Planeta Pullmaster-II Manual

PLANETA
1861
Heben ohne Grenzen
Operating and maintenance instructions for:
Pullmaster-II chain hoist
Installation – Operation – Maintenance
© Copying, even in part, is only allowed with the written permission of PLANETA-Hebetechnik GmbH
01-02-11-0000-0221-00-BA-EN-PLA
IMPORTANT - READ BEFORE USE!
PLANETA-Hebetechnik GmbH •Resser Str. 17 & 23 • D-44653 Herne
Tel. [phone] • Fax [phone] • [email protected] • www.planeta-hebetechnik.de

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Table of contents Page
SAFETY INSTRUCTIONS...............................................................................................4
I. General...................................................................................................................5
II. Important notes ......................................................................................................5
III. Particular safety instructions ..................................................................................6
IV. Installation information ...........................................................................................6
A. Before commissioning........................................................................................6
B. Installation and inspection before each use.......................................................7
C. Important notes..................................................................................................7
V. Inspections, repair and maintenance .....................................................................8
Additional inspection ..............................................................................................8
Adjusting the brakes...............................................................................................8
Checking the chains and hook ...............................................................................8
Maintenance.........................................................................................................10
 Lubricationspecication .......................................................................................10
VI. Technical data ......................................................................................................11
VII. Spare parts for Pullmaster-II chain hoist .............................................................12
VIII. Spare parts list for Pullmaster-II chain hoist ........................................................13
IX. Annual checks for statutory accident prevention..................................................19
CE DECLARATION OF CONFORMITY ........................................................................20

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SAFETY INSTRUCTIONS
1. Read the manu-
al!
2. NEVER lift
an excessive
load!
3. NEVER lift
over people!
4. NEVER pull
the chain
across sharp
edges!
5. NEVER
operate the
equipment
when it is
defective!
6. NEVER carry
people!
7. NEVER throw
the hoist
8. NEVER use
the load chain
for slinging
purposes
9. NEVER work
up to the end
of the chain!
10. NEVER attach
the load with
the tip of the
hook!
11. NEVER work
with a chain
that is twisted or
damaged!
12. NEVER work
without a
hook safety
catch!
13. NEVER
remove the
warning
notices

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I. General
These operating and maintenance instructions are intended to provide you with
important instructions for the safety and reliability of your chain hoist. They are not a
substitute for the industrial safety regulations and the accident prevention regulations
issued by the employer’s liability insurance associations and the many standards,
which may differ in the respective countries.
Pleaseobservethecountry-specicrulesandregulations.
In Germany, the currently valid industrial safety regulations, the regulations of the
DGUV employer’s liability insurance association and the legal regulations of the
community for machinery 2006/42/EC (Machinery Directive) apply.
Intellectual property
Designs, drawings and technology are the sole property of the manufacturer.
It is expressly prohibited to copy or utilise this type of information, or pass it on to third
parties, without express written permission.
II. Important notes
– Before installation and use, you must read through the operating manual and make
it available to the operator of the equipment.
– The operator must be properly instructed in how to use the equipment.
– Never exceed the working load limit (WLL) on the product label plate.
– Do not pull chains over edges.
– Never use the product to carry people or lift loads over areas where there could be
people.
– The equipment must be inspected once a year by aqualiedexpert, more
frequently in harsher operating conditions.
Thecompanymustensurethattestcerticatesareissued.
– Before use, inspect the equipment for damage, loose bolts or twisted chains and
rectify any faults.
– Repairs to hoists may only be performed by the manufacturer or by a trained
service partner, using original spare parts.
– Failure to observe the instructions in the manual, improper use, corrosion due to
inadequateprotectionorunauthorisedmodicationstotheproductwillvoidthe
guarantee.
– Risk of corrosion due to it being continuously subjected to unfavourable weather
conditions,suchashighhumidityorharmfulenvironmentalinuences,e.g.
atmospheres with acidic vapours, corrosive gases or a high concentration of dust
will lead to premature wear. This does not constitute entitlement to a warranty
claim.
– We would be happy to provide you or your specialist dealer with further information
or parts lists.

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III. Particular safety instructions
Certain work and activities are not allowed whilst using the chain hoists, because it is
dangerous to life and can cause injuries and damage to the machine, e.g.:
– You must read the operating manual before commissioning
– NEVER lift more than the prescribed rated load
– NEVER lift the load over people
– NEVER pull the chain across sharp edges
– NEVER operate the equipment when it is damaged
– NEVER use the equipment to lift or carry people
– NEVER throw the equipment
– NEVER use the load chain for rigging purposes
– NEVER work up to the end of the chain
– NEVER attach the load with the tip of the hook
– NEVER work with a chain that is twisted or damaged
– NEVER work without a hook safety catch
– NEVER remove the warning notices
– NEVER use the chain as a carrying sling
– NEVER leave suspended loads unattended
– NEVER pull suspended loads at an angle
– NEVER use the chain hoist to free stuck or seized loads
IV. Installation information
A. Before commissioning
– Chain hoists made movable by means of a trolley or which were already delivered
with a trolley are subject to the German industrial safety regulation (BetrSichV) and
the DGUV regulations for cranes. Theymustbecheckedbyacertiedinspector
before initial commissioning (load-bearing capacity over 1 t).
– Never use the chain hoist at temperatures below -20 degrees Celsius or above
+60 degrees Celsius.

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B. Testing before each use
– Hang the chain hoist with the hook in the support structure and turn once.
– The hand chain and load chain must hang down freely without any bends or twists.
– Pull the hand chain all the way through once.
– Inspecting the load brake: Raise the load slightly and hold it in place. If the load
holds securely, raise it further. During lowering, the load must not slip when the
hand chain is stopped.
– If all goes well, operation can be initiated.
– Important for equipment with multiple chain strands: Load hook
block shall not be passed through the chain loop. This can
be recognised from the twisted chain. The respective second
chain link in a row is not evenly aligned. If the weld seams of
the chain links do not run in the same direction, the hook block
must be folded back through the chain loop.
– The last chain link must be attached to the housing, or be
equipped with a chain end stopper.
C. Important notes
– Check that the delivered chain hoist corresponds with your order, that it is compete
andthatallscrewsandnutsarermlytightened.
– Make sure that no transport damage has occurred.
– Check whether the load-bearing structure supporting the hoisting equipment is of
the correct type and strength for the required loads. A statics appraisal must be
obtained for on-site load-bearing constructions, if necessary.
– Never attach the top hook just on the tip to the load support structure.
Always load the chain in a straight pull!
– Before use, the hooks must undergo a special check for wear, bending or other
damage.
– Ensure that the hook is suspended properly.
Do not apply loads to the tip, do not overload!
– When the minimum load (approx. 10% of the rated load) is attached, the brake
engages automatically.
– The chain hoist is only suitable for raising and lowering vertically.
– To move the load, pull the hand chain up or down.
NEVER

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V. Inspections, repair and maintenance
Regular visual inspection must be carried out by authorised, trained personnel
according to the legal regulations. Also pay attention to any unusual working noises!
Additional inspection: more than one visual inspection is required for the braking
system. Brake tests should be executed as follows:
– Attach the load (rated load)
– Lift the load
– Lift and lower the load to various heights
– Check whether holding of the load is guaranteed in any position.
Adjusting the brakes
(see adjacent illustration):
– (A) Setting with highest braking effect
– (B) Release of the brake by slowly turning from
position (A),
Insertion of the safety split pin
– Change the friction plates if the disc thickness is less
than 1 mm.
If it is discovered that parts are not okay when the chain hoist is being dismantled, they
should be replaced with corresponding original parts.
The names of the individual replacement parts can be obtained from the list on the
following pages. The proper order number, name and carrying capacity of the device
shouldbespeciedwhileorderingtheparts.
In case of doubt, the defective part should be sent in for inspection.
Please check the chain regularly at short intervals.
Check for wear, nicks, cuts, cracks, gauges, bednings, cross-sectional deviations and
other damages.
Chains and hook
– The chains and hooks must be inspected on a regular basis! Clean the chain before
inspection. Lightly oil the load chain from time to time! Never oil or grease the
brake!
– The threaded chain must not creak under load.
– Check the chain for elongation! The inner length (t) of a worn chain link, the
smallest wire diameter (D) and the length over 11 chain links are measured using a
calliper, whereby the chain must be kept taut.
If the measured dimension then exceeds the dimension (a) stated in the following
table, then the chain must be replaced. The diameter must not be less than
dimension (D), do not exceed the spacing (t) on an individual link.

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Load
bearing
capacity
Max. measurement over Min. chain link
diameter (D)
1 chain link
(t)
11 chain links
(a)
0.5t 15.5mm 170.5mm 4.5mm
1t & 2t 18.6mm 204.7mm 5.4mm
1.5t & 3t 24.8mm 272.8mm 7.2mm
5t & 10t 31.0mm 341.0mm 9.0mm
If the chain needs replacement, it is assumed that the chain sprocket is also affected.
This must also be checked for wear.
Hook test (items 30, 34): Hooks can be bent open or elongated due to an
impermissible heavy load and improper handling of the equipment.
If the original dimension "G" is exceeded by 10%, the hook must be replaced.
Since the hooks vary due to forging tolerances, actual dimension "G" on
the equipment in question must be measured by the operator before initial
commissioning, and entered in the following table.
Load-
bearing
capacity
Hook opening "G"
Max. x 1.1
Normal Maximum Measured
0.5t 28mm 30.8mm mm mm
1t 32mm 35.2mm mm mm
1.5t 38mm 41.8mm mm mm
2t 40mm 44.0mm mm mm
3t 45mm 49.5mm mm mm
5t 50mm 55.0mm mm mm
10t 64mm 70.4mm mm mm
Caution: For any repairing works never perform any welding work or other hot
treatment directly on hooks or chains!
The material properties are otherwise changed, possibly causing accidents.
Jaw span
a = 11 links

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Measurement must be carried out as follows:
– Measure from metal to metal in the hook opening, not including
the hook safety catch.
– The abrasion of the hook surface must not exceed 10 %
of the actual value.
– Determine the lateral torsion of the hook!
Intheeventoftwistingthatexceeds10degreesbeyondatness,
the hook must be replaced.
– Check the hook safety catch for tight closure and smooth
operation! Replace if damaged!
– Excessivedamageduetochemicalorcorrosiveinuences
require replacement of the hooks.
– Do not repair a hook by welding or grinding!
These tests are to be carried out qualied specialists for hoisting equipment only. If you
do not have this knowledge, please contact your supplier or us. We perform regular
testing, also within the framework of the Maintenance Agreement.
Maintenance
When you stop using the equipment, pay attention to the following:
– Wipe off dirt and water, lightly oil the chain and the rotating parts of the hooks.
– From time to time - depending on the frequency of use - check whether there is still
asufcientamountofgreasethegearwheels.
Lubrication specication
Put a thin coat of Molykote grease on all mechanically moving parts (gear wheels, etc.).
Exception: Brake components must not be lubricated!
When not in use, hang the chain hoist up in a dry place.
Please note that safe and problem-free operation is only guaranteed if original spare
parts are used.
If you would like to have the device checked or repaired within the scope of the
guarantee, please send in the device in the assembled condition.
If you are sending in dismantled devices, we are unfortunately no longer able to accept
warranty claims.
Torsion