Operating and Maintenance Manual. HADEF Spur Gear Hoist Type 9/98

Transcription

1 edition /sq GB Operating and Maintenance Manual HADEF Spur Gear Hoist Type 9/98 Explosion proof configuration Warning : no use at gases classified into group IIC 1

2 Contents 1. General Information page 3 2. Product Description page 4 3. Explosion proof configuration page 4 4. Design page 6 5. Functional Description page 6 6. Technical Data page 7 7. Important Components page 8 8. General Safety Instructions page 9 9. Transport and Storage page Installation page Commissioning page Load chain page Load hook page Safety and Functional checks page Use and Operation page Help with problems page Servicing and Maintenance page Decommissioning page Additional information page 21 2

3 1. General Information Dear customer, you have made your choice for a high-quality HADEF product. It fullfills the requirements of the EU, and in particular the EU Machine Directives (98/37/EG). Our entire company works according to a certified quality assurance system as per EN ISO 9001:2000. In order to ensure flawless and trouble-free functioning of the unit for you, it is necessary that you read these operating instruction thoroughly and fully before the initial start-up and commissioning. These operating instructions help you to put the units into operation with due regard to the relevant regulations. They include information to be followed concerning set-up, commissioning, operation, use and maintenance and thus ensure that the units can be operated safely and stay in good condition. Production of the individual components is subject to constant strict intermediate inspections by HADEF. Each HADEF product is subject to an overload of 25% or 50% after assembly at the final inspection. In general, when using lifting gear, the stipulations of accident prevention regulations BGV D8 (VBG8), BGV D6 (VBG9) and VBG9a (among others) apply in Germany. HADEF hoists for use in areas at risk from explosion fullfil all recent regulations and rules in accordance with their prevailing class of explosion. These regulations are e.g. ATEX 95 ( EU Machine Directives 94/9/EG ), ExVo, BGR 104, Zh1/200, followed by DIN EN and pr DIN EN We wish to refer to the stipulated tests and checks for the units before initial start-up and commissioning, before starting up again after a period of disuse, and the routine scheduled checks. In other countries the national regulations applicable there should also be taken into consideration. The stated performance of the units and meeting any claims made under warranty require that you comply with all the details given in these instructions. HADEF products are suitably packed before being shipped out. For that reason we request you to check the goods for damage in transport on receiving them and to make any complaints at once to the transport company. We wish you all the best with your HADEF product 3

4 2. Product Description 2.1 Appropriate Use The appropriate use for these units is vertical lifting and lowering of loads that are not guided. It is forbidden to use these hoists in an area where there is IIC gases! Trolleys with non-positive drive units (such as rack and pinion gear) can also move the load on inclined beams (max. inclination approx. 4 to 8 for the beam. Pulling fixed loads loose, pulling loads along the ground and pulling at an angle are prohibited The permissible maximum loading of the units may not be exceeded! The exception to this is any load testing carried out before initial start-up and commissioning by an expert as per the German accident prevention regulations BGV D6 (VBG9) It is not permitted to carry people with these units! Do not allow anyone to stand under a suspended load Use of the hoist in explosive area is only allowed within the classified group or a lower lower group that is mentioned on each Ex-plate! The owner may only trust the setting-up, maintenance and independent operation of the units to person who have been suitably trained and can be trusted to work properly! Only resume work with defective units and lifting tackle once they have been serviced! Only use original HADEF spare parts. All claims under warranty with respect to HADEF shall be null and void if these stipulations are not complied! All liability and warranties are null and void if the user makes unauthorised changes to the units on his own initiative! If the units are not used appropriately, it is not possible to ensure safe operation. The owner and operator have sole liability for all personal injury and damage to property arising from inappropriate use. 3. HADEF EX Proof Configuration HADEF Ex-Hoists are suitable for the following maximum operation conditions and must only be used for these classifications or lower classifications. EX- classification of the hoist is mentioned on a special EX-type plate. EX II 2G IIB T4 for gas EX II 3G IIB T4 for gas EX II 2D 135 C for dust EX II 3G 135 C for dust EX IIA 3G T2 EX IIA 3D 135 C 4

5 example: EX classification: EX II 3G II A T2 EX II 3D 300 C explosion proof equipment equipment class equipment category explosive mixture: gas/dust class of hazard of gases,only temperature class 3.1 EX- classification EX-zone 2 1 Equipment category 3 2 Class of hazard of gases IIA+IIB IIA + IIB Temperature class- gas Temperature class- dust T1-T4 at C T1-T4 at C Classification of the hoist is mentioned on its type plate. Only use the hoist for the class mentioned hereon. Use of the hoist in a lower class is also possible. 3.2 Surface treatment of the hoists When operating the hoist pay attention to the stipulated temperature class and never exceed the max.surface temperature of the hoists. Maximum surface temperature of the hoist must always be lower than the ignition temperature of the gas/exhaust air mixture.it is possible to use the hoists in lower temperature classes if they are classified for higher temperature classes. Our hoists are not suitable for temperature class T5 for gas/air mixtures and for temperature class T6 i.e. carbon disulphide ( IIC) as this applies seldomly, only. Temperature class Ignition temperature of gases C T1 > T2 >300 < T3 >200 < T4 >135 < T5 >100 < T6 >85 < max. surface temperature of hoist C 5

6 3.3 EX -Zone Areas with explosion hazard are classified into zones. Information about explosion zones are given in IEC and in the national standard. The following table shows the zones in relation to the equipment category. gas mist steam 4. Design Equipment category dust Equipment category Existing explosive atmosphere Zone 0 1G Zone 20 1D permanently long lasting or often Zone 1 2G Zone 21 2D from time to time Zone 2 3G Zone 22 3D G= gas D= dust Seldomly or shortly HADEF Spur Gear Hoists for stationary use are fitted with a suspension hook. They can optionally be combined with monorail push travel or hand geared trolley. Trolley and hoist is operated through a hand chain. Units acc. to table 1 up to a capacity of kg/4-falls Units acc. to table 2 capacity kg/2-falls and more 5. Functional Description The load is lifted or lowered by pulling the endless hand chain of the hoist unit. The incorporated load pressure brake holds the load when the hand chain is released. The unloaded hook can be moved by pulling the hand chain. 6

7 Suspension hook Hand chain wheel Load hook 6. Technical Data table 1 capacity (kg) Number of chain falls Load chain (mm) 5x15 6,3x19,1 8x24 6,3x19,1 8x24 10x30 10x30 Lift at 30 m hand chain (mm) Hand chain pull for lifting approx. (dan) Weight at 3 m suspension height 8,9 12,2 19,6 13,6 27,0 42,0 105,0 approx. (kg) Weight per add. suspension height 1,5 1,8 2,3 2,7 3,7 5,5 9,7 (kg) Subject to changes table 2 capacity (kg) Number of chain falls x3 2x4 2x5 Load chain (mm) 13x36 Lift at 30 m hand chain approx. (mm) Hand chain pull for lifting approx. (dan) x33 2x35 2x37 Weight at 3 m suspension height (kg) Weight per add. m suspension height 8,6 12,4 16,2 20,0 24,8 32,4 40,0 (kg) Subject to changes 7

8 7. Important Components 7.1 Load pressure brake The load pressure brake holds the load safely in every position. It is fitted with hardened pawls and asbestos-free brake linings. The load pressure brake also actuates if the overload protection of the hoist is in action Operating Time ( OT ) The following working cycles must not be exceeded: light duty (seldom lifting of heaviest load ): normal duty ( seldom lifting of heaviest load ): severe duty ( permanently lifting of heaviest load ): 60 minutes 30 minutes 15 minutes Let the hoist stand still after this lifting period for at least 15 minutes to cool down the brake of the lifting unit. 7.2 Housing The housing of the hoist is made of steel plate. 7.3 Load chain The load chain used is acc. to DIN Since the individual components of the chain drive precisely match to eachother, only original chains should be used to guarantee correct function. 7.4 Overload protection The hoist is fitted with a slipping-clutch as overload protection. It protects the hoist from damage in case of overload by immediate stop of the lifting movement. The present load must be lowered and reduced before lifting again. 7.5 Special components and surface treatment The hoists have been made suitable to operate in areas at risk from explosion through special treatment of surfaces and/or exchange of standard materials against special materials. 8

9 8. General Safety Instructions 8.1 Requirement for due care by the user The units were designed and constructed with regard to a risk analysis and after a careful check of the harmonized standards to be complied with and also a number of additional technical specifications. It therefore complies with current state of technology and ensures a maximum degree of safety. The safety can only be attained in operational use if all necessary measures have been complied with. The user/owner of the units is required to show due care in planning these measures and checking that they are carried out. The user/owner of the units is obliged to classify the working areas into Ex-zones. This classification should be done in accordance with all recent and valid rules and regulations for hazardous areas at risk of explosions. The user must ensure in particular that the unit is only used appropriately ( see the Product Description section ) The unit is only to be used when it is in a flawless and fully functional condition, and in particular, the safety devices must be regularly checked to see that they function properly The necessary personal protective equipment for operation, maintenance and repair personnel is always available and used The operating manuals are always kept in full and in a legible condition at the place of use of the equipment Only qualified and authorised personnel may operate, maintain and repair the unit The personnel are regularly instructed in all relevant matters concerning the safety of work and the protection of the environment and also must be familiar with the operating instructions, in particular with the safety instructions given in them If applicable, any safety and warning information applied to the unit may not be removed and also must remain legible Explanation of the safety symbols used The following safety symbols are used in these operating instructions. These symbols are intended to bring the adjacent safety information given in the text to the attention of the reader. This symbol means that there are potentially lethal hazards or risks of injuries to persons and also risk of damage to the unit or other items. This symbol indicates the danger of injury or death when standing under suspended loads This symbol indicates danger of injury of inproper use of hoists used in explosive atmosphere. This symbol flags useful additional information, notes and tips for use. 9

10 8. 3 Recognize and prevent the danger of explosion does inflammable material exist yes No No protective measures against explosion necessary Can a gas/air mixture arise in a concentration that may lead to explosion yes No No protective measures against explosion necessary Find out where the origin of the gas/air mixture is and how the concentration is Is there the danger that hazardous explosive atmosphere may emerge yes No No protective measures against explosion necessary It is necessary to undertake suitable steps to prevent explosion! Prevent, as far as possible, that hazardous explosive atmosphere emerges! Is it totally prevented that hazardous explosive atmosphere emerges No yes No further protective measures against explosion necessary It is necessary to undertake further suitable steps to prevent explosion! Hazardous, explosive atmosphere exists Always, long lasting or often from time to time seldomly and for a short time by gas, steam or mist Zone 0 Zone 1 Zone 2 by dust Zone 20 Zone 21 Zone 22 Preventing ignition sources* Gas, steam, mist or dust with normal, troublefree operation and with anticipated trouble with seldomly occuring trouble with normal, troublefree operation and with anticipated trouble with normal, troublefree operation *please take into account that settled dust can also ignite in zones 20,21 and 22 Is it safely prevented that hazardous, explosive atmosphere occurs N0 yes No protective measures against explosion necessary It is necessary to undertake further suitable steps to prevent explosion! Take measures that reduce effects of an explosion to a negligible minimum 10

11 8.4 Basic safety information The units are solely to be used to move items. Under no circumstance may person be carried. In any case ensure that nobody stands unnecessary under suspended load. We wish to refer to the relevant stipulations of the accident prevention regulations ( German UVV) and to the relevant national regulations that apply outside of Germany. Ensure that the building walls, ceilings or other structures to which the units are built on, suspended or installed have an adequate stability before installing and first using the units to ensure that the unit can carry any possible load and also its own weight with safety. If there is any doubt, consult a structural engineer! Check that the brakes function properly each day before starting work! After long periods of disuse, check all the functional important parts such as chains, load hooks a.s.o. before using a unit again by means of visual check and replace any damaged parts against new original HADEF spare parts. Make sure with multi-strands configuration in particular that the load chain is not twisted. Twisted chains must be aligned properly before the load is suspended. It is possible to see that the chain links are aligned properly from the welds. They must always line up in one direction. The vertical chain links must always line up in one direction. Do not make any changes or alterations to HADEF units. Anything added on must not affect proper safety and functionning! Any damage or defects must be reported immediately to a responsible superior. Do not use the units until the damage or deficiency has been corrected! If the unit is put into motion, any person in the immediate vicinity must be informed of this fact by calling them! Never load the units beyond the stipulated permissible maximum loading capacity! 11

12 Never use the load chain as a sling and never pull the chain around sharp corners! Do not side-pull. Lift all loads vertically! Do not drag loads or pull off loads that are stuck! Motor drive of manual hoists is not permitted! Stop lowering the load once the bottom block or the load have been put down or prevent it from being lowered further! The units are not designed to sustained operation and to avoid an overheating of the brake discs. The following working cycles must not be exceeded: Light duty( seldom lifting of heaviest load ) = 60 minutes Normal duty ( lifting of light, medium and heavy loads ) = 30 minutes Severe duty (permanent lifting of heaviest load = 15 minutes Let the hoist stand still after this lifting periods for at least 15 minutes to cool down the brake of the lifting unit. The lifting tackle of the load must be securely suspended from the load hook and placed right into the hook itself. The safety catch of the hook must always be closed to prevent the lifting tackle or the load from slipping out of the load hook! The units are solely to be used with due regard to all recent national rules and regulations, information given in this operating manual and in accordance with their prevailing class of explosion. Read the Product Description section. Even in case of insignificant wear of surface treated parts such as chains a.s.o, these parts must be replaced by new original HADEF spare parts. Never straighten damaged hooks ( e.g. by blow of a hammer ) but replace them by original hooks. Protect the hoist against inflammable dust deposit. Clean the unit every day from dust and make sure that there is no dust between the movable parts. It is forbidden to clean the hoist by blowing off with compressed air. Overhaul and repair works must be carried out in a non-explosive atmosphere! It is essential that the operating personnel wear appropriate shoes, clothes and glowes. Glowes must have a derivation of < 10 8 Ω. It is forbidden to take off clothes in areas of risk from explosion. Routine- checks supported by operative checks must be carried out to make sure that the surface temperature of the units falls short of the permissible surfacge temperature indicated on the Ex-type plate. Temperature increase caused by heat accumulation or chemical reaction must be taken into account. Protect the unit against shock, friction, hard treatment and humidity. 12

13 Friction linings must be exchanged in time; check and lubricate all bearing regularly. Make sure that the area is force-ventilated sufficiently to minimate the grad of disposition as far as possible. 8.5 Requirements for the operating personnel Only entrust suitable person who have been appropriately trained to use the equipment independently. They must be autorised by the owner to use the equipment. The owner must ensure that the operating instructions are available and easily accessible for the operating personnel. 9. Transport and Storage 9.1 Transport HADEF lifting units are checked and properly packed before delivery. They are not to be thrown or dropped. Please use suitable means of transport. The transport and means of transport should depend on the local circumstances. Transport work should be done by suitably qualified person with due regard to the appropriate safety information 9.2. Storage If the unit is not be put into operation immediately or if there are longer breaks in operation, ensure that it is stored in a clean place and protect the unit against dirt, damp and damage by using suitable coverings. Prevent the chains, hook and brakes from being attacked through damage by corrosion. Units that show slight corrosion must immediately be taken out of operation. 10. Installation In order to avoid damage or serious injury when setting up the unit, the following points must be complied with without fail: The setting-up work assembly and installation of the unit may only be done by suitably qualified person with due regard to the safety information The unit is to be checked for damage in transport before starting the installation and assembly work. Installation and dismantling works must be carried out in a non-explosive atmosphere! Also read the General Safety Information section. Suspend the unit in such a way that it moves freely 13

14 If a hoist with trolley is used, please also pay attention to the operating and maintenance manual for the trolley. Other hoists or transport equipment (i.e. pallett trucks, lifting platforms,etc.) used for installation must hold the weight of the equipment safely. End stops must be fitted to both ends of the trolley track way. The end stops must be placed so that the elastic trolley end stops ( optional ) or the surfaces of the trolley wheels drive against these track way end stops when they reach the end of the track. Other hoists or transport equipment ( i.e. fork lifts, lifting platforms, a.s.o.) used for installation must hold the weight of the equipment Installation instructions Installation must be done in accordance with the space available. Suspend the hoist so that it can balance itself freely Make sure that supporting structures and load-attached devices used in connection with the hoist are stable enough. In case of doubt consult a structural engineer. 11. Commissioning The equipment must be inspected by an expert before commissioning and regularly during operation, - at least once a year! Please observe the national regulations for inspections valid in the country of use. (in Germany the BGV D8 (VBG 8), BGV D6 (VBG 9) and VBG 9a must be adhered) 11.1 Environmental Conditions The units should be operate indoors. If they are used in the open, either a protective roof should be provided or else units should be covered. Nevertheless, the best way to protect the hoist from malfunctionning is to use it regularly. 12. Load Chain The load chain must not be twisted or knotted. Is this the case, the load chain must be aligned properly before the load is suspended. The load chain is to be lubricated with motor oil ( no grease ) when it is not under load before the initial start-up and commissioning. It is important that the oil gets between the links of the chain so that wear from friction can be kept as low as possible. If necessary, the chain must be cleaned before lubrication. Long-term good lubrication considerably increases the life of the chain compared to dry running. Use a dry lubricant such as graphite powder in case of environmental conditions that increase wear ( sand, etc.). A special lubricant can be ordered from HADEF if the hoists are being used in the food industry. 13. Load Hook The safety catch of the load hook must be able to move freely and close by itself. It is essential to read the safety instructions. 14

15 14. Safety and Functional Check 14.1 Safety Check Before the initial start-up or if starting again after a long period of disuse, it is essential to check that: all fastening screws have been done up and locked, the chains have been arranged correctly, have been lubricated and are in good condition there is no corrosion the surface treated parts have enough thickness 14.2 Functional check It is essential to check the following functions before the initial start-up and commissioning and before starting again after a long period of disuse: 14.3 Checks before the first start-up General Check Clean the unit from dust every day! It is not permitted to use compressed air! Check the unit for corrosion and abrasion of the surface coating. Even in case of insignificant abrasion and/or slight corrosion, the unit must be taken out from work immediately. Manual drive - lifting unit Make sure that the hand chain for lifting hang freely from the hoist and that it is not twisted. Lifting unit Lubricate the load chain before it is loaded for the first time, using motor oil or suitable chain lubricant. Ensure that the load chain is not twisted. functional check Check the function lifting lowering of the hoist when it is not under load. Check the function of the brake under load. It is correct when the load is hold safely after releasing the hand chain. 15. Use and Operation 15.1 Operation It is essential to check the following points: Only entrust suitable persons who have appropriately trained to use the equipment independently. They must be authorised by the owner to use the equipment. The owner must ensure that the operating instructions are available and easily accessible for the operation personnel Lifting and lowering by pulling the hand chain:. - lifting: hand chain wheel turns clockwise (right ). - lowering: hand chain wheel turns vice versa (left ). 15

16 15.2 Use It is essential to check the following points: Read the safety information Never load the units beyond the stipulated permissible maximum loading capacity! Ensure that the units are free of dust. Clean the unit from dust every day! Ensure that brake discs are clean and free of grease The stipulated inspection and maintenance intervals must be strictly observed! The lifting tackle or the load must be securely suspended from the load hook and placed right into the hook itself. The safety catch of the hook must always be closed. Do not stand under suspended loads! 16. Help with Problems In order to avoid damage or severe injuries when correcting problems with the unit, the following points must be followed: Only deal with a problem if you have the suitable qualification that is required for this job. Secure the working area of the moving parts of the unit. Read the section "General safety instructions". You can find information on dealing with problems within the table troubleshooting. Please also contact our service department concerning troubleshooting.problems due to wear or damage to components such as chains, chain sprockets, axles, bearings, brake discs a.s.o. are to be corrected by replacing the defective parts with original spare parts 17. Servicing and Maintenance 17.1 General All test results and actions taken are to be kept in writing! All monitoring, maintenance and servicing work is intended to secure safe operation of the units. The work is to be carried out with extreme care. The work must be carried out by suitably qualified personnel. The work must be carried out as far as possible when there is no load but in any case in non-explosive atmosphere. 16

17 17.2 Inspection and Maintenance The stipulated inspection and maintenance intervals apply for normal conditions and singleshift operation. If the conditions of use are more severe ( e.g., frequent operation under full load ) or due to special environmental conditions ( e.g., heat, dust a.s.o.) the intervals must be shortened suitably. Inspection intervals On commissioning daily checks Check screw and bolt X connections Check the function of the brake X X Check the thickness of brake discs Check the surface treatment of load chain for wear Clean and lubricate the load chain Check the load chain for elongation and wear Check the surface treatment of hand chain for wear Check the load hook for cracks and deformation Check the lubrication of all bearings X 1rst maintenance after 1 year Check, maintenance every month X X X X X X X X X X Check every 12 months X 17.3 Scheduled Checks Regardless of the regulations of the relevant countries, HADEF lifting units must be checked at least once a year by a suitably qualified person ( or by a person with suitable qualifications for cranes ) to check their functional safety. In Germany the accident prevention regulations are to be complied with. In other countries the relevant tests and national safety regulations shall apply 17.4 Checking the load chain In the case of the stipulated routine checks to be carried out once a year, the dimension of the load chain and the load hook must be compared with the dimensions in the following table. In addition, a visual check must be carried out for deformations, cracks and corrosion Load chain Warning! If one or more of the following dimensions is too great or to small, or if cracks or corrosion are found, the parts must be replaced by original spare parts! L11 = pitch increase over 11 chain links L1 = pitch increase over 1 chain link dm = determined link thickness, measure d1, d2 = (d1+d2)/2 Lp1 = elongation due to plastic deformation - 1 link = 1,03 x La La = nominal outside length of a chain link = t + 2d 17

18 dimension Chain type 5x15 6,3x19,1 8x24 10x30 13x36 L ,4 271,9 504,9 407,9 L1 15,8 20,1 25,2 46,9 37,8 dm 4,5 5,7 7,2 14,4 11,7 Lp1 1,03xLa The chain is to be replaced if the dimensions in the table are reached due to wear or deformation Checking the load hook dimension Capacity/chain falls mm 500/1 1000/1 1500/1 2000/2 3000/2 5000/ /4 X H 19, dimension Capacity/chain falls mm 10000/ / / / / / /10 X (Y) X=56 Y=130 Y=145 Y=160 Y=180 Y=200 Y=225 H X +Y= biggest dimension of hook saddle H = thickness of hook saddle The dimensions mentioned are theoretical dimensions without tolerances capacity X bzw. Y H kg mm mm Please measure X resp. Y and H at your hoist and fill the values into this table Bitte Load hooks acc. To DIN from hook no. 6 up ( for units with a capacity of more than kg ) are marked with Y. Mak Make sure that the surface coating is always thick enough otherwise the surface coating must be renewed. Check the deformation of hook. Deformed hooks (dimension X or Y is exceeded ) or dimension H is fallen short of by 5%, must be replaced Maintenance of the load chain It is essential to check the load chain for wear and abrasion of the surface every day. Even in case of slight abrasion, the chain must be replaced immediately. 1) Wash dirty chains with petrol or a similar cleaner; never heat the chain. 2) Always lubricate the chain when it is not under load. The adjacent link points must always show lubricant, otherwise this causes increased wear of the chain. 3) Lubricate the chain with a lubricant that creeps, such as engine oil. 4) Use a dry lubricant such as graphite powder in the case of environmental conditions that increase wear ( sand, a.s.o.) 18

19 Chain wear in the links is primarily due to inadequate maintenance of the chain and lubrication is of special importance here. In order to ensure optimum lubrication of the links, the chain must be lubricated at regular intervals depending on the type of use. When carrying out the lubrication the oil can cover the links that are subject to wear. It is not sufficient to lubricate the chains from outside, since in this case it is not possible to ensure that a film of lubricant is formed within the links. If there is a constant lifting path for the chain, it is necessary to pay special attention to the changeover area from lifting to lowering movement. Lubrication that was carried out carefully on a chain lenthens the life of the chain by approx. 20 time compared to its dry unlubricated state. When carrying out the lubrication, check the state of wear of the chain. No lubrication means no liability or warranty! 17.7 Maintenance of the hand chain It is essential to check the hand chain for wear and abrasion of the surface every day. Even in case of slight abrasion, the chain must be replaced immediately Change of the load chain Please note the following: The chain must be changed in the event of visible damage; at the least once it has reached the replacement state of wear i.e.,if one or more of the dimensions as shown in the table of wear, page 18 were reached, if the chain is corroded, or if it shows plastic elongation. The chain pulleys must be checked at the same time. Change the load chain always in non- explosive atmosphere Draw in the new chains exactly in the same way as the chains that are already within the unit in other words, do not install them twisted. Undo the chain from the end fastening and suspend from it a link that is open to the side Place the new chain ( the same size and already oiled ) likewise in the chain link that is open to the side. Fix the chain to the end fastening The open chain link is only a help to thread-up the new chain. It is not allowed to load this open link. Chain link open to a side 17.9 Maintenance of the load hook From time to time, the shaft of the load hook should be lubricated with some drops of oil Gearbox Maintenance Regular lubrication checks, cleaning and re-lubrication of teeth and bearings are necessary after 6 months e.g., using SHELL Alvania EP 2 or similar products. If the conditions of use are more severe ( e.g., frequent operation under full load ) or due to special environmental conditions ( e.g., heat, dust a.s.o. ) the interval of maintenance must be shortened accordingly. 19

20 17.11 Load pressure brake / Brake discs The brake discs must be checked for wear every month.. The brake discs must be replaced if the brake lining has reached the wear limit thickness(vb) mentioned below in the table. capacity kg 500/1 3000/2 5000/-1000/ / /10 Nominal thickness mm 1,5 2,0 3,0 Wear limit thickness 2,5 mm 1,0 1,5 Vb The brake lining must not be exposed to oil, dirt or humidity! The brake needs no readjustment Maintenance of the slipping clutch ( overload protection ) After frequent slipping of the clutch or by environmental conditions, the value adjusted in our factory can change so that re-adjustment is necessary. Please proceed as follows: 1) Dismantle the cover - C of the hand chain wheel 2) Re-adjust the slipping moment by turning the nut - A - (situated at the face of the hand chain wheel). The slipping moment increases if the nut is turned clockwise (right ), it decreases if turned to the left side 3) Fit the cover C- again and check the correct adjustment with a test load or a dynamometer. Values to be adjusted acc. to the table below. Warning! The hoist must not be loaded again unless the nut - B is fitted onto the driving shaft, firmly tightened and secured by a pin capacity/ chain falls adjustment value approx /- 10% of nominal load kg from - to kg 300/ / / / / / / / / / / /6*) /8*) /10*) The slipping clutch must be adjusted for both drives Hoists with a capacity of kg/2-falls or more A B C Linings for slipping clutch Hoist with a capacity up to kg/4-falls The slipping clutch must slip at 160 % of the rated load! It must then be impossible to lift a load. 20

21 18. Decommissioning In order to prevent damage to the unit or the risk of serious injury when taking the unit out of commission, it is essential to note the following points: - All the work steps for taking the hoist out of commission must be done in the stated order without fail. - Make the working area safe over a wide area for the decommissioning - Decommission is to be done in non-explosive atmosphere - Read also the " General safety instructions " - Check that the operating media will be disposed of appropriately - Disassembly is done in the reverse order to assembly 18.1 Temporary Decommissioning Proceed as mentioned above. Please read the section Transport and Storage 18.2 Final decommissioning / Disposal Proceed as mentioned above. It is necessary to ensure that the equipment any contents are disposed of appropriately after disassembly. 12. Additional Information Annex: EU declaration of conformity 21