HADEF Gentry Crane 800 Assembly instructions

5.52.800.00.01.00 Rev.00
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HADEF Gentry Crane
Type 800
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Installation,- Operating and
Maintenance Instructions

Information
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NOTICE!
The installation or mounting instructions for incomplete machines you’ll find in chapter “Installation”
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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.
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Table of Contents
1Information..........................................................................................4
2Safety...................................................................................................5
2.1Warning notice and symbols............................................................................................5
2.2Duty of care of the owner..................................................................................................5
2.3Requirements for the operating personnel.....................................................................6
2.4Appropriate use.................................................................................................................6
2.5Basic safety measures......................................................................................................7
3Transport and Storage.......................................................................8
3.1Transport............................................................................................................................8
3.2Safety device for transport...............................................................................................8
3.3Storage ...............................................................................................................................8
4Description..........................................................................................9
4.1Areas of application ..........................................................................................................9
4.2Design.................................................................................................................................9
4.3Functions............................................................................................................................9
4.4Important components......................................................................................................9
5Technical data...................................................................................10
6Installation.........................................................................................13
6.1General .............................................................................................................................13
6.1Dangers during assembly...............................................................................................13
6.2Montage – Zusammenbau...............................................................................................13
6.3Table of screws................................................................................................................13
6.4Disassembly.....................................................................................................................14
6.5Tools.................................................................................................................................14
7Operation...........................................................................................15
8Commissioning.................................................................................16
8.1General .............................................................................................................................16
9Safety check......................................................................................17
10Functional test..................................................................................18
10.1Checks before initial start-up.........................................................................................18
10.2Functional test.................................................................................................................18

Information
5.52.800.00.01.00 3
11Maintenance...................................................................................... 19
11.1General.............................................................................................................................19
11.2Monitoring........................................................................................................................19
12Inspection ......................................................................................... 20
12.1Periodic checks...............................................................................................................20
12.2Inspection intervals.........................................................................................................20
13Service............................................................................................... 21
14Trouble .............................................................................................. 22
15Remedy ............................................................................................. 23
16Decommissioning ............................................................................ 24
16.1Temporary decommissioning ........................................................................................ 24
16.2Final decommissioning/disposal...................................................................................24
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Information
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1 Information
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The products meet European Union requirements, in particular the EU Machine Directive (2006/42/EG).
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 accident prevention regulations BGV D8, BGV D6 and BGR 500 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.
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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.
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Safety
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2 Safety
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2.1 Warning notice and symbols
Warnings and notice are shown as follows in these instructions:
DANGER! This means that there is a high risk that leads, if it is not avoided, to death or severe injury.
WARNING! This means that there is a risk that could lead, if it is not avoided, to death or severe injury.
CAUTION! This means that there is little
risk that could lead, if it is not avoided, to slight injury or damage to the device or its
surrounding.
NOTICE! Gives advice for use and other useful information.
Danger from electricity.
Danger from explosive area.
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2.2 Duty of care of the owner
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 < 106Ωagainst earth.
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WARNING!
It is not allowed to make constructive changes of the equipment!
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Safety
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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 authorisation 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 jewellery.
Do not wear cloths that are too big/wide.
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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, carried out by a licensed qualified person in accordance with the accident prevention regulations
UVV BGV D6 before initial operation.
The permitted environmental temperature during equipment operation is –20°C up to +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!
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Moving of loads on plain and stable ground. In combination with hoists also vertical lifting and lowering of
unguided loads.
In case of wind velocity of more than 40 km/h the crane must be fixed to the ground or dismantled.
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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.
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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
to transport people
persons must not stand under a suspended load
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Safety
5.52.800.00.01.00 7
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 BGR500 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.
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Observe separate installation-, operation and maintenance instruction of hoists.
Please consider oscillation of the load and stopping distance.
Make sure that the device stands stable.
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Transport and Storage
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3 Transport and Storage
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CAUTION!
Transport may only be done by qualified personnel. No liability for any damage resulting from improper
transport or improper storage.
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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.
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Description
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4 Description
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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 + 40°C. Humidity: 100 % or less but not under water
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DANGER!
It is not permitted to use the unit in an area at risk from explosion!
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4.2 Design
Movable gantry crane with single beam
Illustration 1
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4.3 Functions
The standard gantry crane is equipped with two static wheels and two rotatable wheels.
For better transport, the gantry crane is supplied demounted.
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4.4 Important components
4.4.1 Beam
Single beam made of profiled steel.
4.4.2 Beam support
Welded steel.
4.4.3 Wheels
Wheels of polyamide for cranes up to 3,2 t capacity.
Wheels with polyurethane lining from 5 t capacity up.
4.4.4 Wheel brake (as option)
To lock the wheels.
4.4.5 Power supply (as option)
For gantry cranes with electric chain hoist, including lockable main switch.
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Technical data
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5 Technical data
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optionally
Illustration 2
Capacity dimensions in mm weight
kg span S up to track height H1 H L L1 E d I kg
500
2500
3000
318026402040150015091257
3000318031402540150015091266
3500318036403040150015091276
4000318041403540150015091285
4500318046404040150015091295
5000318051404540150015091304
2500
3500
368026402040150015091269
3000368031402540150015091278
3500368036403040150015091288
4000368041403540150015091297
4500368046404040150015091307
5000368051404540150015091316
2500
4000
418026402040200015091307
3000418031402540200015091316
3500418036403040200015091325
4000418041403540200015091335
4500418046404040200015091344
5000418051404540200015091354
2500
4500
468026601860200015091416
3000468031602360200015091426
3500468036602860200015091435
4000468041603360200015091444
4500468046603860200015091454
5000468051604360200015091463
2500
5000
518026601860240015091462
3000518031602360240015091472
3500518036602860240015091481
4000518041603360240015091490
4500518046603860240015091500
5000518051604360240015091509
1000
2500
3000
3200264020401500200100285
30003200314025401500200100296
35003200364030401500200100307
40003200414035401500200100319
45003220464040401500200110348
50003220514045401500200110361
2500
3500
3700264020401500200100297
30003700314025401500200100308
35003700364030401500200100320
40003700414035401500200100331
45003720464040401500200110360
50003720514045401500200110373
2500
4000
4200264018402000200100426
30004200314023402000200100437
35004200364028402000200100448
40004200414033402000200100459
45004220464038402000200110488
50004220514043402000200110501
2500
4500
4700266018602000200100444
30004700316023602000200100455
35004700366028602000200100466
40004700416033602000200100477
45004720466038602000200110506
50004720516043602000200110519
2500
5000
5200266018602400200100490
30005200316023602400200100501
35005200366028602400200100512
40005200416033602400200100523
45005220466038602400200110552
50005220516043602400200110565