4
©
2019 Columbus McKinnon Industrial Products GmbH
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 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
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.
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.
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.
Repairs may only be carried out by authorized specialist workshops that use
original Yale spare parts.
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.
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.
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 (LIFTING chain movement).
• 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.
• Fix the end of the idle fall of the new load chain on the housing or frame (depending
on model) of the hoist.
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 (chain movement UP).
• 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.
• Fix the loose end of the idle fall on the hoist instead of the old load chain.
ATTENTION: The loose end of the idle fall must always be fitted to the chain stop.
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.
Replacing the hand chain
• 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.
• Open the old hand chain (preferably on the connection link) and suspend the open link
into the loose end of the hand chain which lies "in front of" the hand chain wheel.
• Suspend the new hand chain also in the open link and pull it through the chain guides
and over the hand chain wheel.
• Do not fit a twisted chain. The welds must face outwards.
• Separate the old hand chain including the open connection link from the new hand
chain and connect the two loose ends of the new hand chain by means of a new hand
chain connection link.
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.
• Hand chains and 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 chains.
• Since the brake disks may freeze at temperature below 0 °C, the unit should be stored
with closed brake. Turn the hand chain wheel clockwise to this effect and hold the load
fall at the same time.
• 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
Nominalwerte und Verschleißgrenzen / Nominal values and wear limitation
Valeurs nominales et limites d’usure
VS
III
0,25/1 0,5/1
1/1
1,5/1
2/1
2/2
3/1
3/2
5/2
Rundstahlkette / Round link chain / Chaîne à maillons [mm]
4 x 12
5 x 15 6 x 18 8 x 24 8 x 24 6 x 18 10 x 30 8 x 24 10 x 30
Güteklasse / Grade / Grade
T
T
T
T
T
T
T
T
T
Durchmesser / Diameter / Diamètre
d
nom.
d
min.
[mm]
[mm]
4,0
3,6
5,0
4,5
6,0
5,4
8,0
7,2
8,0
7,2
6,0
5,4
10,0
9,0
8,0
7,2
10,0
9,0
Teilung / Pitch / Division
p
n
nom.
p
n
max.
[mm]
[mm]
12,0
12,6
15,0
15,8
18,0
18,9
24,0
25,2
24,0
25,2
18,0
18,9
30,0
31,5
24,0
25,2
30,0
31,5
Meßlänge / Length / Longueur
11 x p
n
nom.
11 x p
n
max.
[mm]
[mm]
132,0
136,0
165,0
170,0
198,0
203,9
264,0
271,9
264,0
271,9
198,0
203,9
330,0
339,9
264,0
271,9
330,0
339,9
Tab. 2
b
h
a
Hakenmaße / Hook dimensions / Dimensions du crochet
VS
III
0,25/1
0,5/1
1/1
1,5/1
2/1
2/2
3/1
3/2
5/2
Hakenöffnungsmaß / Hook opening
Ouverture du crochet
a
nom.
a
max.
[mm]
[mm]
26,0
28,6
30,0
33,0
33,0
36,3
36,0
39,6
40,0
44,0
40,0
44,0
46,0
50,6
46,0
50,6
54,0
59,4
Maß Hakenbreite / Hook width
Largeur du crochet
b
nom.
b
min.
[mm]
[mm]
11,0
10,5
17,0
16,2
19,0
18,1
22,0
20,9
26,0
24,7
26,0
24,7
30,0
28,5
30,0
28,5
40,0
38,0
Maß Hakendicke / Hook height
Hauteur du crochet
h
nom.
h
min.
[mm]
[mm]
12,0
11,4
21,0
20,0
27,0
25,7
33,0
31,4
35,0
33,3
35,0
33,3
43,0
40,9
43,0
40,9
47,0
44,7
Tab. 3
Beschreibung
1 Traghaken mit
Sicherheitsbügel
2 Handraddeckel
3 Lastkette
4 Unterflasche
5 Getriebedeckel
6 Handkette
7 Lasthaken
mit Sicherheitsbügel
8 Kettenanker
9 Handrad
Description
1 Top hook with
safety latch
2 Hand wheel cover
3 Load chain
4 Bottom block
5 Gear cover
6 Hand chain
7 Load hook
with safety latch
8 Chain anchorage
9 Handwheel
Description
1 Crochet de suspension,
linguet de sécurité
2 Capot de protection
3 Chaîne de charge
4 Moufle
5 Carter engrenage
6 Chaîne de manoeuvre
7 Crochet de charge,
linguet de sécurité
8 Arrêt de chaîne
9 Volant de manouvre
2
3
4
9
6
7
8
1
5
VS
III
0,25/1 0,5/1
1/1
1,5/1
2/1
2/2
3/1
3/2
5/2
Tragfähigkeit / Capacity / Capacité
[kg]
250
500
1.000
1.500
2.000 2.000
3.000
3.000
5.000
Anzahl Kettenstränge / Number of chain falls / Nombre de brins
1
1
1
1
1
2
1
2
2
Kettenabmessung d x p
n
/ Chain dimensions d x p
n
Dimensions de la chaîne d x p
n
[mm]
4 x 12
5 x 15 6 x 18 8 x 24 8 x 24 6 x 18 10 x 30 8 x 24 10 x 30
Hub je 1 m Abhaspelung der Handkette
Lift per 1 m hand chain overhaul
Course pour 1 m de chaîne de manoeuvre
[mm]
50,0
33,0
23,0
17,0
18,0
12,0
12,0
9,0
6,0
Hubkraft bei Nennlast
Hand pull at rated load
Effort sur la chaîne de manoeuvre
[daN]
20,0
21,0
28,0
30,0
33,0
29,0
37,0
31,0
35,0
Gewicht bei Normalhub
Net weight at standard lift
Poids net en course standard
[kg]
3,9
9,0
12,2
17,5
19,3
18,2
35,0
29,0
41,0
Tab. 1
