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OPERATING, MAINTENANCE AND SERVICE MANUAL 320 kg to

1. Parts list required for reduction gear 14 Ref no Description Part no 1 Bearing 6206 2 Load wheel 7x5x22 RWL 1120 0020 3 Oil seal 45 72 8 4 Oil seal 20 47 7 5 Bearing 6209 6 Bearing 6006 7 Spiral bevel ring gear RWL 1120 0021 8 Screws Tcei 8x25 9 Bearing 6204 10 Spiral bevel ring gear RWL 1120 0022 middle 11 Bearing 16004 12 Spiral bevel ring gear RWL 1120 0024 main 13 Pinion gear RWL 1120 0029 14 Bearing 6205 15 Bearing 6203 16 Oil seal 20 35 7 LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 Issue 2 0 18 June 2014 www litectruss com info litectruss com 7 2 320kg EXE Rise Hoist perspective view LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info glitectruss com Issue 2 0 18 June 2014 page 46 7 2 1 Exploded diagram 320kg EXE Rise Hoist Parts list required for 320kg EXE Rise Hoist Ref no Description 1 End cover 2 Brake 3 Reduction flange 4 Reduction housing 5 Reduction unit 6 Main body from reduction unit side 7 Suspension hook 8 Chain bag bracket 9 Chain guide 10 Guide plate 11 Main body from motor side 12 Rotor assembly 13 Motor housing 14 Cover LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39
2. ee se ee ee ee AR ee AR ee AR Re AA ee ee AR ee AR nennen enters a 27 LEM des E 28 4 2 1 Mechanical bypass of hoist ee se ee ee ee AR ee Ak Ge Re AA Seena AR Re AA ee nennen entes nennen inen nnns nennen en be REE i 28 43 Shutdown for long periodS ii ee ek AA Ge AA AR AA AA Ge AA ee RA AG AA Re ee ee en Ak AA ee inten en 29 5 MAINTENANGE OF HOIST iiis es Es bed sie ivive EE deus oae ee obo c cit eeu be bede ainda aaa 30 51 Gefieral safety rules ee EE EER Ee ES EET 30 5 2 vesels pe 31 5 3 Summary of periodic maintenance eise se ee Ge AA Ge aeaa eaaa Ge AA Ge AA ee enne ee AA ee AA tenens 31 LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 3 5 4 Maintenance asslistanco ied iet tei merecen id ie pede ee ek Ke Be lend d Ride due ea aa Pe we d dde ew ku PLE Vi EE die 541 Hook Mapeclion EE EE ER OE RE NE OR EE EER AE NE N liane 5 4 2 Chain el ede OR RE ER EE N EE N EE Na 5 4 3 Clutch maintenance OE RE OE RE OE OE OE OE EER OR addas ENE LERE EE ie ME EE EE ET EO EE IE EE EE S 5 4 5 Limit switch maintenance sees se ee Re ee ER Ge ee AR Be AR Re AA Re ee RE Re AR Re EEES Re AAR Re neta anne ee inte nnns AR ee ee 5 40 Perodic ETE 5 4 7 Load ch
3. LIFTING TECHNOLOGY OPERATING MAINTENANCE AND SERVICE MANUAL 320 kg to 2 000 kg DC CHAIN HOISTS LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info glitectruss com Issue 2 0 18 June 2014 page 1 Do not use the chain hoist before all operators have carefully read this manual Failure to operate the equipment as here described may cause injury or even death Retain this manual for future reference and use Before using the hoist please fill in the following information refer to the hoist identification plate Such information must be communicated every time that the LITEC maintenance service is called Model number Instructions for use Serial number Purchase date Voltage Nominal capacity If you are in doubt or need any further information please contact LITEC LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 2 TABLE OF CONTENTS 1 INFORMATION S Ge EG EE E LL LE DR ELM EE M IM E M d 6 1 1 Preliminary information nennen ene ee AR Re ed RAA sn dnte inen nensi ndn nens nnne nennen ein 6 EEN GE Teel id siele ES 6 13 es Ee di RE N RE AAE AAEE faeries eden 7 14 Selection and PKOVISIO NN RE NE N AE IE 8 1 9 Technical dala ii EE EE 9 1 6 Technical dra
4. dangerous zone and person exposed Course of action to eliminate or reduce risk Malfunction or falling load due to overload Do not exceed the hoist load limit Various types of risks owing to the wrong installation and use of the hoist Read the instructions before installing or using the hoist Fall risk to people being lifted by the hoist It is prohibited to lift people by means of the hoist Damage to hoist due to dry chain Chain should be kept lubricated Risks of structural collapse Check structure is able to support the proposed load Check all components in the lifting system are suitably rated and able to bear the proposed load Risk of injury from malfunction hoist or manoeuvre error Working area should be managed and access controlled Fall risks of the installer or serviceman from the load or structure Various types of risks owing to the illegibility of the labels Appropriate PPE should always be used Climbing the load or structures should be avoided if possible When possible carry out all maintenance at ground level Do not remove or cover labels Various types of risks owing to the lack in periodical maintenance Check that the annual periodical maintenance has been carried out Various types of risks when used in severe weather conditions Check the environment conditions before using the hoist Malfunctioning risks owing to wrong power supply Make sure that the
5. info litectruss com Issue 2 0 18 June 2014 page 23 Figure 18 The hoist mounting in self climbing mode 3 6 2 Mounting the hoist Body up chain climbing mode In certain applications it may be more useful to mount the hoist body up Use an appropriate method of lifting the hoist body and attach the anchorage hook to the point of the structure Figure 19 Mounting the hoist body up LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info glitectruss com Issue 2 0 18 June 2014 page 24 3 7 Connections WARNING Before connecting the hoist to the power supply check that voltage and power of the electric line correspond to those reported in Table 1 check also that the earthing system of the factory is sufficient Installers must equip the branch circuit with an earthing system and a protection against current overloads that comply with the requirements of the laws on safety and health protection on work place of the Country where the hoist is installed Check that the cables powering the hoist are protected against possible external damages risk of electrocution and malfunctioning WARNING Do not insert the plug of the hoist directly into a power socket the hoist would suddenly start Insert the plug of the hoist into that of the mobile controller Insert the other plug of the controller into the
6. 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 47 7 2 2 Main body 320kg EXE Rise Hoist Parts list required for main body Ref no Description Part no 1 Bearing Bearing 61817 2 Bearing Bearing 16004 3 Oil seal Oil seal 12 28 5 4 Lift wheel RWL 320 0022 5 Bearing Bearing 16006 6 Bearing Bearing 6001 7 Oil seal Oil seal 90 110 12 8 Main body from reduction unit side RWL 320 0004 9 Chain guide RWL 320 0009 10 Guide plate RWL 320 0008 11 Chain bag bracket RWL 320 0027 12 Main body from motor side RWL 320 0003 LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 48 7 2 3 Chain fastener 320kg EXE Rise Hoist Parts list required for chain fastener Description Part no Chain fastener for D8 320kg amp D8 160kg Chain fastener EXE Rise 4x12 LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info glitectruss com Issue 2 0 18 June 2014 page 49 7 24 Clutch Rotor Stator 320kg EXE Rise Hoist 05 qum UN L Components Rotor Components Stator JE yi Clutch system Clutch system Parts list required f
7. 3 Environmental conditions ee se ee ee Ge ee AR uns EEEE ENNE EKUE ee ee AR ee ee ee ee be ee ee ee ee de ee ee i 17 PARAS iy G EE AE RE ER ER OE R P 17 27 Hoistsafety COVICOS EE EE N EE EE OE 17 2 0 1 CDU RE EE EE EE ER OE EE OE EE die 17 P2 HOOKS RA OR EE N vaaedunny seccuransecdunag agteumnGeematG 18 dd RR ER EE was enti OR EE ER OE 18 NA dae ie es ore OR 19 ELI Vi SR EE RE EE ER ee EE N ER N ne 19 2 9 Secondary safety components iii se de Ee ek AA Ge AA Re RR AA AA Ge AA ee RA Ge AA Re entente de ee ee tenen nennen 20 3 INSTALLATION EE EE oi 22 3 1 Handling amp transportation Ge ee AR ee ee ee AR nennen Re ee ee ee AR ee de ee nnns net be ee de ee ee ee ee ee 22 X2 PACKAGING delg eN EE a dus 22 3 3 PACKAGING transpor EE 22 34 Unpacking and ground handling of the hoist 0 0 eee eee ee ee Ee ee eee ee AR ee AR ee AR ee AR ee AR ee ee ee ee ee 23 3 5 oe lo el AU AE EE EE RR m 23 3 6 SUSPENGING the MOIST asec ect c rte le er ie ote br ended aded eed be need edat dn d ask e ep ge ee Ee ga 23 3 6 1 Mounting the hoist body down self climbing mode seen 24 3 6 2 Mounting the hoist body up chain climbing mode ees se ed Ee ee AR ee AR ee AR ee AR nene 24 3 7 ee Te oi OE EE RE EE ER RE OR OR EE EE 25 eN EE OE EO EEN eN 25 EX Visual Ee eie EE 26 382 TOS WITMOUT IOAN ER OE N AR 26 4 USE OP HOIS EE ER AE 27 4 1 Attaching and moving the load
8. 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 52 7 3 2 Wiring Diagram For Direct Control Chain Hoists V 400 Hz 50 60 LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 53 8 DEMOLITION AND DISPOSAL Before carrying out demolition and disposal of the hoist complete the working cycle and disconnect power Upon demolition plastic parts must be separated from electric components and must be sent to selective collections according to regulations in force With regard to metal housing for a correct forwarding to melting recycling its splitting in aluminium parts and parts in other metals or alloys is sufficient To dispose hydraulic oil refer to what indicated in the product safety report It is prohibited to pour rejected liquids such as oils circuit liquids etc on the ground or into draining piping Dispose health and environment hazardous components or fluids in compliance with regulations in force on the matter During operations of hydraulic oil replacement and disposal the operator must wear gloves and protective overalls indicated in the product safety report 9 WARRANTY The complete chain hoist comes with a 12 month manufacturer s limited warranty from the date of purchase A 24 month warranty covers the mechanicals parts excluding electrical and
9. LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 57 MAINTENANCE Date Activity Result Signature Notes LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 58 MAINTENANCE Date Activity Result Signature Notes LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 59 Note The information contained in this publication is correct at the time of printing but can be modified without prior notice or compulsory notification when necessary in compliance with the continuous improvement policy of the LITEC Italia Spa products The reproduction transmission or storage in an information search system even partial as well as the translation into another language in any form are absolutely prohibited without the prior written authorisation of LITEC Italia Spa Copyright LITEC Italia S p A All rights reserved LITEC Italia spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy Tel 39 0422 997300 Fax 39 0422 997399 www litectruss com info litectruss com Follow us also on Facebook htto
10. hoists hook 1 8 Marking The hoist was designed and manufactured in compliance with the regulations indicated in the related CE confort On the hoist is affixed a plate indicating Model EXE Rise in an indelible manner the following information Power supply 4 EE ar n Model idiom pen Power supply Var and month of contrunction Control supply in LVC chain hoists raas ep ere er Mechanism group Self weight 40 5 k Load bearing capacity Identification number Year and month of manufacture YY MM Indication of hoist typology either D8 or D8 Figure 10 An example of labels WARNING Removing or covering the labels affixed to the hoist is prohibited Labels must be kept in good conditions and replaced in case of damaging loss LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 12 2 SAFETY PRECAUTIONS 2 1 Regulations and standards EXE Rise chain hoists are built in accordance with the specifications contained herein and at the time of manufacture complies with our interpretation of applicable sections of the European FEM or equivalent to American Society of Mechanical Engineers Code B30 116 Overhead Hoists the National Electrical Code ANSI NFPA 70 and the Occupational Safety and Health Act OSHA Since OSHA states the National Electrical Code applies
11. power socket WARNING Dangerous voltage drop can be caused by using excessively long extension cables The following chart should be used to determine the size of the wires in the extension cord in order to minimize the voltage drop between the power source and the hoist Length of extension cord Minimum wire size Up to 15 2 m 1 6 mm 24 4 m 1 6 mm 36 7 2 0 mm 61 0 2 0 mm 91 4 2 7 mm Table 7 Minimum wire size 3 8 Testing WARNING The following test should be carried out prior to each new use of the hoist The purpose of the following test and inspection is to ensure the hoist has been correctly assembled is not damaged in any way and is safe to use In addition the user should refer to the local laws regarding use of lifting equipment LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 25 3 8 1 Visual inspections Visual inspections should be carried out on the following elements to check for any damage or faulty parts Connection to power supply Power and control cables from the hoist Body work Chain hook Chain bag connection Load chain Identification labels on the hoist Any visible damage to the hoist 3 8 2 Tests without load Operate the hoist in both directions to check phasing is correct
12. the manufacturer The operational parameters do not include exceeding the defined load capacity pulling or applying a diagonal load to the chain heaving pulling or dragging the load standing under suspended loads transporting excessive loads pulling on the control cable failing to observe the load hook constantly running the chain over edges failing to observe the load constantly LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 13 allowing the load to fall due to a slack chain use at temperatures below 10 C or above 40 C E use in an explosive environment Inching operations ground mooring and driving against the limit switches should be avoided The manufacturer accepts no responsibility for damage to equipment and third parties ensuing from such action 2 3 Safe operating instructions and procedures Assembly disassembly and operation of the hoist must be carried out according to the procedures specified in this document In addition only the accessories specified by LITEC Italia Spa must be used When choosing a hoist for use always check the lifting capacity is adequate for the load being moved It is good practice not to run the hoist to against its limits Experience proves that it is an advantage to work at 10 15 below the extreme limit Use ind
13. they are to include those items listed in Table 10 WARNING Any deficiencies are to be corrected before the hoist is returned to service Also the external conditions may show the need for more detailed inspections which in turn may require the use of non destructive type testing In addition to the above inspection procedure a preventive maintenance program should be established to prolong the useful life of the hoist and maintain its reliability and continued safe use LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 31 The program should include the periodic and frequent inspections with particular attention being paid to the lubrication of the various components using the recommended lubricants For reduction gear please use LITEX EP 1 lubricant on 320kg D8 160kg D8 chain hoists and Mobil Gear 600xP460 on all other chain hoists Table 8 Minimum frequent inspections TYPE OF SERVICE ITEM Normal Heavy Severe a gt b x gt 2 a o p 8 6 96 9 d zt gt a A e Brake for evidence of slippage Control functions for proper operation Hooks for damage cracks twists excessive opening latch engagement and latch operation Load chain for adequate lubrication as well as for signs of wear damaged links or foreign bodies Load chain for pr
14. to all electric hoists installers are required to provide current overload protection and grounding on the branch circuit section in keeping with the code Check each installation for compliance with the application operation and maintenance sections of these articles Table 3 FEM classification Load spectrum Load spectrum Average operating time per day in hours lt 0 25 x05 lt 1 lt 2 lt 4 lt 8 S16 Light 1Bm iAm 2m 3m Moderate 1Bm 1Am 2m am Heavy iBm 1Am 2m 3m Very Heavy 1Bm 1Am 2m 3m Table 4 FEM classification Class Class 1Bm iAm 2m 3m Duty factor of motor 25 30 40 50 Starts per hour 150 180 240 300 EXE Rise chain hoists have 1Am classification 2m pending 2 2 Operational parameters EXE Rise chain hoists are hoists of differing load capacities They can be installed as stationary or mobile units Electric chain hoists are manufactured in accordance with the latest technical developments and recognised safety standards and are tested for safe operation by the manufacturer Electrical chain hoists of the above series may only be used when in an acceptable technical condition in accordance with their operating parameters by trained personnel in a safe and responsible manner The operational parameters of the electric chain hoist also encompass compliance with the predefined operating service and maintenance requirements laid down by
15. 0kg When used in other Countries the possible presence of this kind of provisions must be verified 1 3 Modes of use The hoist is an electrically operated lifting mechanism equipped with a steel chain that acts as a bearing element The hoist is suitable to be mounted in two ways Either body up where the main hoist is mounted upper most see Figure 1 or body down where the hoist body is at low level with chain mounted upper most The body travels up the chain as lifting is carried out see Figure 2 Supporting structure Supporting structure Load to be lifted Load to be lifted Figure 1 Lifting a load with the hoist positioned upper Figure 2 Lifting a load with the hoist positioned most Known as body up at low level and the chain hook upper most Known as body down or self Climbing Electric chain hoists are designed to lift and lower loads vertically and to travel horizontally with trolleys Every other use is prohibited Please ask the producer for any special mode of use in advance WARNING Using the hoist to carry people is strictly forbidden The EXE Rise chain hoists are intended for use in setting up events Events include concerts shows conferences meetings exhibitions presentations demonstrations film or television shoots and similar LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss co
16. 9 1 6 Technical drawings Y N hy Figure 4 Perspective view of a single fall EXE Rise hoist T Figure 6 Perspective view of a double fall EXE Rise hoist Figure 5 End view of a single fall EXE Rise hoist cag lei J Figure 7 End view of a double fall EXE Rise hoist LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 10 1 7 Exploded diagrams 1 7 14 320 kg EXE Rise chain hoist Brake Reduction Body swivel Chain bag gear container hook amp bracket AS CS Main body d reduction gear Chain guide Main body Pi motor side Motor housing End cover End cover Gear housing Reduction flange gear Chain Swivel Rotor hook Group Figure 8 Exploded diagram of 320kg hoist LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 11 7 2 620 2 000 kg EXE Rise chain hoists Bod swivel ica End ousing hook Mator flange cover housing Motor Gear flange End housing Reduction cover gear Central l body gasket Gear gasket Chain bag Chain Screws Gasket Gear Chain bracket guides housing flange 9 N Chain swivel Figure 9 Exploded diagram of 620 2 000kg
17. 97 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 33 5 4 6 Periodic testing The hoist must be tested at least once a year by an expert authorised for the purpose In case of heavy Services or intensive use the user must carry out additional extraordinary testing based on his own risk evaluation In case of heavy services or intensive use the user must carry out additional extraordinary testing based on his own risk evaluation Periodic testing must be required and carried out by the LITEC maintenance service 5 4 7 Load chain lubrication Contact your dealer for details on the correct lubricant as it will certainly differ from country to country Before lubricating the chain secure the hoist To assure extra long life and top performance be sure to lubricate the chain using the lubricants specified below A small amount of lubricant will greatly increase the life of load chain Do not allow the chain to run dry Keep it clean and lubricate at regular intervals with chain oil Normally weekly lubrication and cleaning is satisfactory but under hot or dirty conditions it may be necessary to clean the chain at least once a day and lubricate it several times between cleanings When lubricating the chain apply sufficient lubricant to obtain natural run off and full coverage especially in the interlink area WARNING Used motor oil contains known carcinogenic components TO AVOID H
18. Check E stop is working correctly Check the chain runs smoothly through the hoist Listen for any strange noises from the hoist while chain is running Chain should run smoothly into the chain bag Ensure chain is not allowed to bunch up while entering or exiting the hoist Chain should be allowed to run clear of the hoist LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 26 4 USE OF HOIST Improper operation of the hoist can create a potentially hazardous situation which if not avoided could result in death or serious injuries Permit only authorised and qualified personnel to operate unit Do not use the hoist or any other overhead materials handling equipment for lifting persons WARNING STAY ALERT Watch what you are doing and use common sense Do not use the hoist when you are tired distracted or under the influence of drugs alcohol medication causing diminished control Do notuse the hoist unless it is perfectly efficient even if the hoist still operates Do not use the emergency stop button to habitually stop hoist motion Do not carry out operations or manoeuvres on one s own initiative that do not fall within one s area of expertise and can compromise the safety of everyone Do not wear loose fitting clothes as these can get entangled in moving parts Do
19. EALTH PROBLEMS Never use used motor oil as a chain lubricant Only use chain oil lubricant as specified by LITEC or its distributors Keep load chain well lubricated WARNING Lubricants must not be ingested and must be handled with care in case of contact with delicate parts immediately call a doctor Follow safety indications mentioned in the safety reports of the product used CAUTION Used operating materials oil lubricants etc should be safely collected and disposed of in an environmentally friendly manner 5 4 8 Decommissioning criteria for bearing elements The hoist bearing elements must be decommissioned when a8 inspection of chain or load hooks shows deformation or wear beyond the allowed limits b chain or load hooks show sign of severe damage 5 4 9 Replacing the fuse Before replacing a fuse the hoist must be secured The new fuse must have the same characteristics as the replaced fuse LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 34 5 4 10 Extraordinary testing In case of extraordinary events which can jeopardise the safety of the working equipment extraordinary testing must be carried out In particular extraordinary events include accidents modifications to the hoist prolonged downtime periods and natural phe
20. ING USE ONLY ORIGINAL SPARE PARTS 7 1 620 2 000kg EXE Rise Hoists perspective view y LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info glitectruss com Issue 2 0 18 June 2014 page 38 7 1 1 620 2 000 kg EXE Rise chain hoists Parts list required for 620 2 000kg EXE Rise Hoists Ref no Description 1 Screws 2 End cover 3 Brake 4 18 Gasket 5 Gear housing flange 6 Gear gasket 7 Reduction gear 8 Gear housing 9 Chain 10 Chain swivel hook 11 Body swivel hook 12 Chain bag bracket 13 Chain guide 14 Motor flange 15 Motor flange gasket 16 Motor 17 Motor housing 19 End cover LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info glitectruss com Issue 2 0 18 June 2014 page 39 7 12 Main body 620 2 000kg EXE Rise Hoists Parts list required for main body Ref no Description Part no 1 Screws Screw Tcei 6x40 2 Screws Screw Tcei 6x35 3 Screws Screw Tcei 6x30 4 Motor flange RWL 1120 0201 5 Chain guide RWL 1120 0218 6 Suspension assembly RWL 1120 0059 7 Dead end block RWL 1120 0213 8 Guide plate RWL 1120 0011 9 Chain connector RWL 1120 0012 10 T nut for suspension hook RWL 1120 0058 11 Lift wh
21. T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 42 7 1 5 Single Brake Unit 620 2 000kg EXE Rise Hoists B Parts list required for single brake unit Ref no Description Part no 1 Brake disk RWL 1120 0027 2 Brake disk with shoes RWL 1120 0218 3 Disk hub RWL 1120 0219 4 Adjustment pins RWL 1120 0220 5 Brake anchor RWL 1120 0221 6 BFK458 08 Electromagnet RWL 1120 0222 7 Screws Tcei 50x50 LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 43 7 1 6 Double Brake Unit 620 2 000kg EXE Rise Hoists Parts list required for double brake unit Ref no Description Part no 1 Brake disk RWL 1120 0027 2 Brake disk with shoes RWL 1120 0218 3 Disk hub RWL 1120 0219 4 Adjustment pins RWL 1120 0220 5 Brake anchor RWL 1120 0221 6 BFK458 08 Electromagnet RWL 1120 0222 7 Screws tcei 50x50 8 Joint double brake flange RWL 1120 0010 9 Screws Tcei 5x45 LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 44 7 1 7 Reduction Gear 620 2 000kg EXE Rise Hoists
22. ain lelies EN OE N EE NE EE EN OE OE EED 5 4 8 Decommissioning criteria for bearing elements ie ee ee ee ee Ge Re ee Ge ee ee Re ee ee ee ee ee ee ee ee 54 9 IREPlACIAG the TUS E s 5 410 Extraordinary te SUING og o oerte eine E re avacedaca sande res E 59 Se tese le Te An ie Uie EE ER OR EE EE ER AE 5 6 General overlal l NE RR EE RE EE Xd Ri 6 jirieliBzIlj leexjlcpe t etn 7 RECOMMENDED SPARE PARTS issie intor nasus tn tete Geskenke ee trien iul eed ga ene eeue ee ee be uie eg 7 1 620 2 000 kg EXE Rise hoists perspective VIEW sees see ee es se se ee ee ee ge ee ee ee ge ee ee ee ke ee ee Ge ke ee ee ee ke ee ee ee ee ee ke ee ee 7 1 1 Parts list required for 620 2 000 kg EXE Rise chain hoist esse se ees se se ee ee se ge ee ee ee ke ee ee ee ke ee ee ee ke en 7 1 2 Parts list required for Main body 620 2 000 kg EXE Rise chain hoist iese esse se ee es se se ee ee se ge ee ee ee ge ee ee 7 1 3 Parts list required for Chain Fasteners 620 2 000 kg EXE Rise chain hoists iss see ee se se ee se ee ee ee ee ee 7 1 4 Parts list required for Clutch Rotor Stator 620 2 000 kg EXE Rise chain hoists 7 1 5 Parts list required for Single Brake unit 620 2 000 kg EXE Rise chain hoists ssssssss 7 1 6 Parts list required for Double Brake unit 620 2 000 kg EXE Rise chain hoists sessssss 7 1 5 Parts list req
23. al rules on health protection and safety at work and with the rules of good technical practice technical regulations issued by the Country in which the hoist is used The expert must be able to verify the safety and mechanical equipment and give the related evaluation 2 6 Structural and environmental requirements CAUTION Below are indicated the structural and environmental requirements that must be checked by the user for guaranteeing safe use of the hoist 2 6 1 Structural resistance The operator is responsible for the construction method used for the set up structure the related load capacity and the conditions of the connection points load suspension points arranged in the place of use In addition to the risk evaluation and the previously mentioned operating procedures project documentation calculation reports drawings etc related to such aspects must therefore also be prepared The set up structure and the related elements involved hoist anchoring point hoist and related accessories and the load thereof must be able to bear the imposed loads during the handling and suspension of the load with a suitable safety factor In the overall analysis the dynamical forces for ex impact factors that intervene in the reasonably foreseeable use of the hoist must also be considered 2 6 2 Electrical requirements Check that the electrical supply system to be used is adequate and conforms to local standards The hoi
24. and clean area far from heat sources that might jeopardise its integrity 3 3 Packaging transport Packing must be transported up to the envisaged installation point for the hoist The flight case is equipped with translation wheels therefore if possible it must be simply hand pushed On the contrary the cardboard box must be transported by lifters or equivalent equipment LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 22 34 Unpacking and ground handling of the hoist The hoist must be removed manually from the packing Check that the hoist has not suffered damage arising from an inadequate transport Check the hoist frame for dents the external cables for damaged or cut insulation the controller for cut or damaged housing and inspect the load chains for dents or notches If a damage arising from shipment has been detected refer to the accompanying document envelope on the box for the claim procedure Possible claims related to hoist damages must be presented within 8 days from receipt of the goods in any case it must be pointed out that the hoist is subject to an accurate inspection in every part before being packed and shipped to the customer Never throw packing materials away they are the ideal containers for transporting the hoist to another place of use In case of transfer to a
25. cted to a power and control system that is suitably designed to operate the chain hoists and handle the power consumption of the motor EXE Rise chain hoists are standard wired for 400V 3ph 50Hz operations For other voltages the chain hoist motor must be re wired internally WARNING Electrotechnical adjustments may only be performed by authorised specialists 4 2 1 Mechanical bypass of hoist Should the hoist stop due to anomaly overload etc and the load must be lowered for example a structure proceed as follows The operations mentioned below must be carried out by qualified technical personnel During mechanical bypass do not operate the hoist if the area surrounding the suspended load is not and does not remain cleared from persons The User from his control place must be able to be sure of the absence of persons in the risk area Clear the underlying area Tie off the load by applying a mechanical safety device that by passes the lift mechanism from hook to hook refer to the examples of secondary safety components see paragraph 2 9 Lower the load LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 28 4 3 Shutdowns for long periods In case of prolonged downtime the hoist must be stored according to the precautions related to the place and times of storage G
26. e Ge Re ee ee ee Ge meer 9 2 Compensation and use under safety iii ie ee ee AA Ge RA AA AA AA RR ee Ge AA Ge ee enn Ge AA ee ee ee ee nnns 10 MAINTENANGE REGISTER iii iioii nee ioc Goose ed ed Doe eine be Gee GE eeue be ee tage eH Gees be ede ee idee eek Ee p bede ees 4 NOTE OF MANUFAGTURER ieiunio ee ee ee GE Ge ee ee ccc eee oes Ee oe ee ee eg ee eee LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 4 Index of figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Lifting a load with the hoist body positioned upper most Known as body up seeeeeeess 7 Lifting a load with the hoist positioned at low level and the chain hook upper most Known as body down or self climbing eco rtc EE EE otn brad ere ettet erre er dne Yun Ee edu rua 7 Views of EXE Rise chain hoist srainnsear 9 Perspective view of a single fall EXE Rise hoISt ees ees esse ees ee ee ge ee ee ee ge ee ee ee ge ee de ee ge ee ee ee nennen 10 End view of a single fall EXE Rise hOISt ee ees se ees ee ee ee ee ee ee ge ee ee ee ge ee ee ee ge ee ee ee ee ee ee ge ee ee ee be ee ee e
27. e a defect causing subsequent failure at less than rated capacity When in doubt use the next larger capacity EXE Rise hoist Warn personnel of your intention to lift a load in the area Where possible secure the load with a secondary device before entering the area beneath the suspended items Take up a slack load chain carefully and start load gently to avoid shock and jerking of hoist weight chain If there is any evidence of overloading immediately lower the load and remove the excess load When lifting raise the load only enough to clear the floor or support and check to be sure that the attachments to the hook and load are firmly seated Continue to lift only after you are certain the load is free of all obstructions Arrange periodic maintenance to ensure the hoist is functioning correctly according to the modes indicated in paragraph 5 3 STAY ALERT Watch what you are doing and use common sense Do not use the hoist when you are tired distracted or under the influence of drugs alcohol or medication causing diminished control LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 14 WARNING Use of the hoist under conditions other than those described in this document can result in accidents that may cause injuries and or material damages 2 4 Safety precautions D
28. e ee ee ee ee ee 10 Perspective view of a double fall EXE Rise HOS ees esse ees ee ee ge ee ee ee ge ee ee ee ee ee ee ge ee ee ee mener 10 End view of a double fall EXE Rise hoist iese esse se ee ee ee ee ee ee ede ee ee ee ee ee ee ede ee ee ee ee ee ee AA ee ee ee ee ee ee ede ee ee ee ee 10 Exploded diagram of 320kg EXE Rise chain hoiSt ees see ees ee see ee ee ee ge ee ee ee ge ee ee ee ge ee ee ee be ee ee ee ee ee ee ee ee 11 Exploded diagram of 620 2 000kg EXE Rise chain hoistS esse se esse se ees ee ee eed ee ee ge ee ee ee ge ee ee ee ee ee ee ge ee ee 12 Ancexam ple Of labels iet EA EE RE RE EG 12 Aluminium chain guide sesse se ee ee ee AR Re ee ia Re AE AR Re AA Re AR Re AR Re ee aA ee entr ee ee 17 The two hooks of the hoist are equipped with a sprung safety latch 18 Example of securing a load suspended from a tower by means of a locking bar 20 Example of a secondary safety component attached directly to the load that is being lifted front usnm EE RE EE EE NR RE OE AN 21 Example of a secondary safety component attached directly to the load that is being lifted DEFSPECTIVE VSW esii EE RE RE OE daidiauiiaS 21 Example of a secondary safety component attached below the hoist bypassing the hoist lifting mechanism TONE VIEW T 21 Example of a secondary safety component attached below the hoist bypassing the hoist lifting mechanism perspective VIEW Ese ENE reete cene lin eh oe
29. echnical data Figure 3 Views of EXE Rise hoists Table 2 Comparison chart of the main EXE Rise chain hoists Model EXE Rise 320 kg D8 EXE Rise 620 kg D8 EXE Rise 1 120 kg D8 EXE Rise 2 000 kg D8 Load capacity 320 kg 620 kg 1 120 kg 2 000 kg Body dimensions 134x128x339mm 275x188x443mm 275x188x443mm 275x188x443mm Lifting speed 4m min 4m min 4m min 4m min Motor power 0 5 Kw 0 8 kW 1 0 kW 1 5 kW Body weight 15 kg 31 kg 40 kg 46 kg Chain weight 0 35 kg m 0 54 kg m 1 03 kg m 1 03 kg m Power supply Voltage V 230 400 V 50Hz 3 pole Earthing 230 400 V 50Hz 3 pole Earthing 230 400 V 50Hz 3 pole Earthing 230 400 V 50Hz 3 pole Earthing FEM class 1Am 2m pending 1Am 2m pending 1Am 2m pending 1Am 2m pending Load wheel 5 pockets 7 pockets 5 pockets 5 pockets Falls of chain 1 1 1 2 Low voltage control Optional st 2AVAC 50Hz Optional st 2AVAC 50Hz Optional st 24VAC 50Hz Optional st 24VAC 50Hz Suspension with swivel hook standard standard standard standard Noise level 67 5 db at full load 67 5 db at full load 67 5 db at full load 67 5 db at full load Table 1 Technical data of chain hoists LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page
30. ee ee ee AR Re AA GR ee AR ee AR ee AR ee ee ee ee AR nennen 36 LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 5 1 INFORMATION 1 1 Preliminary information Thank you for choosing an Exe Rise chain hoist of LITEC Italia S p A This manual contains important information to help you properly install operate and maintain your chain hoist To carry out these operations all safety rules specified therein must be followed Should some passages not be clear please contact our Technical Office The information reported in this document refers to own use care and maintenance of the single hoist that is to say the rigging process is not included By the term rigging is defined as the process of handling and lifting loads using one or more hoists or other mechanical equipment The ability acquired through specialised experience and study is essential to make rigging operations safe For information on rigging we recommend that reference be made to the specific documentation on the subject Before installing and using the hoist the instructions and advice mentioned in this manual and attached documents must be carefully read and fully observed Operating and service personnel must have read and understood the operating instructions in particular the safety instructions before commencing w
31. eel RWL 1120 0020 12 Reduction unit housing RWL 1120 0202 LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 Issue 2 0 18 June 2014 www litectruss com info litectruss com 7 1 3 Chain fasteners 620 2 000kg EXE Rise Hoists Parts list required for chain fasteners Description Part no Chain fastener for D8 620kg amp D8 310kg Chain fastener EXE Rise 5x15 Chain fastener for D8 1 120kg 2 000kg amp D8 560kg Chain fastener EXE Rise 7x22 LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info glitectruss com Issue 2 0 18 June 2014 page 41 7 1 4 Clutch Rotor Stator 620 2 000kg EXE Rise Hoists Components Rotor Components Stator Clutch system Clutch system Parts list required for the Clutch Rotor Stator Ref no Description Part no 1 Clutch lower support RWL 1120 0003 2 Bakelite clutch RWL 1120 0005 3 Upper clutch support RWL 1120 0006 4 Rotor shaft 1120 RWL 1120 0007 5 Bearing for H60 shaft 51100 6 H60 Rotor bush RWL 1120 0008 7 Yellow spring for H60 rotor RWL 1120 0217 8 Motor ring RWL 1120 0203 9 H60 Stator RWL 1120 0214 10 H60 Bearing 6006 11 Motor guard RWL 1120 0204 LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy
32. ention directions special safety directions as well as hazard protection instructions paragraph 2 3 should be followed 5 1 General Safety rules Working inside or near powered equipment can result in electric shock before carrying out any work on the hoist always disconnect power supply and make sure that no one can insert the plug again until the task is complete When possible maintenance must be carried out without suspended load failing this the area must be enclosed and monitored and the load must be held by means of a secondary safety component see paragraph 2 9 Do not clean the hoist using a pressure washing device Keep control and maintenance reports issued by LITEC together with the manual All maintenance repair adjustment cleaning operations must be carried out only by qualified personnel duly trained and competent who has looked over this document Maintenance must be carried out in a safe area whilst using proper tools and safety equipment n case of poor ambient lighting install a lamp for local lighting for maintenance interventions or use adequate portable devices Replace any cable or wire with like for like items Use only spare parts identical to those to be replaced or previously authorised by the manufacturer Follow industrial hygiene rules during cleaning of the machine n the instance of maintenance work being carried out at height please ensure the correct access equipment is e
33. h various guards and devices designed to prevent accidents and to ensure the product complies with various safety standards WARNING The guards and devices listed below must not be removed by the user Before operation the user should ensure all guards and devices are present and in place Removal of these guards and safety devices should only be allowed during maintenance by competent persons and in controlled conditions 2 7 4 Metal housing The metal housing carries out various safety functions e Prevents accidental contact parts e Prevents accidental contact with the internal parts that could reach high temperatures e Chain protection plate prevents wear between the chain and entry port of the hoist and prevents jamming of the chain e Protection from electrical shock LITEC Italia Spa Via Martin Luther King with the internal moving Figure 11 Aluminium chain guide 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 17 WARNING Removal of the metal housing covers should only be allowed during maintenance by competent persons and in controlled conditions 2 7 2 Hooks The hooks are equipped with a sprung safety latch that prevents accidental release of loads when applied correctly to the hook Figure 12 The two hooks of the hoist are equipped with a sprung
34. ight of the hoist must also be taken into consideration Do not allow the load to swing or twist while hoisting Do not handle the load above people or do not leave hanging loads without the operator s control Do not use the hoist outdoors or anyway in places with water jets or environmental conditions without adequate protection The use in explosive aggressive atmosphere or with high concentration of powders or oily substances suspended in the air is prohibited Electrical devices produce arcs or sparks that can cause a fire or explosion Do not operate hoist at unusual extreme of ambient temperatures above 40 C or below 10 C In general use of the hoist with materials adjustments or modifications not envisaged in this document is prohibited It is prohibited to tamper with the hoist in order to modify its performances Do not remove or tamper with the protections and safety devices described in paragraph 2 7 Use of the hoist is prohibited to unauthorised operators who are not adequately trained in use of the hoist and the associated dangers Use of the hoist outside the limits indicated in this document is expressly prohibited 2 5 Operators requirements Requirements for installation assembly and disassembly of hoist The hoist must be assembled and disassembled only by authorised and qualified experts The necessary qualifications for planning assembly disassembly and activation depend on the risk degree of the locat
35. ions that must be previously assessed LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 15 This manual gives the necessary information for a safe installation use and maintenance generic working environment Since it is not possible to foresee all the risk conditions working environments in which the hoist will be used the person responsible for the management and supervision of the installation assembly and disassembly must produce their own risk assessment for the specific use and environment in which the hoist will be used Testing the hoist The hoist must be tested only by authorised and qualified experts The person in charge of management and supervision is liable to give his approval to the use of electric chain hoists Such approval can only be given on condition that the occurred carrying out of the tests as laid down under paragraph 3 7 is duly proved Every possible transfer to other users must be documented in writing See E DIN 15 750 rules Using the hoist The hoist can be used only and exclusively by authorised and qualified experts By authorised and qualified expert it is intended a person who by virtue of his her training and professional experience has a specific competence in the field of safety and mechanical equipment and is familiar with the related nation
36. ividual safety devices Protect the hoist and its components against possible welding jets corrosive substances mechanical damages or severe weather conditions Keep the hoist clean and efficient by carrying out the suggested maintenance program Do not use the hoist in case of defective anomalous functioning in doubt of breakage incorrect movements anomalous noises In addition to the indications mentioned in this document the user must follow the rules on accident prevention and safety that are in force in the country where the hoist is being used Follow these operating instructions Only competent persons are permitted to use the equipment When preparing to lift a load be sure that the attachments to the hook are firmly seated in hook saddle Avoid off centre loading of any kind especially loading on the point of hook Before lifting load check for twists in the load chain On single reeved chain hoist used in conjunction with head blocks and ground support systems check for twists between the hoist and head block Twisted load can result in a jammed liftwheel On double reeved units a twist can occur if the lower hook block has been upturned between the strands of chain The hook should be reversed to remove the twist from the chain before operation Do not load hoist beyond the rated capacity shown on hoist identification plate or the hoist covers Overload can cause immediate failure of some load carrying part or creat
37. ken wire in circuit control station contacts not making upper limit switch contacts open c Phase failure C See item 1b 4 Hook raises but will not a Open lowering circuit open or shorted a Check electrical continuity and lower winding in reversing contactor coil repair or replace defective part loose connection or broken wire in circuit control station contacts not making lower limit switch contacts open 5 Hook lowers when hoisting a Phase failure a See item 1B control is operated b Phase reversal b Refer to installation instruction in chapter 3 6 Hook does not stop a Brake slipping a Check brake promptly b Excessive load b See item 1H 7 Hoist operates sluggishly a Excessive load a See item 1H b Low voltage b Correct low voltage condition c Phase failure or unbalanced current c See item 1b in the phases d Brake dragging e Check brake 8 Motor overheats a Low voltage a Correct low voltage conditions b Excessive load b See item 1H c Extreme external heating c Above an ambient temperature LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 36 of 40 C 104 F the frequency of hoist operation must be limited to avoid overheating of motor Special provisions should be made to ventilate the space or shield the hoist fr
38. lied by the vendor and must use them and request his labour force to follow such instructions and manuals and take suitable care in the maintenance of such products The purchaser must not remove or allow anyone to remove any warning plates or instructions on the product In the event of personal injury or damages to property or the Company resulting from the use of the product the Purchaser must give a written notification of such injury or damage to the vendor within 48 hours The Purchaser must cooperate with the Vendor in the inquiries on such injury or damage and in defence of any claim for damages If the Purchaser fails to follow this section or if the injuries or damages are caused totally or partially by the Purchaser s non observance of the federal or state laws on safety the Purchaser must indemnify and keep harmless the Vendor from any claim loss or expense for injuries or damages connected to the use of the product LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 55 10 MAINTENANCE REGISTER Date Activity Result Signature Notes LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 56 MAINTENANCE Date Activity Result Signature Notes
39. m info litectruss com Issue 2 0 18 June 2014 page 7 The location of such events include amongst other places theatres multipurpose halls studios film sets television and radio broadcasting concert halls conference centres schools exhibitions fairs museums discotheques vaudeville recreational parks sports facilities open theatres and meetings 1 4 Selection and Provision Electric chain hoists are offered in a multiplicity of designs and feature options as well as with different safety devices This means that the choice of chain hoist is extremely important Here consideration must be given to risks arising from the nature of the operational use and the specific operating conditions The selection must be based on the hazards arising from the type of use taking into account the specific conditions of use whilst abiding to the local laws in the country of use nok This standard differentiates between three types of electric chain hoists D8 Hoist ZN Electric chain hoist according to BGV D8 GUV V D8 previously GUV 4 2 Winches lifting and pulling devices for use as a chain hoist for lifting loads in construction D8 Plus Hoist Electric chain hoist based on BGV D8 GUV V D8 previously GUV 4 2 Winches lifting and pulling devices for use as a chain hoist for lifting loads in construction with the special characteristic of being able to hold loads statically above personnel without the use of secondary safe
40. mployed and local safety regulations are taken into consideration No makeshift repairs with the aid of extra pieces or taping are allowed It is prohibited to warm equipment with flames hot air or other instruments in case they are stiffened or blocked Always wait for parts to cool if the hoist has been running intensively before maintenance LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 30 5 2 Safety procedure Before carrying out any kind of maintenance repair cleaning or any activity that requires a manual intervention on the machine disconnect the power supply to the hoist Ensure the power can not be re connected to the hoist be securing or clearly marking the plug do not connect WARNING Before restarting the working cycle make sure all protections and protection devices in case removed are operating and properly functioning 5 3 Summary of periodic maintenance In order to keep a continuous and satisfactory operation a regular inspection procedure must be initiated to replace worn or damaged parts before they become unsafe Inspection intervals must be determined by the individual application and are based on the type of service to which the hoist will be subjected and the degree of exposure to wear deterioration or malfunction of the critical compone
41. nomena Testing must be carried out only by qualified personnel duly authorised for the purpose 5 5 Extraordinary maintenance The following operations replacement of equipment structural parts adjustments repairs or replacement of parts for the electrical system other operations not envisaged in this document are not included in the normal ordinary maintenance operations therefore an intervention request for qualified and authorised personnel is necessary by calling the manufacturer 5 6 General overhaul The provisions on industrial hygiene and safety provided by EC Directive 98 37 require the exclusion of all the risks deriving from fatigue and ageing of machinery Furthermore this request is contained in the 3rd updating of UW BGV D8 VBG8 industrial injuries rules of April 1 1996 In compliance with these rules the user of serial lifting equipment is compelled to determine the real use of the chain hoist based on the working hours load profiles and or recording coefficients For this purpose reference is made to FEM 9 755 06 1993 standard that defines measures for achieving safe periods of use for serial motorised chain hoists S W P Please see paragraph 2 1 From the mentioned FEM 9 755 standard the following points referring to the electric chain hoist have been extrapolated 1 the definition of the real use calculated based on the operating time and load must be documented at least once a year 2 the opera
42. nother place or non use for a long time pack it again and keep it in a dry place Place the hoist on the ground and hook the bag again make sure that the screw closures of the bag have been correctly closed 3 5 Checks before use Check integrity of the plug and wires Check integrity of the hoist metal housing No cracks or dents must be present All casing screws should be present and tight Check for water ingress Check that the sprung latches on the hooks are present and functioning correctly Check chain bag for damage Check brakes are working correctly 3 6 Suspending the hoist It is users responsibility to ensure all fixing points fixing hardware and control systems are visually inspected Cables must be placed in such a way that they do not come into contact with sharp edges and do not run the risk to be cut off Cables must not be placed under tension 3 6 14 Mounting the hoist Body down self climbing mode It is common to position the hoist in the required location whilst still in the flight case Power is connected to the hoist and the hook end of the chain is taken to the fixing point at height The hoist can then be operated to a working height position allowing the load to be connected This method of rigging is most commonly used in entertainment applications LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com
43. nts Check periodically that all the labels are present and readable on the hoist In addition to the suggested maintenance program below please also refer to the local regulations relating to lifting machinery The type of service to which the hoist is subjected can be classified as Normal Heavy or Severe Normal Service Involves operation with randomly distributed loads within the rated load limit or uniform loads less than 65 percent of rated load for not more than 25 of the time Heavy Service Involves operating the hoist within the rated load limit which exceeds normal service Severe Service Normal or heavy service with abnormal operating conditions Two classes of inspections frequent and periodic can be performed Frequent Inspections These inspections are visual examinations by the operator or other designated personnel Records of such inspections are not required The frequent inspections are to be performed monthly for normal service weekly to monthly for heavy service and daily to weekly for severe service and they should include those items listed in Table 9 Periodic Inspections These inspections are visual inspections of external conditions by an appointed person Records of periodic inspections are to be kept for continuing evaluation of the condition of the hoist Periodic inspections are to be performed yearly for normal Service every six months for heavy service and quarterly for severe service and
44. o not use the hoist if it is damaged malfunctioning or functioning in an unusual way Do not use the hoist if the chain is distorted corroded damaged or worn out Do not make modifications nor apply accessories other than those provided by LITEC Italia S p A Accessories causing dynamic overstressing or leading to accidental unexpected overloads or limiting the free handling of the load are not allowed Therefore only the lifting accessories that interpose in a passive way between the equipment and the load are allowed Do not try to lengthen the lifting chain or repair it if damaged Do not hit deform or crush the hoist chain danger of cracks or broken links may occur Do not weld Keep the chain away from open fire or flame Do not use the lifting chain as sling and do not wrap the chain around the load Do not put tools or foreign bodies in the links of the chain Do not place the load on the point or on the spring latch of the hook Do not operate the hoist beyond the limits of the chain Do not use the lifting chain or the hook as earthing for welding Do not connect the lifting chain or the hook to an energised welding electrode Do not use the hoist if this is not perfectly efficient even if it can work Do not use the hoist with worn out open hook or with missing spring latch Do not use the hoist to lift support or transport people Do not lift loads exceeding the maximum load limit of the hoist in body down mode the we
45. om radiation d Frequent starting or reversing e Phase failure or unbalanced current in the phase d Avoid excessive inching jogging or plugging This type of Operation drastically shortens the motor and contactor life and causes excessive brake wear e See item 1B f Brake dragging f Check brake 9 Hook fails to stop at either or both ends of travel a Limit switches not opening circuits a Check switch connections electrical continuity and mechanical operation Check the switch adjustment b Limit switch shaft not rotating b check for damaged Limit Switch gears 10 Hook stopping point varies c Travelling nuts not moving along shaft guide plate loose shaft or nut threads damaged a Limit switch not holding adjustment d Tighten guide plate screws Replace damaged part a see item 9 b Brake not holding b check the brake C binding of Limit Switch Shaft c Check Limit Switch Bearing for proper seating LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 37 7 RECOMMENDED SPARE PARTS To insure continued service of the EXE Rise chain hoists the following is a list of parts that are recommended to be kept on hand at all times to replace parts that have worn or failed WARN
46. oper reeving and twists Table 9 Minimum periodic inspections TYPE OF SERVICE ITEM Normal Heavy Severe a b c 5 D gt E 58 l D E 26 e gt DE LLI L f LLI All items listed in Table 9 for frequent inspections External evidence of loose screws bolts nuts External evidence of worn corroded cracked or distorted hook block suspension screw bearings and dead end block and chain pin External evidence of damage to hook retaining nut and pin Check the operation of the controller making sure the buttons operate freely and do not stick in either position Check the electrical cords and cables and controller for damaged insulation Inspect for signs of lubricant leaks LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 32 5 4 Maintenance assistance 5 4 1 Hook inspection Hooks damaged from chemicals deformations or cracks or that have a 10 twist from the hook s unbent plane excessive opening must be replaced Also hooks that are opened and allow the latch to not engage the P tip must be replaced Any hook that is twisted or has excessive opening indicates abuse or overloading of the unit Inspect other load sustaining parts hook block screws load pins and chain block body for damage Figure 20 To measure the opening the sprung la
47. or branch a Close switch replace fuse or the controler or control circuit switch open branch line fuse reset breaker device blown or circuit breaker tripped b Phase failure open circuit grounded b Check for electrical continuity or faulty connection in one line of and repair or replace defective supply system hoist wiring reversing part contactor motor leads or windings C Open control circuit open or shorted c Check electrical continuity and winding in transformer reversing repair or replace defective part contactor coil or loose connection or broken wire in circuit mechanical binding in contactor control station contacts not closing or opening d Wrong voltage or frequency d Use the voltage and frequency indicated on hoist identification plate e Low voltage Correct low voltage condition f Brake non releasing open or shorted f Correct low voltage condition coil winding armature binding g Excessive load g Reduce loading to the capacity limit of hoist as indicated on the identification plate 2 Hook moves in wrong a Phase reversal a Refer to installation instruction direction in chapter 3 3 Hook lowers but will not a Excessive load mechanical load a Refer to installation instruction raise protector slipping in chapter 3 b Open hoisting circuit open or shorted b Check electrical continuity and winding in reversing contactor coil repair or replace defective part loose connection or bro
48. or the Clutch Rotor Stator Ref no Description Part no 1 Motor shaft RWL 320 0010 2 Bakelite RWL 320 0012 3 Bearing Bearing 61903 4 Rotor Rotor 66 60 5 Pressure spring RWL 320 001 1 6 Bearing Bearing 61905 7 Blue Spring Blue spring 20x30 8 Self blocking D8 nut M8 nut 9 Stator Stator 110 60 66 4P LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 50 7 2 5 Reduction Gear 320kg EXE Rise Hoist Parts list required for Reduction gear 9 Ref no Description Part no 1 Screws Screw Tcei 6x100 2 Reduction flange RWL 320 0006 3 Main body from reduction unit side RWL 320 0005 4 Oil seal Oil seal 12 24 7 5 Bearing Bearing 6001 6 Primary pinion RWL 320 0018 7 Gear shaft RWL 320 0019 8 Bearing Bearing 61901 9 Toothed flange RWL 320 0017 10 Secondary pinion RWL 320 0015 LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 51 7 3 Wiring Diagrams 7 3 1 Wiring Diagram For Direct Control Chain Hoists V 230 Hz 50 60 f LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997
49. ork Protective equipment must be made available for operating and service personnel and worn at all times These sections should be adhered to and followed to ensure safe reliable and correct function of the product and to eliminate the possibility of damage persons or equipment WARNING The information reported in this manual represents important instructions on safety Non compliance to such instructions can endanger the safety of persons and or cause material damages detrimental to you or to others The operator or his representative is responsible for supervising operating personnel and ensuring they are aware of the hazards and safety implications of working with the electric hoist You should keep this manual clean complete and in a legible condition for future references Furthermore supplementary to the manual the statutory regulations governing general accident prevention and environmental protection are to be enforced This manual and the other documents contained in the packing are an integral part of the hoist supplied to you and must be carefully kept protected against humidity and any other deteriorating agents for all the lifecycle of the hoist They must follow the hoist in case of transfer to any other user or new owner 1 2 Replacement policy The hoist has been checked and performance verified by LITEC Italia S p A or one of its authorised service agents before shipping If the correctly maintained hoist
50. position the controller so it is safe and comfortable to use Do pay attention at all times when operating the hoist Do ensure the chain container is not obstructed in any way Do stay clear of moving chains Do ensure chain is lubricated at all times Please see paragraph 5 4 7 for chain lubrication guidelines It is prohibited to warm equipment with flames hot air or with other instruments if they are stiffened or blocked Call your EXE Rise supplier if the hoist does not work properly WARNING If damaged or worn parts are detected do not use the hoist Seek assistance for service of the unit 4 1 Attaching and moving the load Insert the hoist hook intended for load lifting into the load anchoring point Do not load hoist beyond the rated capacity shown on hoist identification plate Make sure hook travel is in the same direction as shown on the controls Check to be sure that the attachments to the load hook are firmly seated Make sure the hook latches are closed and not supporting any part of the load Check to ensure that the load point is in line with the hoist head WHEN APPLYING A LOAD IT MUST BE DIRECTLY IN LINE WITH THE HOIST AVOID OFF CENTRE LOADING OF ANY KIND Make sure the load has enough room to be free to move no obstructions must be present along its travel Do not allow the hook to swing risk of collision against things or people Do not wrap the hoist chain a
51. power supply is correctly in phase and voltage ranges between 230 and 400V Chain fall due to damaged chain bag Check bag for damage before use Do not fill bag over 75 capacity Various types of risks owing to electrocution malfunctioning etc non sectioning before any maintenance intervention Before any maintenance intervention disconnect the power supply from the hoist Sudden start owing to the insertion of the plug into a normal socket that is to say other than that of the controller or a suitable power unit It is prohibited to insert the plug into a socket other than that of the controller or the suitable power control unit Various types of risks owing to tampering or removal of the safety devices It is prohibited to tamper or remove the safety devices LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 19 2 9 Secondary safety components WARNING When operating a system according to D8 or if maintenance is required on a hoist that is still suspended a secondary safety device should be used A secondary safety component is a second independent equipment element suited to prevent the fall of the load Some application examples are illustrated here below Figure 13 Example of securing a load suspended from a
52. r tr teu ra e teen Lee E ER es hn ug e x cn 21 The hoist mounting in self climbing mode see se ee naana aa Re AA Ee ener nnne nnne nennen nn 24 Mounting the hoist DOGY Up i e ees Gees Gee Ee vy gee ee Bee SP og e hee nie Love et ieu eden 24 To measure the opening the sprung latch must be pushed against the body of the hook 32 Recommended el RE OR EE OR N NR N ER A 38 51 Wiring diagram for Direct Control chain hoists V230 Hz 50 60 sse 52 Wiring diagram for Direct Control chain hoists V400 Hz 50 60 sse 53 Index of tables Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Selection criteria for electric chain hoists for moving and holding loads above people 8 Comparison chart of the main EXE Rise chain hoistS ees se ee se se ee ee ee ee ge ee ee de ee ee ee ee ee ee ke ee eed ee ee ee ke ee nt 9 FEM classification Load speCtUM sissies niece ierit enini eg ske eg KRONE EG ERGER GARS SKEER bee ek Ge 13 FEM classification OE AR IE RE OE RE IE bea Fue e Ed 13 Environmental conditions ee ee AA Ee EA ae AA Ge AR Ge AR Ge AA Ge AA Ge ee sinere AR Ge ee ee ee 17 Residual c 19 Minimumi Mire SIZE Em 25 Minimum frequent inspections iese se ee Re AR AA AR ee ee de ee AA ee ee AR ee ee ee AAKE EAEE AAEE 32 Minimum periodic inspeetionS EE EE TUER 32 Troubleshooting based on hoist behaViOUF iese ees se
53. rease the chain Pack the hoist again Keep packaging in a safe covered place protected against shocks or contamination of corrosive substances protected against humidity or high differences in temperature maximum temperatures 10 C to 40 C LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 29 5 MAINTENANCE OF HOIST Simple inspection of the hoist and lubricating of the chain are the only interventions that should be undertaken by the user of the hoist All other maintenance replacement adjustment interventions that involve the opening of the hoist housing are allowed only to maintenance service authorised by LITEC The hoist must therefore be delivered to LITEC authorised centre that will issue special control and maintenance reports WARNING Maintenance and service are preventive measures designed to preserve the full functionality of electric chain hoists Non compliance with maintenance and service routines can result in reduction in the useful function of and or damage to chain hoists Maintenance work encompasses visual checks and cleaning routines Service work includes additional functional checks During the functional checks all securing elements and cable clamps must be checked for secure seating During maintenance and service work general accident prev
54. round the load or use it to carry out operations other than those indicated The loss of the swivel effect of the hook could result in twisted chain and a jammed lift wheel LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 27 Handle the load by using control buttons with a man present Motion stop occurs upon release of the activated button Move the load by operating the go button of the associated controller Maintain a firm footing or be otherwise secured when operating the hoist Before moving the load check for twists in the load chain Make sure the load is free to move it must not be fixed to the ground entangled etc Raise the load only enough to check the attachments to the hook and load are firmly seated Move the load slowly to avoid shock and jerking of load chain If there is any evidence of overloading immediately lower the load and remove the excess load Do not allow the load to swing During the movement of the load always appoint a responsible person to monitor and ensure the load is safe If the load encounters any obstruction stop movement immediately If the load is being moved on multiple hoists a safe operating procedure must be pre defined 4 2 Power Supply EXE Rise chain hoists are available in both direct and low voltage control They must be conne
55. s www facebook com litecitalia YouTube http www youtube com user litectruss LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 60
56. safety latch 2 7 3 Clutch The clutch is designed to slip in the case of excessive load If overloaded the hoist will not lift WARNING If the clutch is subject to prolonged slipping it can overheat and become damaged The clutch should not be allowed to slip continuously for more than 2 seconds Considering the above statements these hoists should not be used in an application where a suspended load can be increased by adding additional weight For example food lifts etc In addition if the hoist is used in extreme temperatures above 65 or below 10 degrees C the slipping properties of the clutch can be affected allowing heavier loads than normal resulting in possible damage accident or injury LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 18 2 7 4 Electrical connectors The electrical plug must be used to disconnect the power supply to the hoist in case of maintenance or emergency 2 8 Residual risks Residual risks related to a machine are accident risks that remain after the carrying out of all the safety measures taken by the manufacturer and which therefore must be managed by the user The most serious residual risks to which the safety signs installed on the hoist are associated are listed hereunder Table 6 Residual risks Residual risk
57. should present a performance problem due to faulty material or workmanship after inspection by LITEC Italia Spa or authorised agent repairing or replacement of the unit will be made free of charge in favour of the original purchaser This repairing replacement policy only applies to installed under maintenance and operating Hoists as highlighted in this manual and does not include the parts subject to normal wear and tear misuse improper installation inadequate and incorrect maintenance the effects of hostile environments and unauthorised repairing modifications LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 6 The manufacturer and dealers cannot accept responsibility for any damage or lack of functionality due to the following situations Carrying out inappropriate operations for an electric chain hoist Product modification without the express authorization of the manufacturer Inappropriate operation of the hoist Operational errors Failure to use the product as stated in the manual LITEC ITALIA SPA DECLINES LIABILITY FOR ANY DAMAGES ARISING FROM A NON COMPLIANT INSTALLATION AND MAINTENANCE INDICATED IN THIS DOCUMENT It is hereby reminded that if the hoist is used in Italy the user is compelled to follow the provisions of law provided for lifting equipment with load limit over 20
58. st must be used with a control system that meets local electrical safety regulations LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 16 2 6 3 Environmental conditions To ensure the hoists function correctly the following environmental conditions should be observed Table 5 Environmental conditions Temperature Temperatures ranging between 10 C and 40 C The relative humidity must not be higher than 5096 with maximum Humidity temperature of 40 C A higher relative humidity is allowed at lower temperatures ex RH 90 at 20 C Altitude Maximum altitude of 3 000 m Electromagnetic environment The hoist is designed to work correctly in an industrial type electromagnetic environment falling within the emission and immunity limits provided by the harmonised rules currently in force 2 6 4 Lighting During the set up and maintenance phases the lighting of the working place must meet the provisions indicated by Directive EEC 89 654 lower than 300 lux Nevertheless it is opportune that the diffusion intensity has not a value In case of use in environments with poor lighting typical of the entertainment sector the localised lighting of the control devices and the intervention area must be arranged 2 7 Hoist safety devices The hoist is equipped wit
59. tch must be pushed against the body of the hook On latch type hooks check to make sure that the latch is not i Y damaged or bent and that it operates properly with sufficient spring pressure to keep the latch tightly against the tip of the hook and allow the latch to spring back to the tip when released If the latch does not operate properly it should be replaced If the opening is greater than 5 the normal value 5 42 Chain inspection Chain should feed smoothly into and away from the hoist or hook block If chain binds jumps or is noisy first clean and lubricate it see below If trouble persists inspect chain and mating parts for wear distortion or other damage WARNING Use of commercial or other manufacturers chain and spare parts to repair the hoist may cause load loss Use only chains and spare parts supplied by the manufacturer 5 4 3 Clutch maintenance Any intervention on the clutch is prohibited Only LITEC authorised maintenance service is allowed to carry out possible maintenance interventions 544 Brake maintenance Any intervention on the Brake is prohibited Only LITEC authorised maintenance service is allowed to carry out possible maintenance interventions 5 4 5 Limit switch maintenance The device is calibrated in a standard way at the factory Operators can adjust it according to their specific needs LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 9
60. ted to shield it from the effects of the weather Wherever possible the electric chain hoist should be transported in its original packaging The goods delivered should be checked for completeness and the packaging disposed of in an environmentally sound manner 3 1 Handling amp transportation The customer must carefully check the goods for damage upon delivery Any damage in transit is the responsibility of the carrier Ensure all routes and areas are intended for handling are free from obstacles WARNING Lifting shifting and handling operations must be carried out by trained personnel duly equipped Do not halt for any reason below suspended loads during lifting operations During transport with trolleys or cranes the presence of a suspended load must be audibly and visually signalled A Banksman should be present when moving goods with machinery such as lift trucks Packaging elements such as plastic bags expanded polystyrene must not be released to the environment but must be kept in order to pack again the hoist after using it When working at height the user should employ relevant and suitable access and safety equipment 3 2 Packaging storage The goods are packaged in a way that offer protection from damage This packaging should be stored in a dry environment away from damp and heat Should the hoist not be operated immediately it is recommended to store it inside its packaging in a covered possibly dry
61. ting time T daily use hours can be estimated or recorded through an hour meter The load K duty factor must be estimated 3 When the operating time T is recorded by an hour meter the read value must be multiplied by the recording coefficient 1 1 4 When the operating hours and duty factor are estimated values they must be multiplied by the recording coefficient 1 2 5 The real use S is calculated with the formula S k x T x f 6 Upon reaching the theoretical life a general servicing must be carried out 7 All the verifications and general servicing are at the chain hoist user s charges General servicing includes the overhaul of the machine in order to detect structural elements and or particulars which are already defective or ready to become defective and replace them After general servicing for what concerns the operation and performance the machine is in the same conditions as a new one Please consider the calculation of the duty factor the additional factor and theoretical period of use LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 35 6 TROUBLESHOOTING Table 10 Troubleshooting based on hoist behaviour TROUBLE PROBABLE CAUSE CHECK AND REMEDY 1 Hoist does not respond to a No voltage at hoist main line
62. to a reimbursement of the purchase price upon return of the goods to the vendor Any action against the vendor for breach of contract negligence or others must be initiated within one year from the occurrence of such trial action No claim for damages to the vendor for any defects of the goods shall be deemed valid or applicable without the written notification of the purchaser if it is not received by the vendor within one year from the shipping date The vendor is not liable for any damage injury or loss due to improper use of the goods if before such damage injury or loss such goods are 1 damaged or used in an improper manner following the delivery of the vendor to the forwarding agent 2 not serviced inspected or used in compliance with the applicable laws and vendor s written instructions and advices or 3 installed repaired tampered or modified without LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 54 compliance with such law instructions or advices Under no circumstance the vendor shall be liable for accidental or consequential damages since these terms are defined in section 2 715 of the uniform commercial code 9 2 Compensation and use under safety The purchaser must follow and request his labour force to follow the provisions indicated in the instructions and manuals supp
63. tower by means of a locking bar LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info glitectruss com Issue 2 0 18 June 2014 page 20 4 tid Figure 14 Example of a secondary safety component attached Figure 15 Example of a secondary safety component attached directly to the load that is being lifted front view directly to the load that is being lifted perspective view 3 i 6 i me a a rj v f 7 n a Figure 16 Example of a secondary safety component attached Figure 17 Example of a secondary safety component attached below the hoist bypassing the hoist lifting mechanism front below the hoist bypassing the hoist lifting mechanism view perspective view LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 21 3 INSTALLATION When handling and unpacking the hoist you should use safe handling techniques Electric chain hoists must be assembled by qualified staff always bearing in mind the accident prevention directions in chapter 2 Before assembly the electric chain hoist must be stored in an enclosed room or covered area Should the electric chain hoist be destined for operation outdoors then it is recommended that a protection cover is erec
64. ty devices C1 Hoist scenery hoist Electric chain hoist according to BGV C1 GUV V C1 previously GUV 6 15 Staging and production facilities for the entertainment industry for holding and moving loads above personnel The types of electric chain hoists specified above can be operated both individually and in groups The choice of the type of electric chain hoist depends on the operating conditions D8 with D8 secondary safety D8 Plus C1 device Where personnel are under the load Holding loads not permitted permitted permitted permitted Erection not dismantling not permitted not permitted f permitted uide permitted rigging operations not n Scene movement not permitted not permitted permitted permitted Complex Scene i not movement not permitted not permitted permitted permitted Table 1 Selection criteria for electric chain hoists for moving and holding loads above people Where equipment is permanently installed in locations where events take place electric chain hoists according to BGV C1 GUV V C1 should be provided on account of the mode of operation and the anticipated risks The use should refer to VPLT standard for information Source igw SQ P2 Electric chain hoists LITEC Italia Spa Via Martin Luther King 70 31032 Casale sul Sile TV Italy T 39 0422 997 300 F 39 0422 997 399 www litectruss com info litectruss com Issue 2 0 18 June 2014 page 8 1 5 T
65. uired for Reduction gear 620 2 000 kg EXE Rise chain hoists esse se se ee es se se ee ee ee ge ee ee 7 2 320 kg EXE Rise Hoists perspective view iese se se ees se se ee ee ee ge ee ee ee ee ee ee ee ge ee ee ee ke ee ee ee ke ee ee ee ke enne ee ke ee ee 7 2 1 Parts list required for 320 kg EXE Rise hoist iese se ees se se ee es se se ee erences ee ee ke ee ee ee ke ee ee Ge ke ee ee ee ke ee ee ee nnne 7 2 2 Parts list required for Main body 820 kg EXE Rise hoist iese esse se ee es se se ee ee ee ee ee ee ee ee ee ee ee ke nennen 7 2 3 Parts list required for Chain fastener 320 kg EXE Rise hoist sse 7 2 3 Parts list required for Clutch Rotor Stator 320 kg EXE Rise hoist esse dese ee esse ee ee ee ee ee ee ee ee ee ee ee ee ee 7 2 4 Parts list required for Reduction gear 320 kg EXE Rise hoist iese esse se ee es se ee ee ee ee ke ee ee ee ke ee ee ee e Lo WING ClaGraMS RE EE EE EE OR EE NE NE OE NE EN 7 3 1 Wiring diagram for Direct Control chain hoists V230 Hz 50 60 ees ee ee ee ke ee ee ee ee RR ee ee Ge ee ee ee 7 3 2 Wiring diagram for Direct Control chain hoists V400 Hz 50 60 esse ee sse 8 DEMOLITION AND DISPOSAL toritate tortor ese dee acc ek bes ee saec eran See aiaa danse a Ure ace RR ee AE ER en 9 WARRANTY Es 9 1 Warranty limitations remedies and damage ee se ee ee ee ee e
66. wear parts brake disc pendant with cable safety catch plastic box 9 1 Warranty limitations remedies and damages This warranty does not apply where normal wear abuse improper or inadequate maintenance eccentric or side loading overloading chemical or abrasive actions excessive heat or unauthorised modifications or repairs cause deterioration of the hoists This warranty does not apply to products which LITEC Italia has determined to have been misused or abused connected to voltages other than those recommended improperly maintained by the user or where the malfunction or defect can be attributed to the use of non genuine LITEC Italia parts This expressed warranty is in lieu of all other warranties expressed or implied of marketing fitness for a particular purpose or in any other manner no promise or assertion of fact declared by any vendor s agent or representative shall constitute a vendor s warranty or shall determine any liability or obligation The vendor guarantees that at the delivery date to the forwarding agent the goods are free from defects in workmanship and materials The sole obligation of possible breach of the warranty or contract for negligence or in any other manner concerning the goods sold shall be exclusively limited to repair or replacement f o b vendor s shipping point of any part that the vendor determines to be faulty or should the vendor determine that such repair or replacement cannot be undertaken
67. wings eret EE EG Ag Ee RE tt SE RED ee duce Ci EED c ge GED ee ins EE ce Ge ered DR GED ee as 10 1 7 amp Exploded Ee Te EE EE EE EE EE 11 1 7 1 320 kg EXE Rise chain hoist ss ee esse ee es se se ee ee ee ee ee se ee ee ee ee ee ee ee ee ee ee ee ee ee ee Re ee ee Re ee ee trennen nennen nn ee 11 1 7 2 620 2 000 kg EXE Rise chain hoists esse see ee ee ee ee ee ee ede ee ee ee ee ee Ge ede ee ee ee ee ee ee Re de ee ee ee ee Ge Re de ee ee ee ee tenete ee ee ee 12 1 8 VEG ER OR RR EE N EE EE ON 12 2 SAFETY PRECAUTIONS As SE ke N t ee EE E EO 13 2 1 Regulations and Standards eicere KEPER ge OR KEEP eg ee etti ge eN KEUSE ee ha eO tu we ees EE US EEU Ve eg 13 2 2 Operational parameters iis ee AA Ge AA Re AR ek AA Ge AA Re AA AA AA Ge AA ee inns senis ss Re ee ee ee Ak AA ee ke ee ee 13 2 3 Safe operating instructions and procedureS iese ee RA Ge AA Ge ee AR AA Ge AA ee ee ee RA ee de enneunen ee 16 2 4 ese eM 17 2 5 Operatorsreguirement ss ee GER EE ES ee eu Tuner eat a E RN n Oe See ERR REC ave EE DER ARE ene de ee ee Gey ee van 15 2 6 Structural and environmental requirements eise esse ee ee Re AA AA ee AR Re Ge AA ee ee ee ee AA ee ee ee enne 16 2 6 1 Structural resistance see ee AA Ge AA de AR ek AA Ge AA Re AR ee AA ee AA ee ennt AG AA Re ean ee ee sens s nnns internen 16 2 6 2 Electrical requirements esse see ee ee ee ee EA ee AA Ge AA Ge AA Ge AA Ee Ke tris Ge nnns entr ness Ge Ge nns 16 2 6

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