HADEF 27/12 Manual chain hoist Owner's Manual

Installation, Operating and
Maintenance Instructions
Spur Gear Chain Hoist
27/12
with monorail push travel trolley
with monorail hand geared trolley
HR
HH
Rev.06 5.52.172.00.01.06
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
2
Information .......................................................................................... 3
Safety ................................................................................................... 3
2.1
2.2
2.3
2.4
2.5
Warning notice and symbols ............................................................................................ 3
Duty of care of the owner.................................................................................................. 4
Requirements for the operating personnel ..................................................................... 4
Appropriate use ................................................................................................................. 5
Basic safety measures ...................................................................................................... 5
3
Transport and Storage ....................................................................... 6
3.1
3.2
3.3
Transport ............................................................................................................................ 6
Safety device for transport ............................................................................................... 6
Storage ............................................................................................................................... 6
4
Description .......................................................................................... 7
4.1
4.2
4.3
4.4
Areas of application .......................................................................................................... 7
Design ................................................................................................................................. 7
Functions............................................................................................................................ 7
Important components ...................................................................................................... 8
5
6
Technical data ..................................................................................... 8
Installation ........................................................................................... 8
6.1
6.2
6.3
Adjusting the gauge .......................................................................................................... 8
Installation on the beam.................................................................................................... 9
Tools ................................................................................................................................... 9
7
Control ............................................................................................... 10
7.1
Brake and pawl ................................................................................................................ 10
8
Commissioning ................................................................................. 11
8.1
8.2
General ............................................................................................................................. 11
Load chain ........................................................................................................................ 11
9
10
Safety check ...................................................................................... 11
Functional test .................................................................................. 12
10.1
10.2
Checks before the initial start-up ................................................................................... 12
Functional test ................................................................................................................. 12
11
Maintenance ...................................................................................... 12
11.1
11.2
General ............................................................................................................................. 12
Monitoring ........................................................................................................................ 12
2
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11.3
Replacing the load chain ................................................................................................ 12
12
Inspection ......................................................................................... 12
12.1
12.2
12.3
12.4
12.5
12.6
Periodic checks ............................................................................................................... 12
Checking the load chain ................................................................................................. 13
Checking the load hook .................................................................................................. 14
Checking - pawl ............................................................................................................... 14
Checking – Brake System .............................................................................................. 14
Checking – Suspension and load hook bolt ................................................................. 14
13
Service ............................................................................................... 15
13.1
13.2
13.3
13.4
13.5
13.6
13.7
13.8
13.9
Load chain ....................................................................................................................... 15
Pulleys .............................................................................................................................. 15
Load hook ........................................................................................................................ 15
Gear .................................................................................................................................. 15
Trolley ............................................................................................................................... 15
Gear spring pressure brake ........................................................................................... 16
Overload protection ........................................................................................................ 16
Lubricant - Selection ....................................................................................................... 16
Lubricant for food industry – Selection (as option*).................................................... 16
14
15
16
Trouble .............................................................................................. 16
Remedy ............................................................................................. 17
Decommissioning ............................................................................ 17
16.1
16.2
Temporary decommissioning ........................................................................................ 17
Final decommissioning/disposal ................................................................................... 17
1
Information
The products meet European Union requirements, in particular the valided EU Machine Directive.
The entire company works acc. to a certified quality assurance system as per ISO 9001.
The production of components at our work is subject to strict, intermediate checks.
After assembly, each product is subject to a final test with overload.
For the operation of hoists, the national accident prevention regulations apply in Germany, amongst others.
The stated performance of the devices and meeting any warranty claims require adherence to all instructions
in this manual.
Before delivery, all products are packed properly. Check the goods after receipt for any damage caused
during transport. Report any damage immediately to the forwarding agent.
This manual allows a safe and efficiently use of equipment. Images of this manual are for a principle
understanding and can be different from the real design.
NOTICE!
We refer to the prescribed equipment tests before initial start-up, before putting back into operation and the
regular periodic inspections.
In other countries any additional national regulations must be observed.
2
Safety
2.1
Warning notice and symbols
Warnings and notice are shown as follows in these instructions:
DANGER!
This means that there is a high risk that leads, if it is not avoided, to death or severe injury.
WARNING!
This means that there is a risk that could lead, if it is not avoided, to death or severe injury.
CAUTION!
This means that there is little risk that could lead, if it is not avoided, to slight injury or damage to
the device or its surrounding.
5.52.172.00.01.06
3
NOTICE!
Gives advice for use and other useful information.
Danger from electricity.
Danger from explosive area.
2.2
Duty of care of the owner
DANGER!
Failure to follow the instructions of this manual can lead to unpredictable hazards.
For any resulting damage or personal injury, HADEF assumes no liability.
The unit was designed and built following a risk analysis and careful selection of the harmonized standards
that are to be complied with, as well as other technical specifications. It therefore represents state-of-the-art
technology and provides the highest degree of safety.
Our delivery includes the hoist supplied beginning at its suspension and ending at the load hook and if
supplied with control, the control line/hose that leads to the hoist. Further operating material, tools, load
attaching devices as well as main energy supply lines must be assembled according to the valid rules and
regulations. For explosion-proof equipment, all these parts must be approved for use in area prone to
explosion, or they must be suitable for use in area prone to explosion. The owner is responsible for this.
However, in everyday operation this degree of safety can only be achieved if all measures required are
taken. It falls within the duty of care of the owner/user of the devices to plan these measures and to check
that they are being complied with.
Complete the operating and installation instructions by any instructions (regarding supervision or
notifications)that are important for the special kind of use of the equipment, i.e. regarding organization of
work, work flow and human resources.
In particular, the owner/user must ensure that:
 The unit is only used appropriately.
 The device is only operated in a fault-free, fully functional condition, and the safety components, in
particular, are checked regularly to ensure that it is functioning properly.
 The required personal protective equipment for the operators, service and repair personnel is available
and is used.
 The operating instructions are always available at the location where the equipment is used and that they
are legible and complete.
 The unit is only operated, serviced and repaired by qualified and authorized personnel.
 This personnel is regularly trained in all applicable matters regarding safety at work and environmental
protection, and that they are familiar with the operating manual and, in particular, the safety instructions it
contains.
 Any safety and warning signs on the devices are not removed and remain legible.
 customers equipment at site must comply with currently applicable ATEX-regulations
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.
4
5.52.172.00.01.06
DANGER!
In order to avoid severe injury, please pay attention to the following when using the equipment:
 Use protective clothes/equipment.
 Do not wear long hair hanging down open.
 Do not wear rings or other jewelry.
 Do not wear clothes that are too big/wide.
 Do not reach into ropes, chains, drive parts or other moving parts with your hands
2.4
Appropriate use
The appropriate use of the hoists is vertical lifting and lowering of unguided loads up to the maximum rated
load. In combination with trolleys, loads can also be moved horizontally.
The permitted safe working load of the devices must not be exceeded! An exception can be made during the
load test before initial operation, carried out by a licensed qualified person.
 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!
 The permissible ambient temperature when operating the devices:
Type of drive
Manually driven
Motor driven
Device classification for
Explosive atmosphere
not explosive atmosphere
according to
ATEX )* )**
-20°C/+50°C
-20°C/+40°C
-20°C/+40°C
-20°C/+40°C
) * At an atmospheric pressure range from 0.8bar to 1.1bar and an oxygen content of approx. 21%
) ** Devices of this category have been specially modified and labeled by the manufacturer
DANGER!
The ambient temperature range must not be exceeded!
NOTICE!
If the units are not used as intended, safe operation is not guaranteed.
The operator alone is responsible for all personal injury and damage to property resulting from improper
use.
2.5












Basic safety measures
Observe installation-, operation and maintenance instruction.
Take notice of caution notes at units and in the manual
Observe safety distances.
Take care for a free view on the load.
Only use the hoists appropriately.
The equipment is to be used exclusively for movement of goods. Under no circumstances my persons be
moved.
Never load the devices beyond their working load limit.
Pay attention to the accident prevention regulations (UVV).
Should the hoist be used outside of Germany, please pay attention to the national regulations that apply.
Supporting structures and load-attached devices used in conjunction with this equipment must provide an
adequate safety factor to handle the rated load plus the weight of the equipment. In case of doubt, consult
a structural engineer.
If the equipment has not been used for a period of time, carry out visual checks of all main components
such as chains, load hooks etc. and replace any damaged parts with new, original spare parts before
putting the equipment back into operation!
Do not use a hoist that is defective, pay attention to any abnormal noise it makes during operation.
5.52.172.00.01.06
5




Stop working immediately in case of disturbances and remedy failures.
Any damage and faults must be reported to a responsible supervisor immediately.
If the unit is put into motion, any persons in the immediate vicinity must be informed by calling to them!
Please pay attention to the regulations for load carrying devices UVV for both positive and non-positive
methods of attaching loads.
 The lifting tackle or the load must be securely attached to the hook and be seated at the bottom of the
hook.
 The safety catch of hooks must be closed.
 When charged, the housing may not be in contact somewhere.
 Stop lowering the load when the bottom block or the load is being set down or is prevented from being
lowered further.
 The loose chain end may not be charged or locked.
 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.
Illustration 1
 The chain links must always be aligned in one direction.
 Do not bounce the load or hook against something.
 Motor drive is prohibited.
The devices are not suitable for continuous operation. In order to avoid too high temperatures of the brake
discs that are not permitted, the following maximum continuous operating times must not be exceeded:
Light use
Highest load is seldom lifted
= 60 min
Medium use
Roughly equal frequency of light, medium and heavy loads
= 30 min
Heavy use
Nearly always largest permissible load
 Let the hoist stand still at least 15 minutes afterwards to cool down the brake.
= 15 min
WARNING!
The following is not allowed:
 to lift another load than the nominal safe working load
 to manipulate the sliding clutch if units are equipped with
 The use of elongated or damaged chains or wire ropes. Replace them immediately by new, original
parts.
 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), but replace them by original hooks.
3
Transport and Storage
CAUTION!
Transport may only be done by qualified personnel. No liability for any damage resulting from improper
transport or improper storage.
3.1
Transport
The devices are checked and if so adequately packed before delivery.
 Do not throw or drop the equipment.
 Use adequate means of transport.
Transport and means of transport must be suitable for the local conditions.
3.2
Safety device for transport
NOTICE!
Should a safety device for transport exist, please remove it before commissioning.
3.3
Storage
 Store the equipment at a clean and dry place.
6
5.52.172.00.01.06
 Protect the equipment against dirt, humidity and damage by an appropriate cover.
 Protect hooks, wire ropes, chains and brakes against corrosion.
4
Description
4.1
Areas of application
The devices must be as far as possible installed in a covered room.
If they are used in the open, protect the units against the effects of weather such as rain, hail, snow, direct
sunshine, dust, etc. - we recommend to use a cover in parking position. If the device is set up in a
continuously humid environment with strong temperature fluctuations, the correct functionings are
endangered by the forming of condensation.
NOTICE!
Use only in the intended atmosphere with a humidity of up to 100%, but not under water!
DANGER!
In particular, use is not permitted:
 for tearing loose fixed loads, dragging of loads as well as diagonal pulling
 for pulling against a fixed point without additional safety and/or measuring equipment against exceeding
the nominal load
 in potentially explosive atmospheres, unless the equipment has been modified for this purpose and
this is shown on special type plates it carries for this purpose.
 in reactor containments
 for transporting persons
 for holding lifted loads
 for scenic use
 when persons are under suspended loads
4.2
Design
HADEF Spur Gear Hoists of compact design are
monorail trolleys combined with manual hoists.
With monorail push travel trolley or
with monorail hand geared trolley
Operation by hand through hand chain.
Illustration 2
4.3
Functions
The load is lifted or lowered by pulling one of the chain falls of the endless hand chain of the hoist. A load
pressure brake prevents automatic lowering of the load after releasing the hand chain.
In combination with hand geared trolleys, the trolley is moved to the left or to the right side by pulling the
hand chain.
In combination with push travel trolleys the trolley is moved by pushing or pulling the load or, without load, by
pulling the load chain.
NOTICE!
The best protection against functional failures in case of extreme environmental impact is the regular use of
the equipment.
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7
4.4
Important components
 Gear
Gear components are made of high-quality material.
 Load pressure brake
Holds the load in any position. Hardened safety pawls.
 Housing
Depending on the model made from steel plate or aluminium die-casting (Not for explosion proof equipment).
In case of ex proof hoists, the housing is only made of steel plates.
 Load chain
According to EN 818-7-T high quality chain. All components match precisely to each other. Therefore please
only use original chains.
 Load hook
Forged steel. Rotating, this facilitates attaching the load and avoids twisting of the chain. With safety catch.
 Overload protection
Hoists with overload protection protects the hoist by a slipping clutch from damage by overload. When the
slipping clutch operates, lifting of the load is stopped. Lifting is only possible again after the load has been
lowered and reduced to nominal load.
DANGER!
The overload protection serves exclusively to protect against damage to the device due to overloading
when moving loads. Its function must not be integrated into the operational work process!
5
Technical data
HH
Capacity
Number of chain falls
Load chain
Load bar size at beam flange width
from - to
1N
Load bar size at beam flange width
from - to
2
Lifting path when reeling off
30 m of hand chain
Hand chain pull for lifting
Travel path when reeling off
30 m of hand chain
Hand chain pull for travel
weight at 3 m track height
weight per add. m lift
kg
500
1000
1500
2000
3000
5000
7500
10.000
mm
1
5 x 15
1
6,3 x 19,1
1
7,1 x 21
1
8 x 24
2
7,1 x 21
2
9 x 27
3
9 x 27
4
9 x 27
50-146
50-179
66-185
66-185
74-196
74-192
119-215
119-215
147-302
180-310
186-310
186-310
197-310
193-310
216-310
216-310
1112
690
519
423
260
151
101
67
23
28
34
35
35
33
34
35
7,8
10
9,8
9,8
6,3
6,3
6,3
6,4
65
22
2,5
100
31
2,8
110
52
3,1
150
56
3,3
110
92
4,2
170
121
5,4
190
230
7,2
210
250
8,9
kg
500
1000
1500
2000
3000
5000
mm
1
5 x 15
1
6,3 x 19,1
1
7,1 x 21
1
8 x 24
2
7,1 x 21
2
9 x 27
50-146
50-179
66-185
66-185
74-196
74-192
147-302
180-310
186-310
186-310
197-310
193-310
23
21
1,5
28
27
1,8
34
47
2,1
35
51
2,3
35
86
3,2
33
114
4,4
mm
Nmm
mm
daN
m
N
approx. kg
kg
HR
Capacity
Number of chain falls
Load chain
Load bar size at beam flange width
from - to
1N
Load bar size at beam flange width
from - to
2
Hand chain pull for lifting
weight at 3 m track height
weight per add. m lift
mm
Nmm
daN
approx. kg
kg
6
Installation
6.1
Adjusting the gauge
The trolley can be adjusted to various beam flange widths. Adjustment to the relevant beam flange width “B”
depends on the type and size and is to be made as follows:
8
5.52.172.00.01.06
 There are distance tubes (5) and/or washers
(6) situated on the load bars (2) of the trolley.
 Dimension "X" is set by placing washers (6)
from the outer to the inner side ("X" increases)
or from the inner to the outer side ("X"
decreases).
 Washers (6) and rubber discs (depended on
type) leave a distance for the load hook. It is
important that the load hangs in the middle
under the beam so that the two side plates are
equally loaded.
 The suspension eye (9) (if existent) for bigger
load bolts must still be swivelling after it has
been secured.
 Tighten the hexagon nut (3) and safety nuts (4)
again.
 Check correct flange width "B" and dimension
"X". Adjustment must be repeated if necessary.
6.2
1 side plates
2 load bars
3 hexagon nut
4 safety nuts
5 distance tubes
6 washers
7 --8 rubber disc (depended on type)
9 suspension eye
Installation on the beam
1 Tighten the hexagon nut (3) and safety nuts (4).
2 Push on the trolley at the face of the beam flange.
3 If this is not possible, the trolley can also be mounted
on the beam from below.
4 Therefore, remove the hexagon nut (3) and the safety
nut (4) on the side without gear.
5 Pull apart the side plates (1) as far until it is possible to
push the trolley onto the beam flange from below.
Afterwards, push the trolley together to correct gauge.
6 Secure the washers (6) and distance tubes (5) by
tightening the hexagon nuts (3) and the safety nuts (4).
6.2.1
Illustration 3
Bolt securing with collar
Securing the load bolts with set collars (1) and safety
screws (3).
 In order to adjust the beam flange width dismantle
the safety screws (3) at one trolley side.
 After adjustment of dimension "X" and installation on
the beam, install the safety screws (3) again and
secure them with a nut (4).
 When pulling apart the side plates, the trolley drive
shaft will also be moved.
 To do this, loosen the safety screws at the stern tube
bearing and secure them again after the side plates
have been pushed together.
Illustration 4
1
2
3
4
5
set collar
load bar
safety screw
hexagon nut
washer
CAUTION!
The distance “X” between the wheel flanges of the trolley wheels must be
for trolleys up to 3,2 t: 2-3 mm (1-1,5 mm each side) bigger and
for trolleys from 4 t up: 3-5 mm (1,5-2,5 mm each side) bigger than the flange width "B" of the beam
6.3
Tools
Capacity
5.52.172.00.01.06
Size
Tool
Use
9
0,5t
1t
to 2t
to 3,2t
to 6,3t
to 10t
SW27
SW36
SW46
SW55
SW60
SW75
Load bar
12,5t
to 60t
SW22
SW24
Load bar
with
fixing ring
diff.
7
Control
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.
Lifting and Lowering by pulling the endless hand
chain.
Lifting - pull the chain fall at the right side –
the hand chain wheel turns clockwise
Lowering - pull the chain fall at the lift side –
the hand chain wheel turns anti-clockwise
Illustration5
NOTICE!
For double lifting mechanism
Operate both lifting mechanism, synchronous resp.evenly.
CAUTION!
Run in of chain into the chain container for hoist with double lifting mechanism
For a correct run in of chain into both chain containers, the lowering operation must be carried out, without
load, at certain intervals, until both chain container are empty.
For motorized devices with operating limit switches "lowering"
Lower until the operating limit switch is released.
Non-observance can lead to device damages!
WARNING!
The hoist must always hang centrally under the beam or under its suspension point.
Monorail push travel trolleys are moved by pushing the load.
Monorail hand geared trolleys are moved by pulling the hand chain.
7.1
Brake and pawl
The brake system needs a minimum load of 3% of the capacity.
10
5.52.172.00.01.06
Only this minimum load makes sure that the load-pressure-brake closes correctly. When the brake closes
correctly, the load is safely held
DANGER!
Working situations with no guarantee that the minimum load is charged, are forbidden!
8
Commissioning
8.1
General
The operator of the unit is responsible for the entire system.
According to the Ordinance on Industrial Safety and Health, a hazard analysis must be carried out by the
operator.
Observe the respective national standards, regulations and directives of the responsible bodies at the place
of operation.
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).
8.2
Load chain
 Before commissioning the load chain must be aligned and oiled.
 Move safety note and fixing wire away from the chain.
CAUTION!
Do not use grease for lubrication of load chain.
Without lubrication, manufacturer's warranty and/or liability will be void.
NOTICE!
Continuous, thorough lubrication will increase the life of the chain considerably.
9
Safety check
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.
 The chains are correctly placed, oiled and in good condition.
5.52.172.00.01.06
11
10
Functional test
10.1
Checks before the initial start-up
Lifting gear
 Load chains must not be twisted.
 Lubricate the load chain with gear oil or suitable chain lubricant before first loading.
Trolley drive
 The open-lying teeth of the trolley drive must be lubricated.
Hand gear for hand geared trolley
 Ensure correct fit of the hand chain, it must not be twisted and must hang freely.
10.2
Functional test
Lifting gear
Check lifting and lowering functions, initially without a load.
Then check the brake function under load. The load must be securely held.
Trolleys
Carefully move the trolley to the end positions and check the positions of the end stops.
11
Maintenance
11.1
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.
11.2
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
11.3
Replacing the load chain
VORSICHT!
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.
 Assemble the chain to the end fastening.
12
Inspection
12.1
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.
12.1.1 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.
12
5.52.172.00.01.06
CAUTION!
When the wear limit is reached, the part must be exchanged by a new, original part.
Check screw connections
Check lifting, lowering functions.
Check brake function
Check free-wheeling of chain
(only applicable for ratchet lever hoists with free-wheeling
mechanism)
Brake - check the brake disc thickness
Check sprocket wheels, ratchet wheels, pawls, bolts
Clean and lubricate the load chain
Check the load chain for elongation and wear
Check the load hook for cracks and deformation
Load hook - check the safety latch
Check and lubricate the bearing of the chain pulleys
Check the chain pulleys
Check the rubber end stops
Check the trolley wheels for wear
Check lubrication of the trolley driving pinion
Have the equipment checked by a qualified person
(periodic inspection)
on
commissioning
daily
checks
X
X
X
X
X
X
X
1st maintenance
after
3 months
Inspection
Maintenance
every
3 months
Inspection Maintenance
every
12 months
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
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.
12.2
Checking the load chain
CAUTION!
The load chain must be tested over its entire length!
The measure of the load chain must be carried out especially in the areas which are subject to the highest
wear. Through the lifting movement, these are the contact points of the chain with sprocket wheel and
deflection pulleys.
acc. DIN 685-part 5
L11 = pitch increase over 11 chain links
L1 = pitch increase over 1 chain link
Illustration 6
dm= detected link diameter (d1+d2)/2
Illustration 7
Chain dimensions
Table 1
Dimensions
Chain size
mm
3x9
4x12
4,2x12,2
5x15
5,6x15,8
5,6x17
6x18
6,3x19,1
7,1x20,1
L11
L1
dm
105,6
9,9
2,7
136,6
12,7
3,6
138,2
12,8
3,8
170,6
15,7
21,2
179,1
16,6
5,0
194,2
18
5,0
203,9
18,9
5,4
216,4
20
5,7
227,9
21,2
6,4
10x28,1
318,6
29,6
9,0
10x30
340,7
31,8
9,0
13x36
408,3
37,9
11,9
16x45
505,6
47,4
14,4
Table 2
Dimensions
mm
L11
L1
dm
Chain size
7,1x21
238,5
22,3
6,4
7,9x23
260,6
24,1
7,1
8x24
272,1
25,3
7,2
9x24,8
281,2
26,1
8,1
9x27
300,8
28,1
8,2
WARNING!
When the dimensions listed in the table are reached due to wear or deformation, the chain must be
replaced!
5.52.172.00.01.06
13
12.3
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 8
Table 1
Capacity/chain falls
Dimensions
mm
0,5/1
1t/1
1,5t/1
2t/2
3t/2
5t/2
7,5/3
10t/4
X or Y
H
26,5/35
16,8
33,8/45
21
32,5/47
25,2
35,5/52
28,3
41,7/62,5
35,6
50/79
43,2
64/85
60,4
64/85
60,4
Dimensions in the tables are theoretical values without tolerances.
Please fill in the measured
values before
commissioning:
Capacity
X or Y
H
t
mm
mm
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.
12.4
Checking - pawl
A
mm
16
20
24,6
24,5
kg
250
500
1000-3000
5000-1000
12.5
Vmin
mm
14,5
18,5
23
23
Checking – Brake System
Ratchet wheel with brake linings
kg
500
1000-1500
2000
3000
5000-10000
12.6
D
mm
62
69
82
69
82
Vmin
mm
59
66
79
66
79
tn
mm
13
17
16,5
17
16,5
tvmin
mm
12,2
16,2
15,7
16,2
15,7
tn1
mm
3
5
4,5
5
4,5
Checking – Suspension and load hook bolt
Load hook bolt
kg
500
1000
1500+3000
5000-10000
14
tv1max
mm
3,8
5,8
5,3
5,8
5,3
dn
mm
6,2
8,5
10,2
13
Suspension bolt
dvmin
mm
5,5
8
9,6
12,2
dn
mm
12
12
16
16
dvmin
mm
11,4
11,4
15,2
15,2
5.52.172.00.01.06
13
Service
13.1
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.
 Lubricate the chain with oil that creeps.
 Always lubricate the chain when it is not under load 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. The adjacent link points must always be lubricated to prevent excessive wear.
 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.
 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.
Use
Recommendation
Load chain
Interval
oil for example: FUCHS RENOLIN PG 220
or special chain lubricant
Use NO grease!
0,2 l
3 month
CAUTION!
Do not use grease for lubrication of load chain.
Without lubrication, manufacturer's warranty and/or liability will be void.
13.2
Pulleys
Use
Recommendation
FUCHS
RENOLIN PG220
Pulleys
13.3




Interval
Acc. to demand
12 month
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
Use
Recommendation
Load hook
bearing
13.4
FUCHS
RENOLIN PG220
Interval
Acc. to demand
12 month
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.
13.5
Trolley
 Trolleys are lifetime lubricated, Refill lubricant is normally not necessary.
5.52.172.00.01.06
15
 Lubricate gear rim and pinion drive each ¼ year or if required more often, with grease.
Use
Recommendation
Pulleys
Gear rim
Drive pinion
FUCHS
RENOLIT FEP2
Travelling gear
If available
SHELL
Tivela S320
13.6
Interval
0,1 kg
3 month
---
Life time
lubrication
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.
13.7
Overload protection
DANGER!
The factory setting of the overload protection/slipping clutch is secured by sealing. In case of any changes
will void the warranty. Should maintenance be necessary, please contact a service company authorized by
the manufacturer.
13.8
Lubricant - Selection
FUCHS
SHELL
ESSO
MOBIL
TOTAL
CASTROL
Renolit FEP 2
Alvania EP 2
Unirex EP 2
Mobilux EP 2
MULTIS EP2
--
KLÜBER
--
Stabylan 5006
--
--
--
--
Optimol Viscoleb 1500
Klüberoil 4UH 1-1500
--
--
--
--
--
--
Wolfracoat 99113
Chain lubricant OKS 451
Lubricant for food industry – Selection (as option*)
13.9
SHELL
MOBIL
Gearing
FM Grease HD2
Mobilgrease FM 222
CASTROL
--
Load chain
--
Lubricant FM 100
Optimol Viscoleb 1500
Load hook;
Pulleys
FM Grease HD2
Gear rim;
Drive pinion
* must be mentioned by order
14
Mobilgrease FM 222
--
KLÜBER
Klüberoil 4UH 1-1500 N
---
Trouble
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.
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.
16
5.52.172.00.01.06
15
Remedy
Problem
Cause
Remedy
Overload
reduce the load to nominal load
load got stuck
set the load free again
Do maintenance and
exchange the brake linings
Align the load chain
Do maintenance and replace defective parts by original
spare parts
Check the pawl and replace it if necessary
brake linings are worn
Load chain is twisted
Load is not lifted
Defect of chain, gear or chain wheels
Pawl does not engage properly
Pawl spring is missing
Overload
It is difficult to lift the load
Dirty chains, gear or chain wheels
Defect of chain, gear or chain wheels
Do maintenance and replace defective parts by original
spare parts
reduce the load to nominal load
Do maintenance, lubricate chains, gear and chain wheels
Do maintenance and replace defective parts by original
spare parts
Do maintenance and replace defective parts by original
spare parts
Do maintenance and replace defective parts by original
spare parts
Load is lifted with interruptions
Pawl spring is missing or defective
Hoist does not lift without load
Brake spring is missing
Hoist does not lift the whole distance long
Brake remains closed
(stuck)
Hook stucks, chain is twisted
The load hook was pulled against the housing and got
stuck there.
Brake too tight
Place hooks and chains in correct position
Release the hook, suspend the load again, lower the load,
unload the hoist.
Lift the brake.
Hoist does not lower the load
Brake too tight due to rust
Replace rusty parts and effect periodic inspection
Load slips down partially during lowering
Foreign-object between the brake discs
Remove the foreign-object, clean the surface
Should the surface show lines, replace the brake disc
Load slips down during lowering
Brake discs are missing, are installed incorrectly or are
worn
Replace the brake discs resp. install them correctly
16
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:
 First secure the working area for decommissioning, leaving plenty of space.
 Read the chapter "Safety instructions".
 Disassembly is carried out in reverse order to the assembly.
 Please make sure that all operating material is disposed of in accordance with environmental regulations.
16.1
Temporary decommissioning
 Measures are as above.
 Also read the chapter “Transport and storage”.
16.2
Final decommissioning/disposal
 Measures are as above.
 After disassembly, ensure that the disposal of the equipment and any materials it contains is carried out
in accordance with environmental regulations.
5.52.172.00.01.06
17
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