................... 3 
2  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 

3  Transport and Storage ....................................................................... 5 

3.1  Transport ............................................................................................................................ 6 
3.2  Safety device for transport ............................................................................................... 6 
3.3  Storage ............................................................................................................................... 6 

4  Description .......................................................................................... 6 
4.1  Areas of application .......................................................................................................... 6 
4.2  Aufbau ................................................................................................................................ 6 
4.3  Functions............................................................................................................................ 6 
4.4  Important components ...................................................................................................... 7 

5  Technical data ..................................................................................... 7 

6  Installation ........................................................................................... 7 
6.1  Trolley ................................................................................................................................. 7 
6.2  Adjusting the gauge .......................................................................................................... 8 
6.3  Installation on the beam.................................................................................................... 8 
6.4  Tools ................................................................................................................................... 9 

7  Operation ............................................................................................. 9 
7.1  General ............................................................................................................................... 9 

8  Safety check ........................................................................................ 9 

9  Functional test .................................................................................... 9 
9.1  Checks before the initial start-up ..................................................................................... 9 
9.2  Functional test ................................................................................................................. 10 

10  Maintenance ...................................................................................... 10 

10.1  General ............................................................................................................................. 10 
10.2  Monitoring ........................................................................................................................ 10 
2 5.52.122.00.01.02
11  Inspection ......................................................................................... 10 
11.1  Periodic checks ............................................................................................................... 10 

12  Service ............................................................................................... 10 

12.1  Lubricant - Selection ....................................................................................................... 10 
12.2  Lubricant for food industry – Selection (as option*).................................................... 10 

13  Trouble .............................................................................................. 11 

14  Decommissioning ............................................................................ 11 
14.1  Temporary decommissioning ........................................................................................ 11 
14.2  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:
This means that there is a high risk that leads, if it is not avoided, to death or severe injury.
DANGER!
This means that there is a risk that could lead, if it is not avoided, to death or severe injury.
WARNING!
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
CAUTION! surrounding.

Gives advice for use and other useful information.

NOTICE!
Danger from electricity.

Danger from explosive area.

5.52.122.00.01.02 3
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:
ƒ The unit is only used appropriately.
ƒ 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.
ƒ The required personal protective equipment for the operators, service and repair personnel is available
and is used.
ƒ The operating instructions are always available at the location where the equipment is used and that they
are legible and complete.
ƒ The unit is only operated, serviced and repaired by qualified and authorized personnel.
ƒ 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.
ƒ Any safety and warning signs on the devices are not removed and remain legible.
ƒ Devices for use in area prone to explosion must (from customer's side) be earthed with a shunting
resistor of < 106 Ω against 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.

DANGER!
In order to avoid severe injury, please pay attention to the following when using the equipment:
ƒ Use protective clothes/equipment.
ƒ Do not wear long hair hanging down open.
ƒ Do not wear rings or other jewelry.
ƒ Do not wear clothes that are too big/wide.
ƒ Do not reach into ropes, chains, drive parts or other moving parts with your hands

4 5.52.122.00.01.02
2.4 Appropriate use
Horizontal movement on beams.
ƒ The permitted safe working load of the devices must not be exceeded! An exception can be made during
the load test before first start-up, carried out by a licensed expert.
ƒ The permitted environmental temperature during equipment operation is –10°C up to +50°C!
ƒ 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 on HADEF
becoming void.
ƒ Liability and warranty will become void if unauthorized modifications of the units are made!

DANGER!
It is not allowed:
ƒ pulling loose of stuck loads, dragging of loads and inclined pulling is not allowed.
ƒ in explosive atmosphere, except the unit is especially modified for it and marked by an indication label
ƒ In reactor containment vessels.
ƒ to transport people
ƒ The device is not suitable for use on stages and in studios
ƒ 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

ƒ Observe installation-, operation and maintenance instruction.
ƒ Take notice of caution notes at units and in the manual
ƒ Observe safety distances.
ƒ Take care for a free view on the load.
ƒ Only use the hoists appropriately.
ƒ The equipment is to be used exclusively for movement of goods. Under no circumstances my persons be
moved.
ƒ Never load the devices beyond their working load limit.
ƒ Pay attention to the accident prevention regulations (UVV).
ƒ Should the hoist be used outside of Germany, please pay attention to the national regulations that apply.
ƒ 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.
ƒ 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!
ƒ Do not use a hoist that is defective, pay attention to any abnormal noise it makes during operation.
ƒ Stop working immediately in case of disturbances and remedy failures.
ƒ Any damage and faults must be reported to a responsible supervisor immediately.
ƒ If the unit is put into motion, any persons in the immediate vicinity must be informed by calling to them!
ƒ Please pay attention to the regulations for load carrying devices UVV for both positive and non-positive
methods of attaching loads.
ƒ The lifting tackle or the load must be securely attached to the hook and be seated at the bottom of the
hook.
ƒ The safety catch of hooks must be closed.
ƒ When charged, the housing may not be in contact somewhere.

3 Transport and Storage

5.52.122.00.01.02 5
 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.
ƒ Do not throw or drop the equipment.
ƒ 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
ƒ Store the equipment at a clean and dry place.
ƒ Protect the equipment against dirt, humidity and damage by an appropriate cover.
ƒ 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 -10°C up to +50°C. Humidity 90 % or less but not under water.

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

4.2 Aufbau

Push travel trolley Type 18/16R-VA

Hand geared trolley Type 18/16H-VA

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.

6 5.52.122.00.01.02
 NOTICE!
The best protection against functional failures in case of extreme environmental impact is the regular use of
the equipment.

4.4 Important components

ƒ Trolley wheels made in stainless steel
Machined trolley wheels with maintenance-free roller bearings. Profiled wheel surfaces for the use on all
standard beams with inclined and parallel flanges.
ƒ Side plates made in stainless steel
with integrated wheel fracture supports.
ƒ Load bolt made in stainless steel
Different bolt lengths are available for different beam flange widths.
ƒ Hand chain made in stainless steel

5 Technical data
Rush Trolley Type 18/16R-VA
Beam flange width
from - to
Capacity
at load bar size

kg 1N 2N 3N 1N 2N 3N
mm mm
500 55-158 159-260 261-310 6,1 6,8 7,1

1000 55-158 159-260 261-310 6,3 7,2 7,7

Hand Geared Tolley Type 18/16H-VA

Beam flange width Manual
from - to
Travel path when reeling
Capacity Curve radius min. hand chain
off 30 m of hand chain
at load bar size
force
kg 1N 2N m ~N m 1N 2N
mm mm
1000 74-125 -- 1,3 5,4 3,30 28 --

2000 100-150 -- 1,5 11,3 3,50 36 --

3000 100-150 -- 1,6 15,2 3,10 46 --

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.

5.52.122.00.01.02 7
6.2 Adjusting the gauge
The trolley can be adjusted to various beam flange widths. Setting to the relevant beam flange width “B” is to
be made as follows:

Push Travel Trolley Type 18/16 R-VA

ƒ Dimension "X" is set by turning the load bar.

ƒ Secure the safety nuts (L)+(R) tight.
ƒ Check correct flange width "B" and dimension
"X". If necessary, repeat the setting.

Hand Geared Trolley Type 18/16 H-VA

ƒ Tighten the hexagon nut and safety nuts.
ƒ Push on the trolley at the face of the beam
flange.
ƒ If this is not possible, the trolley can also be
mounted on the beam from below.
ƒ Therefore, remove the hexagon nut and the
safety nut on the side without gear.
ƒ Pull apart the side plates as far until it is
possible to push the trolley onto the beam
flange from below.
ƒ Push the trolley together again until it reaches
the correct wheel gauge.
ƒ Secure the washers and distance tubes by
tightening the hexagon nuts and the safety
nuts.

6.3 Installation on the beam

ƒ Push on the trolley at the face of the beam flange.
ƒ If this is not possible, the trolley can also be mounted on the beam from below.
ƒ Therefore, remove the safety nut on one side.
ƒ Pull apart the side plates as far until it is possible to push the trolley onto the beam flange from below.
ƒ Assemble the safety nut again and adjust the trolley to the correct track gauge.
ƒ Tighten the safety nuts again (left and right).

CAUTION!
It is important that the load hangs in the middle under the beam so that the two side plates are equally
loaded.

CAUTION!
The distance "X" between the wheel flanges of the trolley wheels must exceed the flange width "B" of the
beam by 2-3 mm (1-1,5 mm each side).

8 5.52.122.00.01.02
6.4 Tools

500kg = SW30
18/16R-VA
1000kg = SW35
1000kg = SW55
18/16H-VA 2000kg = SW55
3000kg = SW65

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.
Monorail push travel trolleys are moved by pushing the load.
Monorail hand geared trolleys are moved by pulling the hand chain.

7.1 General
Should the unit be used in Germany:
Please observe the validated, national accident prevention regulations.
For other countries:
Inspections as above. Please observe the national rules and regulations and the instructions in this manual!

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 Safety check
Before putting into service initially or when putting back into service, it must be checked whether:
ƒ All fastening screws (if existent), socket pins, flap socket and safety devices are tightened and secured.

9 Functional test

9.1 Checks before the initial start-up

Trolley drive
ƒ The open-lying teeth of the trolley drive must be lubricated.
Hand gear for hand geared trolley
ƒ Ensure correct fit of the hand chain; it must not be twisted and must hang freely.

5.52.122.00.01.02 9
9.2 Functional test
Trolleys
Carefully move the trolley to the end positions and check the positions of the end stops.

10 Maintenance

10.1 General
All monitoring, servicing and maintenance operations are to ensure correct functioning of the equipment;
they must be effected with utmost care.
ƒ Only “qualified persons” may do this work.
ƒ Servicing and maintenance work must only be done when the hoist is not loaded.
ƒ Records must be kept of all test results and measures taken.

10.2 Monitoring
The monitoring and servicing intervals stated are valid for operation under normal conditions and single-shift
operation. In case of severe operating conditions (e.g. frequent operation with full load) or special
environmental conditions (e.g., heat, dust, etc.), the intervals must be shortened correspondingly

11 Inspection

11.1 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 daily 1st maintenance Inspection Inspection
commissioning checks after Maintenance Maintenance
3 months every every
3 months 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
X
(periodic inspection)
*as far as applicable

12 Service
Maintenance must be effected by lubricating the driving pinions (for hand geared trolleys) and by checking
the rubber end stops.

12.1 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

12.2 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 --
FM Grease HD2 Mobilgrease FM 222 --
Gear rim;
Drive pinion
* must be mentioned by order

10 5.52.122.00.01.02
13 Trouble
Please pay attention to the following in case of problems:
ƒ Troubles with the equipment must only be repaired by qualified personnel.
ƒ Secure the unit against unintended operation start.
ƒ Put up a warning note indicating that the unit is not to be used.
ƒ Secure the working area of moving parts of the unit.
ƒ 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.

14 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:
ƒ First secure the working area for decommissioning, leaving plenty of space.
ƒ Read the chapter "Safety instructions".
ƒ Disassembly is carried out in reverse order to the assembly.
ƒ Please make sure that all operating material is disposed of in accordance with environmental regulations.

14.1 Temporary decommissioning

ƒ Measures are as above.
ƒ Also read the chapter “Transport and storage”.

14.2 Final decommissioning/disposal

ƒ Measures are as above.
ƒ After disassembly, ensure that the disposal of the equipment and any materials it contains is carried out
in accordance with environmental regulations.

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