5
©
2019 Columbus McKinnon Industrial Products GmbH
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.
Maintenance of the load chain
In most cases, chain wear in the link points is caused by insufficient care of the chain. In
order to ensure optimal lubrication of the link contact points, lubricate the chain at regular
intervals adapted to the application with creep-type lubricant (e.g. gear oil). A dry film
lubricant, e.g. PTFE spray, should be used in environments where abrasives like sand,
etc., occur. The service life of the load chain can be increased by careful lubrication to 20
- 30 times compared with a chain that is not serviced.
• When lubricating the chain, make sure the chain is in no-load condition so that the oil
can reach the contact points of the chain links which are subject to wear. Chain link parts
contacting each other must always be coated with lubricant, otherwise increased wear
on the chain results.
• It is not sufficient to lubricate the chains on the outside as this does not ensure that a
lubricant film can build up in the contact points.
• With a constant lifting path of the chain, the change-over area from lifting to lowering
movement must be checked in particular.
• Make sure that the load chain is lubricated over its entire length, also including the part
of the chain in the housing of the hoist.
• Clean dirty chains with petroleum or a similar cleaning agent, never heat the chain.
• When lubricating the chain, also check the chain for wear.
ATTENTION: It must be ensured that no lubricant can penetrate into the brake
enclosure. This may result in failure of the brake.
Replacing the load chain
The load chain must be replaced by a new chain of the same dimensions and quality in
the event of visible damage or deformations, however, when the discarding status has
been reached, at the latest. A load chain to be discarded must only be replaced by an
authorized specialist workshop. 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.
NOTE: Replacement of a load chain must be documented!
Hoist with single fall
• Only pull in the new chain in no-load condition.
• An open load chain link is required as a tool. It can be obtained by using an abrasive
wheel to cut a section from an existing link with the same dimension. The length of the
cut section must at least correspond to the thickness of the link.
• Remove load hook from the old load chain and suspend open load chain link in the
loose end of the load chain.
• Suspend the new, lubricated load chain also in the open link and pull it through the hoist
unit (turn hand wheel clockwise).
• Do not fit a twisted chain. The welds must face outwards from the chain wheel.
• When the old load chain has passed through the hoist unit it can be detached together
with the open chain link and the load hook can be fitted on the new load chain just pulled
in.
• Detach the chain stop from the loose end of the old, replaced load chain and fit it to the
loose end of the new load chain just pulled in.
ATTENTION: The chain stop must always be fitted to the loose end of the chain
(idle fall).
Hoist with several falls
ATTENTION: Only pull in the new chain when the bottom block is unloaded,
otherwise the bottom block may drop when the load chain is detached. Danger of
injury!
• An open load chain link is required as a tool. It can be obtained by using an abrasive
wheel to cut a section from an existing link with the same dimension. The length of the
cut section must at least correspond to the thickness of the link.
• Detach the loaded-fall end of the load chain from the housing of the hoist unit or the
bottom block (depending on model).
• Suspend prepared, open load chain link in the now free load chain end.
• Suspend the new, lubricated load chain also in the open link and pull it through the
bottom block and the hoist unit (turn hand wheel clockwise).
• Do not fit a twisted chain. The welds must face outwards from the chain wheel.
• When the old load chain has passed through the hoist unit it can be detached together
with the open chain link.
• Fix the loaded-fall end of the new load chain on the housing/frame or on the bottom
block (depending on model) of the hoist.
• Attach the chain stop to the loose end of the new load chain.
ATTENTION: The loose end of the idle fall must always be fitted to the chain stop
(Fig. 1).
Inspection of the load hook and top hook
Inspect the hook for deformation, damage, surface cracks, wear and signs of corrosion,
as required, but at least once a year. Actual operating conditions may also dictate shorter
inspection intervals.
Hooks that do not fulfil all requirements must be replaced immediately. Welding on hooks,
e.g. to compensate for wear or damage is not permissible. Top and/or load hooks must
be replaced when the mouth of the hook has opened more than 10% or when the nominal
dimensions have reduced by 5% as a result of wear. Nominal dimensions and wear limits
are shown in table 3. If a limit value is reached, replace the components.
Inspection of the brake
Immediately contact the manufacturer, if irregularities are found (e.g. defective friction
disks). All components of the brake must be checked for wear, damage, discoloration
caused by overheating and for functioning.
Friction disks must always be kept free from grease, oil, water or dirt. Check the bonding
of the friction disks.
Repairs may only be carried out by authorized specialist workshops that use
original Yale spare parts.
After repairs have been carried out and after extended periods of non-use, the hoist must
be inspected again before it is put into service again.
The inspections have to be initiated by the operating company.
T
RANSPORT
,
S
TORAGE
,
D
ECOMMISSIONING AND
D
ISPOSAL
Observe the following for transporting the unit:
• Do not drop or throw the unit, always deposit it carefully.
• Load chains must be transported in a way to avoid knotting and formation of loops.
• Use suitable transport means. These depend on the local conditions.
Observe the following for storing or temporarily taking the unit out of service:
• Store the unit at a clean and dry place.
• Protect the unit incl. all accessories against contamination, humidity and damage by
means of a suitable cover.
• Protect hooks against corrosion.
• A light lubricant film should be applied to the chain.
ATTENTION: It must be ensured that no lubricant can penetrate into the brake
enclosure. This may result in failure of the brake.
• Since the brake disks may freeze at temperature below 0 °C, the unit should be stored
with closed brake. For this purpose, move the change-over lever to lifting (
↑
) and operate
the hand lever with a pumping action, while holding the load fall.
• If the unit is to be used again after it has been taken out of service, it must first be
inspected again by a competent person.
Disposal
After taking the unit out of service, recycle or dispose of the parts of the unit in accordance
with the legal regulations.
Further information and operating instructions for download can be found at
www.cmco.eu!
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
