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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.
I
B
S
W
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.
Inspection of the safety gear
The safety gear must not be activated and must be reset before starting work.
ATTENTION: Do not lower against the engaged lock and turn the hand lever
counterclockwise (CCW). This may cause damage to the hoist.
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 lever 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.
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.
Automatic safety gear
The general design of the YaleERGO 360 UT corresponds to that of the standard unit.
In addition, the unit is equipped with an independently acting safety gear, which engages
and locks when a lowering speed of approx. 0.5 m/s is exceeded and holds the attached
load safely.
The function of the chain release is not affected by the safety gear and closes the brake
safely at a load of 30kg - 45kg.
NOTE: The safety gear is permanently effective and cannot be switched off!
In normal operation, no additional action is required, as the device operates
automatically.
Unlocking the safety gear
In the event of overspeed (> 0.5 m/s) the lock engages and blocks.
In this case lowering is not possible.
To unlock the safety gear, move the hand lever clockwise (CW) in the direction of lifting
by more than ½ turn.
This is also possible under load.
ATTENTION: Do not lower against the engaged lock and turn the hand lever
counterclockwise (CCW). This may cause damage to the hoist.
Lifting or turning the hand lever clockwise (CW) is always possible.
Resetting the safety gear
To ensure a constant fast catching speed, the safety gear must be reset and adjusted
before each use of the hoist or after activation.
To do this, press the reset button as far as it will go and keep it pressed. Then turn the
hand wheel clockwise (CW) until the catch unlocks. This is done after approx. ½ turn of
the hand wheel.
The reset button is pushed back to the initial position.
NOTE: The safety gear can only be reset when the unit is unloaded.
Actions to be taken after an emergency engagement of the safety gear
After an emergency engagement of the safety gear, the hoist, the load chain and the
hooks must be checked for damage before any further load movement can be carried
out.
ATTENTION: The load may only be moved by turning the hand lever clockwise
(CW) in the direction of lifting "↑".
ATTENTION: Do not lower against the engaged lock and turn the hand lever
counterclockwise (CCW). This may cause damage to the hoist.
It may be necessary to use another hoist to safely lower the load.
After an emergency engagement, the device must be taken out of operation and checked
by a competent person.
Free chaining device (if available)
Turn pawl rod lever to neutral (central) position. The chain can now be pulled in both
directions and the load chain fall will be quickly tensioned.
Attention: The minimum load to engage the automatic brake lies between 30 and
45 kg.
Usage of the ERGO-Lever
If the integrated handle at the lever should be used, it can be folded into the forward or
backward position. The handle will click into place with a clearly audible snapping sound.
The conical seating of the handle shall be free of dirt at all times. If necessary the seating
has to be cleaned just as well as the associated parts.
To move the handle back into its starting position the handle has to be pulled forwards
out of its conical seating and simultaneously tilted back inside the lever. To do so the
gripping surfaces of the handle should stay parallel to the slot inside the handle. The
handle will be held in its position by spring load.
Lifting the load
Pull the rerwardpawl rod lever along its axis backwards and tilt to position "↑". Make sure
that the lever will click exactly into place.
Operate hand lever with pumping action. If work is stopped while the hoist is still under
load, the pawl rod lever must remain in the lifting position "↑".
Lowering the load
Pull the rerwardpawl rod lever along its axis backwards and tilt to position "↓". Make sure
that the lever will click exactly into place.
Operate hand lever with pumping action.
Brake jamming
lf a hoist, which is under load, is suddenly relieved of load pressure, e.g. by lifting off the
load or when pulling down walls, and lowering has not been initiated first, the brake will
remain locked. The brake will also lock if the load hook with the bottom block is pulled
too tightly against the housing.
Releasing the jammed brake
Turn pawl rod lever to the lowering position "↓" and operate hand lever with a vigorous
stroke. lf the brake is jammed on extremely tight, it can be released by striking the hand
lever.
ATTENTION: Do not lower against the engaged lock and turn the hand lever
counterclockwise (CCW). This may cause damage to the hoist.
Yale overload protection device (if available)
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
& R
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.
©
2020 Columbus McKinnon Industrial Products GmbH
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.
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