HADEF 53/07 Installation, Operating And Maintenance Instructions

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Page 1

5.52.187.00.01.02 Rev.02

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HADEF Ratchet Lever Hoist

Type 53/07

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Installation,- Operating and Maintenance Instructions

Page 2

Information

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Internet download: www.doc.hadef.de/b5307_gb.pdf

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NOTE!

The installation or mounting instructions for incomplete

machines you’ll find in chapter “Installation”

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Heinrich de Fries GmbH, Gauss Str. 20, D-40235 Düsseldorf

Heinrich de Fries GmbH wird im Weiteren als HADEF bezeichnet.

Heinrich De Fries GmbH will be named HADEF in the following text.

Originalbetriebsanleitung in deutscher Sprache.

Translation of the original operating and maintenance instructions

Eine Kopie kann bei HADEF schriftlich angefordert werden.

A copy is available from HADEF on request.

Änderungen vorbehalten. 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......................................................................................................6

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....................................................................................................10

5 Technical data...................................................................................11

5.1 Main dimensions..............................................................................................................11

6 Installation.........................................................................................12

7 Operation...........................................................................................13

7.1 Devices from 250 kg up to 1500 kg capacity (Type A).................................................13

7.2 Devices from 800 kg up to 9000 kg................................................................................14

7.3 Brake and pawl................................................................................................................15

7.4 Transmission of loads.....................................................................................................15

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Information

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8 Commissioning ................................................................................ 16

8.1 General.............................................................................................................................16

8.2 Load chain ....................................................................................................................... 16

9 Safety check .....................................................................................17

10 Maintenance...................................................................................... 18

10.1 General.............................................................................................................................18

10.2 Monitoring........................................................................................................................18

10.3 Replacing the load chain................................................................................................18

11 Inspection ......................................................................................... 19

11.1 Periodic checks...............................................................................................................19

11.2 Checking the load chain.................................................................................................19

11.3 Checking the load hook.................................................................................................. 20

11.4 Checking - pawl...............................................................................................................20

11.5 Checking – ratchet wheel and brake lining................................................................... 21

11.6 Checking – Suspension and load hook bolt................................................................. 21

12 Service............................................................................................... 22

12.1 Load chain .......................................................................................................................22

12.2 Pulleys..............................................................................................................................22

12.3 Load hook ........................................................................................................................ 23

12.4 Gear .................................................................................................................................. 23

12.5 Gear spring pressure brake ........................................................................................... 23

12.6 Lubricant selection ......................................................................................................... 23

13 Trouble .............................................................................................. 24

14 Remedy ............................................................................................. 25

15 Decommissioning ............................................................................ 26

15.1 Temporary decommissioning ........................................................................................ 26

15.2 Final decommissioning/disposal................................................................................... 26

16 Documents available on request .................................................... 27

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Information

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1 Information

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HADEF 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 HADEF is subject to strict, intermediate checks. After assembly, each HADEF 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 HADEF 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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NOTE!

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 < 106 Ω against earth.

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WARNING!

It is not allowed to make constructive changes of the equipment!

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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

Appropriate use of the lever hoist is vertical lifting, lowering, pulling and tightening of loads. Acc. to BGV D6 III§25(4) a ratchet lever hoist is a "unit ready for operation" and obtains the declaration of

conformity EU.

 The permitted safe working load of the devices must not be exceeded!  It must be assured that the hoist can position itself in true alignment to the load.

 The permitted environmental temperature during equipment operation is –20°C up to +40°C!  The units are not suitable for continuous operation!  Defective devices and load suspension devices must not be used until they have been repaired!

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

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

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DANGER!

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

 Pulling loose of stuck loads, dragging of loads and inclined pulling is not allowed.  The use in area at risk from explosion.  To transport people with the equipment.  Persons must not stand under a suspended load.  Motor drive of the equipment.  Blocking of the loose chain end.  Charging the loose chain end.  Dragging of loads with motor-driven hoists.

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2.5 Basic safety measures

NOTE!

When the hoists are used for lashing (i.e. to fasten loads on a lorry) we recommend to use hoists with slipping clutch in order to avoid overloading.

 Only use the hoists appropriately.  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.

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Safety

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 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!

 Check brakes daily before commencing work!

 The load chain must not be twisted.  Twisted chains must be aligned before attaching the load.  The correct alignment of the chain links can be seen from the weld seams.  The chain links must always be aligned in one direction.

 Please pay attention to the regulations for load carrying devices UVV BGR500 for both positive and non-

positive methods of attaching loads.

 Do not use a hoist that is defective, pay attention to any abnormal noise it makes during operation.  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!  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 the hook must be closed.  Stop lowering the load when the bottom block or the load is being set down or is prevented from being

lowered further.

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

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WARNING!

The following is not allowed:

 to lift another load than the nominal safe working load  to manipulate the sliding clutch  The use of elongated or damaged chains. Replace worn out chains immediately by new,

original chains.

 Never loop the load chain around a load nor place or pull the chain over edges.  Never repair damaged load hooks (e.g. by hammering). They must be replaced by original

hooks.

 Do not operate the hoist by stepping on the lever with a foot.  Never use an elongation piece for the lever.  It is prohibited to charge the load hook at its point.  It is prohibited to weld or cut when a load is suspended.  It is prohibited to swing the load.  It is prohibited to use the load chain for earthing during welding.  Do not use the hoist when it makes abnormal noise.  Do not use the lever without rubber handle.  Do not leave a lifted load unintended for a longer period of time.

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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

HADEF 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

NOTE!

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 functioning of the motor and the brake 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

HADEF ratchet lever hoists are compact hoists with suspension hook for stationary use.

Illustration 1

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4.3 Functions

The load is lifted, lowered or tensioned by operating the lever. The load pressure brake prevents automatic lowering of the load.

NOTICE!

If used "over head" or "lashing" undefined forces may appear. We recommend to use a hoist with slipping clutch for these cases.

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NOTE!

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

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Description

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4.4 Important components

4.4.1 Gear

Gear components are made of high-quality material.

4.4.2 Load pressu re brake

Holds the load in any position. A new brake system is used for the hoists (except

for the Aluminium Ratchet Lever Hoists). Brake discs have sintered brake linings which makes them wear-free for lifetime of the hoists and appropriate use.

According to DIN 13157 lifetime is 1500 operating cycles (lifting/lowering movements) with 300 mm lift with nominal load.

Illustration 2

4.4.3 Housing

Depending on the model made from steel plate or aluminium.

4.4.4 Load chain

According to EN 818-7-T high quality chain. All components match precisely to each other. Therefore please only use original chains.

4.4.5 Load hook

Forged steel. Rotating, this facilitates attaching the load and avoids twisting of the chain. With safety catch.

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4.4.6 Free-wheeling of chain

For pulling through of the uncharged chain.

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Technical data

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5 Technical data

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Capacity kg 250 500 750 1500 800 1000 1600 2500 3200 6300 9000

Type A A A A - - - - - - -

Number of chain falls 1 1 1 1 1 1 1 1 1 2 3

Load chain dimensions mm 3x9 4,2x12,2 5x15 7,1x21 5,6x15,8 5,6x15,8 7,1x20,1 9,0x24,8 10x28,1 10x28,1 10x28,1 low headroom dimension mm 200 250 260 330 280 300 335 375 395 540 680 lever force approx. N 200 240 290 320 290 360 340 370 370 380 390 weight* approx. kg 1,5 2,5 3,4 5,9 5,7 5,9 8,0 11,2 15,0 26,0 40,0 weight per add. m lift approx. kg 0,2 0,4 0,6 0,8 0,7 0,7 1,1 1,7 2,3 4,7 7,0

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5.1 Main dimensions

Capacity in kg

Dimensions

250 500 750 1500 800 1000 1600 2500 3200 6300 9000

Typ A A A A - - - - - - -

A 68 81 92 109 119 119 126 150 159 217 304 B 87 100,5 105 122 144 144 159 173 190 190 190 C 32 34,5 35,5 42,5 35,5 42,5 42,5 47 50 60 85 D 140 180 180 220 245 245 265 265 415 415 415 E 55,5 62,5 64 68,5 97 97 100 102 112 112 112 F 11 12 14 21,5 14 15 19 21 24,5 34 41,5 G 21 24,5 28,5 35 26,5 29 32 36,5 39 50 72,5 H 200 250 260 330 280 300 335 375 395 540 680

Illustration 3

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6 Installation

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Please observe the following points in order to avoid any damage to equipment or injury of person:

 Please read chapter "Safety".  Before loading the hoist make sure the hooks are placed safely. The safety catch of the hook must be

closed.

 Make sure that the fastening position cannot be changed either by the load nor by other influences.

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Operation

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7 Operation

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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.

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7.1 Devices from 250 kg up to 1500 kg capacity (Type A)

Before start up please make sure the free-wheeling mechanism is deactivated. Forcible pulling may possibly close the brake and stop the chain. Should this be the case place the switching

pin in position "DN", do some lowering operation movements and begin lifting again.

Lifting or pulling

Turn the switching pin in position "UP" for lifting or pulling and move the load by operating the hand lever.

Lowering or relieving

Turn the switching pin in position "DN", lowering or relieving and move the load by operating the hand lever.

A Chain pin

B Switching pin C Lever

Illustration 4

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7.1.1 Free-wheeling of chain

When the hoist is used appropriately, unintended activation of the free-wheeling mechanism under load is impossible.

DANGER!

Never try to activate the free-wheeling mechanism by force or if the hoist is under charge.

Switching ON the free-wheeling mechanism

 switch in middle position

Illustration 5

 Turn the free-wheeling mechanism anti-

clockwise, if necessary pull the loose fall of the chain jerkily.

 The chain can be pulled through in both

directions.

Illustration 6

Switching OFF the free-wheeling mechanism

 Turn the free-wheeling mechanism clockwise,

if necessary pull the chain fall jerkily.

 Free-wheeling mechanism is switched OFF.  The chain cannot be pulled through any longer

and working operation can be proceeded.

Illustration 7

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Operation

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7.2 Devices from 800 kg up to 9000 kg

Before start up please make sure the free-wheeling mechanism is deactivated. Forcible pulling may possibly close the brake and stop the chain. Should this be the case place the switching

pin in position "▼", do some lowering operation movements and begin lifting again.

Lifting or pulling

Turn the switching pin in position lifting (1) or pulling (2) as marked on the type plate and move the load by operating the hand lever.

Lowering or relieving

Turn the switching pin in position lowering or relieving (2) and move the load by operating the hand lever.

Illustration 8

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7.2.1 Free-wheeling of chain

When the hoist is used appropriately, unintended activation of the free-wheeling mechanism under load is impossible.

DANGER!

Never try to activate the free-wheeling mechanism by force if the hoist is under charge.

Switching ON the free-wheeling mechanism

A free-wheeling switched OFF B free-wheeling switched ON

 switch in middle position

Illustration 9

 Pull the free-wheeling wheel upwards in

direction ▲ .

 The chain can be pulled through in both

directions.

Illustration 10

Switching OFF the free-wheeling mechanism

C free-wheeling switched OFF D free-wheeling OFF

 Turn the free-wheeling wheel with one hand in

direction ◄ and pull the load chain at the same time.

 Free-wheeling wheel turns back to position

OFF.

 Free-wheeling mechanism switched OFF

Illustration 11

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Operation

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7.3 Brake and pawl

The brake remains closed (stuck) if:  The ratchet lever hoist is uncharged without lowering the load, i.e. in case of vertical lifting/lowering when

a load is "transmitted" to another hoist or in case of horizontal pulling/tensioning.  The load hook is pulled against the housing and got stuck there The chain does not move, the load cannot be lowered. Remedy:

 Charge the ratchet lever hoist again  Release the brake by setting down the load  OR: Turn the switching pin to position "Lowering" and release the hand lever with a strong jerk in direction

"▼".

Pos: 12.3.6 /7--BEDIENUNG/Ratschzug/08.Übergabe von Las ten - Alle @ 2\mod_12923 16859244_52.doc @ 17800 @ @ 1

7.4 Transmission of loads

When loads are transmitted from one hoist to another, the hoist that gets the load is not possible to lift or lower as the brake is closed at the time of transmission.

Proceed as follows in such cases:

 Lift the load with the hoist (A).  Suspend the load from the hook of hoist (B)

and lift it unil the load hangs securely in the

hook, but do not uncharge the hoist (A).  Effect movement lowering with hoist (A) until

hoist (B) takes over the complete charge/load.  Now hoist (A) is uncharged and the brake is

open again.

Illustration 12

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Page 16

Commissioning

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8 Commissioning

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8.1 General

Should the unit be used in Germany, please observe the accident prevention regulations, in particular BGV D8, BGV D 6 and BGR 500 (VBG 9a).

For other countries: Inspections as above. Please observe the national rules and regulations and the instructions in this manual!

Pos: 13.2.1.2 /---ALLGEMEIN/Hinweise/Prüfungen/ HINWEIS - Prüfung durc h befähigte Pesonen @ 0\mod_11773 39966681_52.doc @ 5319 @ @ 1

NOTE!

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 quality person” before putting in operation.

An exception is “hoists ready for operation” acc. To BGV D6 II§25(4) 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).

Pos: 13.2.2.1 /9--INBETRIEBNAHME/Allgemein/Lastk ette/06.Lastkett e @ 0\mod_1178195068515_5 2.doc @ 5681 @ @ 1

8.2 Load chain

 Before commissioning the load chain must be aligned and oiled.

Pos: 13.2.2.2 /---ALLGEMEIN/Hinweise/Ketten/VORSI CHT - Ketten: Kein Fett, ohne Sc hmierung keine Haftung @ 0\ mod_1177481784104_52. doc @ 5349 @ @ 1

CAUTION!

Do not use grease for lubrication of load chain. Without lubrication, manufacturer's warranty and/or liability will be void.

Pos: 13.2.2.3 /---ALLGEMEIN/Hinweise/Ketten/HI NWEIS - Kettenlebensdau ererhöhung durch Sc hmierung @ 0\mod_11774819411 92_52.doc @ 5355 @ @ 1

NOTE!

Continuous, thorough lubrication will increase the life of the chain considerably.

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Page 17

Safety check

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9 Safety check

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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.

Pos: 14.3 /10-SICHERHEITSPRÜFUNG/Allgmein/Sicher heitsprüfung Ketten @ 0\ mod_1172661092232_52. doc @ 429 @ @ 1

 The chains are correctly placed, oiled and in good condition.

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Page 18

Maintenance

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10 Maintenance

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10.1 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.

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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

Pos: 15.3.1 /12-INSTANDSETZUNG/Lastkette wechseln/03. Alle @ 0\mod_11732754 48587_52.doc @ 533 @ @ 1

10.3 Replacing the load chain

CAUTION!

If there is any visible damage and when the conditions for replacement are reached (i.e. one or several dimensions in the table have been reached, there is corrosion or elongation), the chain must be replaced.

When replacing the chain, also check the chain wheels.

Procedure:  Only insert new chains in an unloaded state and as the chains that are currently in the device – i.e. not

twisted.

 Remove chain from its fastening at the end and attach a chain link which is open at the side.

 A chain link which is open at the side, can

easily be produced by grinding out a small piece. The opening must have the same thickness as the chain link.

Illustration 13

 Hang a new original chain (same size and oiled) in the side opened chain link and insert it.  Make sure the chain is not installed twisted.  Make sure the chain links are aligned in one direction.  Assemble the chain to the end fastening.

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Page 19

Inspection

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11 Inspection

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11.1 Periodic checks

Independently from the regulations of the individual countries, HADEF lifting devices must be checked at least yearly by a qualified person or licensed qualified person regarding its functional safety.

In Germany it is necessary to observe the accident prevention regulations BGV D6, BGV D8, BGR 500 as well as DIN 15020 (Basics for cable drives). In other countries, the above mentioned tests and the national safety regulations apply.

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11.1.1 Components to be checked

The following must be checked:

 Dimensions of load chain, load hooks, pawls, bolts, ratchet wheels, brake linings.

The dimensions must be compared to the dimensions in the tables.

 A visual inspection for deformations, cracks and corrosion must be carried out.

Pos: 16.3.1.2 /---ALLGEMEIN/Hinweise/Prüfungen/V ORSICHT - Verschleißgr enzen @ 1\mod_1260457845 218_52.doc @ 11380 @ @ 1

CAUTION!

When the wear limit is reached, the part must be exchanged by a new, original part.

Pos: 16.3.2.1 /13-PRÜFUNG/Kettenzug/Tabelle-I nspektionsinter valle/02.Alle H + Ratschzüg e @ 0\mod_1178696489864_ 52.doc @ 5741 @ @ 1

commissioning

daily

checks

1st mainte-

nance

after

3 months

Inspection

Maintenance

every

3 months

Inspection

Maintenance

every

12 months Check screw connections X X Check lifting, lowering functions. X X Check brake function X X for ratchet lever hoists: Check free-wheeling mechanism of the chain

X X

Brake - check wear of brake lining X Check chain wheels, ratchet wheels and pawls. X Clean and lubricate the load chain. X X X Check the load chain for elongation and wear X Check the load hook for cracks and deformation X Load hook - check the safety catch X X Check and lubricate the bearing of the chain pulleys. X X Check the chain pulleys X X Have the equipment checked by a qualified person (periodic inspection)

Pos: 16.3.2.2 /---ALLGEMEIN/Hinweise/Kettenzüge/WARNUNG - Inspektion: Über,-unterschreiten Maße-Ketten,Haken @ 0\mod_117750 4456674_52.doc @ 5496 @ @ 1

WARNING!

If one or several of the dimensions fall below or exceed the dimensions in the table, or if cracks or corrosion are found, the parts must be replaced with original spare parts.

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11.2 Checking the load chain

acc. DIN 685-part 5

L11 = pitch increase over 11 chain links

L1 = pitch increase over 1 chain link

dm = detected link thickness

Illustration 14

Pos: 16.3.3.2 /13-PRÜFUNG/Kettenzug/Lastkette/ Tabelle - Ketten 3x9 - 4, 2x12,2 - 5x15 - 5,6x15,8 - 7,1x20, 1 - 7,1x21 - 9x24,8 - 10x28,1 @ 0\ mod_1178704619245_52.d oc @ 5752 @ @ 1

Page 20

Inspection

5.52.187.00.01.02

Chain dimensions

Chain size

Dimensions

3x9 4,2x12,2 5x15 5,6x15,8 7,1x20,1 7,1x21 9x24,8 10x28,1

L11 105,6 138,2 170,6 179,1 227,9 238,5 281,2 318,6

L1 9,9 12,8 15,7 16,6 21,2 22,3 26,1 29,6 dm 2,7 3,8 4,5 5,0 6,4 6,4 8,1 9,0

Pos: 16.3.3.3 /---ALLGEMEIN/Hinweise/Ketten/WARNUNG - Ketten: Bei Erreichen der Tabellenmaße durc h Verschleiß oder Verf ormung die Ke @ 0\mod_117870515 8838_52.doc @ 5763 @ @ 1

WARNING!

When the dimensions listed in the table are reached due to wear or deformation, the chain must be replaced!

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11.3 Checking the load hook

Load hook

X = measuring distance hook mouth width Y = measured length from hook no. 6 H = thickness of hook saddle

Illustration 15

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Dimensions for load and suspension hooks

Dimension

Capacity in kg / Chain falls

250 500 750 1500 800 1000 1600 2500 3200 6300 9000

X bzw. Y 21/35,5 24,5/42 35,5/42 35,5/52 26,5/41,5 31,5/49,4 35,5/52 41/58,6 43/61,9 53/84,3 64/-

H 13 15,6 20 26,5 20 22 26,5 29 31,2 45,5 60,4

Please fill in the

measured values before commissioning:

Capacity kg

X bzw, Y mm

H mm

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CAUTION!

When the dimension of hook opening width is deformed more than 10% or when the dimension of the hook bottom thickness is fallen short of by 5% due to wear, the hook must be replaced.

Pos: 16.3.5 /13-PRÜFUNG/Kettenzug/Sperrklinke/ Tabelle - 53/07 @ 1\mod_1260 794657564_52.doc @ 11548 @ @ 1

11.4 Checking - pawl

Typ kg A V

min

A 250-1500 14,5 13,8

- 800-1600 22 20,5

- 2500 29,2 27,7

- 3200-9000 31 29,5

Pos: 16.3.6 /13-PRÜFUNG/Kettenzug/Sperrrad+Br emsbelag/Tabelle 53/0 7 @ 1\mod_1260794759898_5 2.doc @ 11552 @ @ 1

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Inspection

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11.5 Checking – ratchet wheel and brake lining

Type kg D V

min

tn tv

min

A 250 36 35 3 2,7 A 500 40 39 2,5 2,2 A 750 45 44 2,5 2,2 A 1500 60 59 3,5 3

- 800 64 61 8 6

- 1000 64 61 8 6

- 1600 64 61 8 6

- 2500 64 61 8 6

- 3200 74 71 8 6

- 6300 74 71 8 6

- 9000 74 71 8 6

Type A 250kg-1500kg

800 kg – 9000 kg

Measure brake disc and ratchet wheel for type A separately. 800kg up to 9000 kg measure brake lining inc. ratchet wheel.

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11.6 Checking – Suspension and load hook bolt

Type Capacity

Suspension bolt Load hook bolt

kg dn dv

min

dn dv

min

A 250 8 7,5 --- --A 500 10 9,5 6,5 5,9 A 750 12 11,4 7,5 6,8 A 1500 12 11,4 10,2 9,5

- 800 7,5 6,7 12 11,4

- 1600 10,2 9,4 12 11,4

- 2500 11,5 10,7 14 13,3

- 3200 13 12,2 16 15,2

- 6300 13 12,2 16 15,2

- 9000 13 12,2 16 15,2

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Page 22

Service

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12 Service

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12.1 Load chain

Wear at the links is mainly due to insufficient maintenance of the chain. To ensure optimal lubrication of the links, the chain must be lubricated at regular intervals, depending on

usage.  When lubricating with suitable oil that creeps, the load must be taken off the chain so that the oil can wet

the links affected by wear.

 It is not sufficient to lubricate the chain from the outside, as this will not ensure the formation of a

lubricating film within the links.

 If the same lifting operations are carried out constantly, the switching area from a lifting to a lowering

movement must be given special attention.

 Thoroughly effected lubrication of the chain will prolong the life of the chain by approx. 20 times,

compared to dry run with unlubricated chain.

 Wash dirty chain with petroleum or a similar cleaner, under no circumstances heat the chain.  Always lubricate the chain when it is not under load. The adjacent link points must always be lubricated to

prevent excessive wear.

 Lubricate the chain with a lubricant that creeps, e.g. automotive gear oil.  If there are environmental influences that foster wear, such as sand, a dry lubricant should be used, e.g.

graphite powder.

 When lubricating the chain’s condition of wear should be checked.

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12.2 Pulleys

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CAUTION!

Do not use grease for lubrication of load chain. Without lubrication, manufacturer's warranty and/or liability will be void.

Pos: 17.2.2 /14-WARTUNG/Kettenzug/Lasthaken/02.La sthaken - Schmierung @ 0\mod_1173364066362_5 2.doc @ 594 @ @ 1

Use

Recommendation

Interval

Load chain

Gear oil for example: FUCHS

RENOLIN PG 220 or special chain lubricant Use NO grease!

0,2 l 3 month

Use

Recommendation

Interval

Pulleys

FUCHS RENOLIT FEP2

1 kg 12 month

Page 23

Service

5.52.187.00.01.02

12.3 Load hook

 Check bearings and pulleys yearly  Clean and lubricate the bearings of hooks and pulleys with grease  Slight bearings are maintenance free  When bearings resp. slight bearings are worn of, change the complete pulley

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12.4 Gear

Regular checks of lubrication are necessary. The teeth must be cleaned and re-lubricated after approx. 3 years. We recommend to use a lubricant of class EP2 or similar products. In case of severe conditions of use (e.g. dust, regular lifting of the nominal load,etc.), please shorten maintenance intervals.

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12.5 Gear spring pressure brake

During the check, brake lining wear is verified. The brake linings must be replaced when the wear limit is already reached at one position of the lining, - as this can be the case when wear of the linings is irregular.

CAUTION!

The brake linings must be free from fracture. Avoid oil, grease, dirt and humidity on the brake linings as this increases wear.

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The brake lining for the ratchet lever hoist is tested for the whole product lifetime - under the precondition of appropriate use - and must only be replaced in case of extraordinary wear.

NOTE!

According to EN 13157 lifetime is 1500 operating cycles (lifting/lowering movements) with 300 mm lift with nominal load and normal operation conditions.

Use by heavy conditions can shorten the product lifetime. In these cases, the thickness of the brake lining must be checked more than 1x yearly. The ratchet wheel with the brake lining must be replaced when the wear limit is reached or wear of the lining (one one side) is clearly visible.

Pos: 17.3 /14-WARTUNG/Schmierstoffe/Schmierstoff -Auswahl_H @ 1\mod_1271 670183002_52.doc @ 13442 @ @ 1

12.6 Lubricant selection

FUCHS SHELL ESSO ARAL MOBIL KLÜBER

Renolit FEP 2 Alvania EP 2 Unirex EP 2 -- Mobilux EP 2 --

Pos: 18.1 /15-STÖRUNG/*Ü1*/#. Kapitel - Störung @ 0\mod_1172648295608_52.doc @ 413 @ @ 1

Use

Recommendation

Interval

Load hook bearing

FUCHS RENOLIT FEP2

0,1 kg 12 month

Page 24

Trouble

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13 Trouble

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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.

Pos: 18.2.2 /---ALLGEMEIN/Hinweise/VORSICHT - Störung bes eitigen bei Versc hleißteilen @ 0\mod_1177 594576085_52.doc @ 5572 @ @ 1

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.

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Page 25

Remedy

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14 Remedy

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Check the ratchet lever hoist by listening to the noise it makes: Lifting: Move the lever forward and backwards - it should make click Lowering: Only move the lever backwards not forward - it should make click

Problem Cause Remedy

Overload Reduce the load to nominal load

Load got stuck Set the load free again

Brake linings are worn

Do maintenance and exchange the brake linings

Load chain is twisted Align the load chain

Defect of chain, gear or chain wheels