Columbus McKinnon LHP 1000 A Operating Instructions Manual Download

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2019 Columbus McKinnon Industrial Products GmbH

EN - Translated Operating Instructions (Also

applicable for special versions)

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.

ORRECT

PERATION

The hoist is used for lifting, lowering and moving of loads up to the indicated max. load
capacity, with model YLLHP/YLLHG featuring an extremely low headroom.

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  trolley  and  the  load  hook  and/or  the  clevis  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 hoist is suitable for a wide range of beams as well as for various profiles (e.g. INP,
IPE, IPB, etc.) with a max. inclination of the beam flange which does not exceed 14°.

The runway and its supporting structure must be designed for the maximum loads to be
expected (deadweight of the unit + load capacity). The runway must only have a
deflection of max. 1/500 of the span.
The longitudinal gradient of the travel path surface may not exceed 0.3%.

The air gap between the wheel flange and the beam flange ("dimension A") must range
between 1.0 and 2.5 mm on either side of the trolley (depends on model).
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.
Loads suspended from a trolley without a gear drive must be pushed. The load must
not be pulled.

If the area in front of the load is not sufficiently visible, the operator must ensure he is
given help.
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.

Always transport the load in the horizontal direction slowly, carefully and close to the
ground.
When the unit is not in use, position the suspension (e.g. bottom block, hook) above
normal head height, if possible.

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.

NCORRECT

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 unit must never be operated with more than the power of a person.
Welding on trolley, 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 the trolley, the housing or the bottom block is forbidden.
The trolley must be perpendicular above the load at any time.
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.
The following applies for all models with integrated trolleys (YLITP/YLITG and
YLLHP/YLLHG): Loads must not be turned in normal operation, since the trolley has not

been designed for this purpose and the wheel flanges may be pressed against the
beam flange (danger of spark formation!). If loads must be turned in normal operation,
an anti-twist swivel must be used or the manufacturer must be consulted.
Enlarging the adjusted trolley width, e. g. to enable the trolley to negotiate smaller curve

radii, is forbidden.
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 (special models on
request).

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.

Assembly instructions

Yalelift ITP/ITG, LHP/LHG up to 5000 kg

The trolleys are built to fit beam range A or B which is indicated on the identity plate.
Before installation, make sure that the track beam width is within this beam range. The
further procedure for assembly of the unit on the track beams depends on whether the
track beam has an accessible open end or not. If this is the case, it is recommended

that the unit be pre-assembled on the ground and then be pushed onto the open end of
the beam.
1. Unscrew locking nuts (10) and hexagonal nuts (9) from the suspension bolt (1) and
remove both side plates (2) from the trolley.

2. Measure flange width "b" of the track beam.
3. Adjust or pre-adjust dimension "B" between the outer flanges of the round nuts (6) on
the four free threaded ends of the suspension bolts (1). Make sure that the four drill
holes in the round nuts face outwards. Select dimension "B" between the outer flanges

of the round nuts on the suspension bolts in such a way that it corresponds to flange
width "b" plus 4 mm. Ensure that the suspension bar (4) is centered between the round
nuts (6).
4. Assembly of one side plate: The roll pins (7) fitted to the side plate (2) must be

seated in one of the four drill holes of the round nuts (6). If necessary the position of the
round nuts must be slightly re-adjusted.
5. Position the washer (8) and tighten the hexagonal nuts (9). Finally screw on the
locking nuts (10) by hand and tighten by 1/4 to 1/2 rotation.

ATTENTION: The locking nuts (10) must always be fitted!

6. Place the second side plate onto the suspension bolts without tightening. Then screw
on washers (8), hexagonal nuts (9) and locking nuts (10) without tightening to facilitate
assembly.
7. Place the entire pre-assembled unit onto the beam.

ATTENTION: For Yalelift ITG and LHG models, pay attention to the position of the
gear drive (5).

8. Insert the roll pins (7) driven into the second side plate in one of the appropriate four
drill holes of the round nuts (6). If necessary the round nuts must be slightly re-adjusted.
9. Tighten the hexagonal nuts (9) on the second side plate. Finally screw on the locking

nuts (10) by hand and tighten by 1/4 to 1/2 rotation.

ATTENTION: The locking nuts (10) must always be fitted!

10. Check the fitted unit:
• The lateral play dimension "A" must not exceed 2 mm between the wheel flange (3)
and the outer edge of the beam.

• The suspension bar (4) must be positioned centrally between the side plates.
• All nuts (9) and locking nuts (10) must be firmly tightened.

Yalelift ITG 10000 kg and 20000 kg Yalelift LHG 10000 kg

1. Measure the flange width of the beam.

2.  Evenly  distribute  the  spacer  sleeves  and  spacer  washers  on  both  sides  of  the
suspension  bolt  accordingly.  A  clearance  of  2 mm  between  the wheel  flange  and  the
beam flange must be maintained (inner dimension = flange width + 4 mm).
3.  After  adjustment  of  the  inner  dimension,  evenly  distribute  the  remaining  spacer

sleeves and spacer washers on the outside of the side plates on the suspension bolt. In
each case, at least 3 spacer washers and 1 spacer sleeve must be mounted between
the side plates and the castle nut.
Tip: For easier assembly, tighten one side plate. Observe the required position of the

drive side. Only slide on the other side plate without tightening.
4. Then lift the entire unit onto the track beam and firmly tighten all castle nuts.
5. Secure all castle nuts with cotter pins.

ATTENTION: A trolley must never be used on a beam with a flange width that

exceeds the maximum adjustable width of the trolley (observe total clearance of 5
mm, depends on model) or with a profile which does not correspond to the
profile the trolley has been designed for.

Shorten or extend the hand chain

Adjust the length of the hand chain so that the distance of the lower end to the floor is
between 500 – 1000 mm.

NOTE: For safety reasons, hand chain links may only be used once.

• Look for the non-welded link of the hand chain, bend to open and discard it.
• Shorten or extend the chain to the required length.

ATTENTION: Always remove or add an even number of chain links.

• Use a new link to close the loose chain ends by bending it (for extending the hand
chain, two new chain links are required).

ATTENTION: Make sure that hand chains are not twisted while they are fitted.

NSPECTION

EFORE

NITIAL

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.

NSPECTION

EFORE

TARTING

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 chain 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

Inspection of the trolley

• The side plates must be parallel to each other.
• All wheels must be in contact with the beam flange.

ATTENTION: The trolley must never be used on beams with flange widths that
exceed the maximum adjustable width of the trolley.

Checking the travel path

Before starting work, check the unit for faultless passage on the beam. Any existing
obstacles must be eliminated.

In addition, check the correct fastening and position of the end stops.

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 load hook and top hook (if fitted)

The load hook and - if fitted - the top hook 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.

Inspection of the hand chain length

Adjust the length of the hand chain so that the distance of the lower end to the floor is
between 500 – 1000 mm.

Function check

Before start-up, check that the chain drive is working in the unloaded condition.

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.

Lifting the load

Pulling the hand chain in clockwise direction will raise the load.

Attention: Depending on the type of load picked up, note that the lifting height

may be reduced for models with chain container!

Lowering the load

Pulling the hand chain in anticlockwise direction will lower the load.

Fitting the hand chain on the trolley

(models Yalelift ITG and LHG only and models with locking device)
To fit the hand chain, position the slot in the outer edge of the hand chain wheel below
the chain guides. Place one link of the endless hand chain vertically into the slot and
turn the hand chain wheel until the hand chain has passed the chain guides on both

sides.

ATTENTION: Do not twist the hand chain while fitting.

Travelling the push-type trolley

The push-type trolley is actuated by pushing the attached load or the suspended load
lifting attachment. It must not be pulled.

Travelling the geared-type trolley
Geared-type trolleys are moved by pulling the appropriate hand chain fall.

Operation of the locking device (optional for models with integral trolley)

The locking device is exclusively used for easily locking the unloaded trolley (parking
position in the shipping sector, for example). The brake shoes are pressed against the
beam flange by pulling on the appropriate hand chain fall so that the chain wheel turns
clockwise. Only tighten the chain by hand for this process. The locking device is

released again by pulling on the other chain fall.

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.

NSPECTION

ERVICE

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.

Modell YLITG