Yale Yalelift IT Instrucciones De Servicio página 4

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 O
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.
I O
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).
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.
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.
5 7
2
3
6
4
9 1
8
10
11
1
Modell YLITG
B
b
A
A
A
Yalelift ITP/ITG 500 - 5.000 kg
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.
I B I O
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.
©
2019 Columbus McKinnon Industrial Products GmbH
I B
NSPECTION
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 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
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functioning.
2
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
7 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.
8 6 4 9 10 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
Modell YLITP Before start-up, check that the chain drive is working in the unloaded condition.
O
PERATION
7
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.
I , S
NSPECTION
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.
S W
EFORE TARTING ORK
& R
ERVICE EPAIR
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