4
©
2019 Columbus McKinnon Industrial Products GmbH
EN - Translated Operating Instructions (Also
applicable for special versions)
I
NTRODUCTION
Products of CMCO Industrial Products GmbH have been built in accordance with the
state-of-the-art and generally accepted engineering standards. Nonetheless, incorrect
handling when using the products may cause dangers to life and limb of the user or
third parties and/or damage to the hoist or other property.
The operating company is responsible for the proper and professional instruction of the
operating personnel. For this purpose, all operators must read these operating
instructions carefully prior to the initial operation.
These operating instructions are intended to acquaint the user with the product and
enable him to use it to the full extent of its intended capabilities. The operating
instructions contain important information on how to operate the product in a safe,
correct and economic way. Acting in accordance with these instructions helps to avoid
dangers, reduce repair costs and downtimes and to increase the reliability and lifetime
of the product. The operating instructions must always be available at the place where
the product is operated. Apart from the operating instructions and the accident
prevention act valid for the respective country and area where the product is used, the
commonly accepted regulations for safe and professional work must also be adhered
to.
The personnel responsible for operation, maintenance or repair of the product must
read, understand and follow these operating instructions.
The indicated protective measures will only provide the necessary safety, if the product
is operated correctly and installed and/or maintained according to the instructions. The
operating company is committed to ensure safe and trouble-free operation of the
product.
C
ORRECT
O
PERATION
The unit is used for lifting, lowering, pulling and tensioning of loads.
The unit is also suitable for lashing of loads on trucks etc. on public roads according to
EN 12195. Tensioning force STF and hand force SHF, which are indicated on the
identity plate, must be taken into account.(
→
Tab. 1).
ATTENTION: The unit may be used only in situations in which the load carrying
capacity of the device and/or the supporting structure does not change with the
load position.
Any different or exceeding use is considered incorrect. Columbus McKinnon Industrial
Products GmbH will not accept any liability for damage resulting from such use. The
risk is borne by the user or operating company alone.
The load capacity indicated on the unit is the maximum working load limit (WLL) that
may be attached.
If the hoist is to be used for frequent lowering from large heights or in indexed
operation, first consult the manufacturer for advice because of possible overheating.
The top hook and the load hook of the unit must be in a vertical line above the load
centre of gravity (S) when the load is lifted, in order to avoid load sway during the lifting
process.
The selection and calculation of the appropriate supporting structure are the
responsibility of the operating company.
The attachment point and its supporting structure must be designed for the maximum
loads to be expected (deadweight of the unit + load capacity).
The operator must ensure that the hoist is suspended in a manner that makes it
possible to operate the unit without exposing himself or other personnel to danger by
the unit itself, the suspension or the load.
The operator may start moving the load only after it has been attached correctly and all
persons are clear of the danger zone.
Do not allow personnel to stay or pass under a suspended load.
A lifted or clamped load must not be left unattended or remain lifted or clamped for a
longer period of time.
The hoist may be used at ambient temperatures between –10° and +50°C. Consult the
manufacturer in the case of extreme working conditions.
ATTENTION: Before use at ambient temperatures of less than 0°C, check the
brake for freezing by lifting and lowering a small load 2 - 3 times.
Prior to operation of the hoist in special atmospheres (high humidity, salty, caustic,
alkaline) or handling hazardous goods (e.g. molten compounds, radioactive materials),
consult the manufacturer for advice.
For attaching a load, only approved and certified lifting tackle must be used.
Correct operation involves compliance with the operating instructions and in addition
also compliance with the maintenance instructions.
In case of functional defects or abnormal operating noise, stop using the hoist
immediately.
I
NCORRECT
O
PERATION
(List not complete)
Do not exceed the rated load capacity (WLL) of the unit and/or the suspension and the
supporting structure.
The unit must not be used for pulling free fixed loads. It is also prohibited to allow loads
to drop when the chain is in a slack condition (danger of chain breakage).
Removing or covering labels (e.g. by adhesive labels), warning information signs or the
identity plate is prohibited.
When transporting loads ensure that the load does not swing or come into contact with
other objects.
The load must not be moved into areas which are not visible to the operator. If
necessary, he must ensure he is given help.
Driving the unit with a motor is not allowed.
The lever must not be extended. Only original hand levers must be used.
The unit must never be operated with more than the power of a person.
Welding on hook and load chain is strictly forbidden. The load chain must never be
used as a ground connection during welding.
Side pull, i. e. side loading of either the housing or the bottom block is forbidden.
The load chain must not be used as a chain sling.
A unit changed without consulting the manufacturer must not be used.
Do not use the hoist for the transportation of people.
Do not knot the load chain or connect it by using pins, bolts, screw drivers or similar. Do
not repair load chains installed in the hoist.
Removing the safety latches from top and/or load hooks is forbidden.
Never attach the load to the tip of the hook. The lifting tackle must always be seated in
the saddle of the hook.
Do not use the chain stop as an operational limit device.
Turning of loads under normal operating conditions is not allowed, as the bottom blocks
of the hoists are not designed for this purpose. If loads must be turned in normal
operation, an anti-twist swivel must be used or the manufacturer must be consulted.
Only one load lifting attachment may be suspended in the load hook of the hoist.
Never reach into moving parts.
Do not allow the unit to fall from a large height. Always place it properly on the ground.
The unit must not be used in potentially explosive atmospheres.
A
SSEMBLY
Inspection of the attachment point
The attachment point for the hoist must be selected so that the supporting structure to
which it is to be fitted has sufficient stability and to ensure that the expected forces can
be safely absorbed.
The unit must align freely also under load in order to avoid impermissible additional
loading.
The selection and calculation of the appropriate supporting structure are the
responsibility of the operating company.
I
NSPECTION
B
EFORE
I
NITIAL
O
PERATION
Prior to initial operation, before it is put into operation again and after substantial
changes, the product including the supporting structure must be inspected by a
competent person*. The inspection mainly consists of a visual inspection and a function
check. These inspections are intended to establish that the hoist is in a safe condition,
has been set up appropriately and is ready for operation and that any defects or
damage are detected and eliminated, as required.
*Competent persons may be, for example, the maintenance engineers of the
manufacturer or the supplier. However, the company may also assign performance of
the inspection to its own appropriately trained specialist personnel.
Before putting the unit into operation, check functioning of the chain drive in unloaded
condition.
I
NSPECTION
B
EFORE
S
TARTING
W
ORK
Before starting work, inspect the unit including the suspension, equipment and
supporting structure for visual defects, e. g. deformations, superficial cracks, wear and
corrosion marks. In addition also test the brake and check that the hoist and the load
are correctly attached.
Checking the brake function
Before starting work, always check operation of the brake:
To do this, lift, pull or tension and lower or release a load over a short distance with the
unit. When the hand lever is released, the load must be held in any position.
This check is intended to ensure that even at temperatures below 0°C, the brake disks
are not frozen. Repeat it at least twice, before starting further work.
ATTENTION: If the brake does not function properly, the unit must be
immediately taken out of service and the manufacturer must be contacted!
Inspection of the attachment point
The attachment point for the hoist must be selected so that the supporting structure to
which it is to be fitted has sufficient stability and to ensure that the expected forces can
be safely absorbed.
The unit must align freely also under load in order to avoid impermissible additional
loading.
The selection and calculation of the appropriate supporting structure are the
responsibility of the operating company.
Inspection of the load chain
Inspect the load chain for sufficient lubrication and check for external defects,
deformations, superficial cracks, wear and corrosion marks.
Inspection of the chain stop
The chain stop must always be fitted to the loose chain end. There must be no wear or
incorrect alignment.
Inspection of the top hook and load hook
The top resp. load hooks must be checked for cracks, deformations, damage, wear and
corrosion marks. The safety latch must move freely and be fully functioning.
Inspection of chain reeving in the bottom block
All units with two or more chain falls must be inspected before initial operation to ensure
that the load chain is not twisted or kinked. The chains of hoists with two or more falls
may become twisted if the bottom block is rolled over, for example.
When replacing the chain, make sure that the chain is reeved correctly. The chain weld
must face outwards.
Only fit load chains which have been approved by the manufacturer. Non-compliance
with this specification will render the legal warranty or guarantee void with immediate
effect.
Function check
Before start-up, check that the chain drive is working in the unloaded condition.
O
PERATION
Installation, service, operation
Operators delegated to install, service or independently operate the hoist must have
had suitable training and be competent. Operators are to be specifically nominated by
the company and must be familiar with all relevant safety regulations of the country of
use.
Releasing the chain
Turn pawl rod lever to neutral (central) position. The chain can now be pulled in both
directions and the load chain fall will be quickly tensioned.
Attention: The minimum load to engage the automatic brake lies between 30 and
45 kg.
Usage of the ERGO-Lever
If the integrated handle at the lever should be used, it can be folded into the forward or
backward position. The handle will click into place with a clearly audible snapping
sound. The conical seating of the handle shall be free of dirt at all times. If necessary
the seating has to be cleaned just as well as the associated parts.
To move the handle back into its starting position the handle has to be pulled forwards
out of its conical seating and simultaneously tilted back inside the lever. To do so the
gripping surfaces of the handle should stay parallel to the slot inside the handle. The
handle will be held in its position by spring load.
Lifting the load
Pull the rerwardpawl rod lever along its axis backwards and tilt to position "
↑
". Make
sure that the lever will click exactly into place.
Operate hand lever with pumping action. If work is stopped while the hoist is still under
load, the pawl rod lever must remain in the lifting position "
↑
".
Lowering the load
Pull the rerwardpawl rod lever along its axis backwards and tilt to position "
↓
". Make
sure that the lever will click exactly into place.
Operate hand lever with pumping action.
Brake jamming
lf a hoist, which is under load, is suddenly relieved of load pressure, e.g. by lifting off the
load or when pulling down walls, and lowering has not been initiated first, the brake will
remain locked. The brake will also lock if the load hook with the bottom block is pulled
too tightly against the housing.
Releasing the jammed brake
Turn pawl rod lever to the lowering position "
↓
" and operate hand lever with a vigorous
stroke. lf the brake is jammed on extremely tight, it can be released by striking the hand
lever.
Yale overload protection device (optional)
The overload protection device is set to approx. 25% (±15%) overload. Its adjustment
must only be carried out by a competent person.
When the load limit is exceeded, the overload protection device is activated and
prevents further lifting of the load, lowering is still possible.
I
NSPECTION
,
S
ERVICE
&
R
EPAIR
According to national and international accident prevention and safety regulations
hoisting equipment must be inspected:
• in accordance with the risk assessment of the operating company
• prior to initial operation
• before the unit is put into service again following a shut down
• after substantial changes
• however, at least once per year, by a competent person.
ATTENTION: Actual operating conditions (e.g. operation in galvanizing facilities)
can dictate shorter inspection intervals.
Repair work may only be carried out by a specialist workshop that uses original Yale
spare parts. The inspection (mainly consisting of a visual inspection and a function
check) must determine that all safety devices are complete and fully operational and
cover the condition of the unit, suspension, equipment and supporting structure with
regard to damage, wear, corrosion or any other alterations.
Initial operation and recurring inspections must be documented (e.g. in the CMCO
works certificate of compliance).
If required, the results of inspections and appropriate repairs must be verified. If the
hoist (from 1 t lifting weight) is fitted on or in a trolley and if the hoist is used to move a
lifted load in one or several directions, the installation is considered to be a crane and
the further inspections must be carried out, as required.
Paint damage should be touched up in order to avoid corrosion. All joints and sliding
surfaces should be slightly greased. In the case of heavy contamination, the unit must
be cleaned.
The unit must be given a general overhaul after 10 years, at the latest.
In particular, check the dimensions of the load chain, the load hook and the top hook.
ATTENTION: After the replacement of components, a subsequent inspection by a
competent person is obligatory!
Inspection of the load chain (acc. to DIN 685-5)
Load chains must be inspected for mechanical damage at annular intervals, however
after 50 operating hours, at the latest. Inspect the load chain for sufficient lubrication
and check for external defects, deformations, superficial cracks, wear and corrosion
marks.
Round-section steel chains must be replaced when the original nominal thickness ´d´
on the chain link with the worst wear has been reduced by more than 10% or when the
chain has elongated over one pitch ´pn´ by 5% or over 11 pitches (11 x pn) by 3%.
Nominal dimensions and wear limits are shown in table 2. If one of the limit values is
reached, the load chain must be replaced.
1.
2.
CLICK
CLICK
K
CLICK
CLICK
C
1.
2.
p
n
11 x
p
n
d
d = Nenndicke der Kette / Nominal thickness of chain
Epaisseur nominale de la chaîne
d
1
, d
2
= Istwert / Actual value / Valeur réelle
d
1
+ d
2
d
min.
=
≤ 0,9 d
2
d
1
d
2
