Tractel tralift TT Series Installation guide

GB
FR
DE
Electric chain hoist 125 - 6300 kg
Palan à chaîne électrique 125 - 6300 kg
Electrokettenzug 125 - 6300 kg
tralift™ TT / tralift™ TTR
Installation, operating and maintenance manual English Original manual GB
Manuel d'installation d'emploi et d'entretien Français Traduction de la notice originale FR
Installations-, Gebrauchs- und
Wartungsanleitung Deutsch Übersetzung der Originalanleitung DE
1
Not for USA and Canada

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Spare parts/Ordering spare parts
The part numbers of original spares can be found in the
respective spare parts list. Please enter the data of your
electric chain hoist below for future reference, so as to
always have them to hand. That will allow you to nd
the right parts quickly.
Electric chain hoist type:................................................
Manufacturing number:..................................................
Year of construction:......................................................
Lifting force:...................................................................
Original spare parts for the electric chain hoist can be
ordered from the following addresses:
1. Manufacturer
TRACTEL TRADING LUXEMBOURG
Rue de l’industrie
Foetz 3895 LUXEMBOURG
Phone [phone]
Fax [phone]
www.tractel.com
Reseller
.......................................................................................
.......................................................................................
.......................................................................................
.......................................................................................
.......................................................................................
1. General instructions
1.1. General safety instructions
1.1.1. Safety instructions and hazards
The following symbols and words are used in this
operating manual to provide safety and hazard
information:
WARNING: This symbol indicates a risk of serious
or fatal injury if working or handling instructions are not
followed or not followed adequately.
Warnings must be strictly followed.
CAUTION: This symbol indicates a risk of serious
damage to property if working and handling instructions
are not followed or not followed adequately.
The instructions under “Caution” must be strictly
applied.
RECOMMENDATION: This symbol means that
following the working and handling instructions makes
work simpler and more e󰀩cient.
Recommendations make work easier.
1.2. General safety and organisational
measures
The operating instructions must always be readily
available at the place where the electric chain hoists
are used. Service instructions must be followed.
In addition, laws and regulations relating to safety and
environmental protection must be followed.
Users and maintenance personnel must rst read and
understand the operating and safety instructions before
starting work. Protective equipment for the user and
maintenance personnel must be provided and used.
The owner of an electric chain hoist, or its supervisor
must supervise the safe and hazard-free use and
handling of the hoist by personnel.
1.2.1. Safety colours/Markings/Warning signs
– Chain lubrication........................................ Figure 1-1
– CE symbols ............................................... Figure 1-2
– Hoist type plate.......................................... Figure 1-3
– Specications plate.................................... Figure 1-4
– Electrical voltage ....................................... Figure 1-5
Contents
Spare parts/Ordering spare parts...........2
1. General instructions ...........................2
2. Description .........................................6
3. Commissioning.................................10
4. Care and maintenance.....................15
5. Measures for safe working ...............18
6. Appendix...........................................19

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Figure 1-1
Figure 1-2
Figure 1-3
Figure 1-4
Figure 1-5
1.3. Special safety instructions
Transport/assembly:
– Carefully attach the electric chain hoist or its
components or units to lifting equipment in perfect
condition and with su󰀩cient lifting capacity.
Connections:
– Connections must be prepared by personnel with
relevant experience.
Starting up/use:
– Prior to commissioning or daily start up, carry out a
visual inspection and check as instructed.
– Only use the electric chain hoist if the protective and
safety systems are in working order.
– Report any damage to the electric chain hoist or any
irregularity in operation to the competent individual.
– After the electric chain hoist has been shut down, take
steps to prevent accidental or unauthorised starting up.
– Do not carry out any unsafe operation.
See also “Proper Use” (section 1.6).
Cleaning/maintenance/repair/servicing:
– Use trestles for assembly work above waist height.
– Do not use machine parts as a substitute for trestles.
– Check electrical cables for rubbing or damage.
– Take care to remove, collect and dispose of operating
and ancillary products in a safe and environmentally
friendly manner.
– Safety devices that have been removed during
assembly, maintenance or repair work must be
reinstalled and inspected immediately after such work.
– Follow the frequencies specied in the operating
instructions for inspection and maintenance work.
– Inform the personnel using the equipment before any
special or routine intervention.
– Adequately demarcate the maintenance area.
– Protect the electric chain hoist from unexpected
starting up during maintenance and repair work.
– A󰀩x warning boards.
– Disconnect the power supply and protect the
equipment from unauthorised starting up.
– Tighten the connecting screws according to the rules
if they have been unscrewed during maintenance or
repair work.
Shutting down/storage:
– Clean and protect (oil/grease) the electric chain hoist
if it is to be put out of service and stored for a long
period.
1.4. Instructions for protection from hazards
Hazard zones must be clearly marked with warning
signs, and access must be closed o󰀨. Make sure that
hazard warnings are followed.
Hazards may arise due to:
– improper use,
– inadequate compliance with safety instructions,
– failure to carry out verication and maintenance work.
1.4.1. Mechanical hazards
Injury:
WARNING:
Loss of consciousness and injury:
– bruises, cuts, tangling, rubbing,
– being pulled, pushed, poked or rubbed,
– slipping, tripping, falling.

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Causes:
– in areas liable to bruise, cut or wind up,
– breakage, splintering of parts.
Protective measures:
– keep the oor, equipment and machines clean,
– eliminate leaks,
– keep safe distances.
1.4.2. Electrical hazards
Work on electrical equipment and operating machinery
may only be carried out by electricians or experts
working under the supervision of an electrician, in
accordance with electrotechnical regulations.
Injury:
WARNING:
Death by electrocution, injuries and burns caused by:
– contact,
– faulty insulation,
– faulty maintenance and repair,
– short circuit.
Causes:
– contact or close proximity with uninsulated conductors
in working condition,
– use of non-insulated tools,
– electrical conductors or parts with defective insulation,
– imperfect maintenance work and lack of inspection
after an intervention,
– mounting of unsuitable fuses.
Means of protection:
– disconnect the power supply to defective machines or
equipment before any work (inspection, maintenance
or repair)
– rst make sure that the power supply has been
switched o󰀨
– regularly check the electrical equipment
– replace loose or damaged cables
– when replacing blown fuses, make sure they are
equivalent
– avoid touching electrical conductors
– only use electrically insulated tools
1.4.3. Noise emission
Noise measurements are carried out at distances of 1,
2, 4, 8 and 16 m from the centre of the electric hoist to
the measuring instrument.
Noise emission measurement according to DIN 45 635.
Noise has been measured:
a. when using the electric hoist in the workshop.
b. when working outdoors.
Table 1-1 - Noise emission
Measuring distance 1 m 2 m 4 m 8 m 16 m
Series Type of
measurement dBA
TT 250/500 a) 65 62 59 56 53
b) 65 59 53 47 41
TT 125, TT 250/500
single phase
a) 76 73 70 67 64
b) 76 70 64 58 52
TT 1000, TT 1000
single phase
a) 80 77 74 71 68
b) 80 74 68 62 56
TT 1600/2500 a) 80 77 74 71 68
b) 80 74 68 62 56
1.5. Technical skills
1.5.1. Periodic inspections
Every user of the equipment or system is required to
correctly record all tests, maintenance and overhauls in
the service logbook and to submit it to the supervisor or
the industry specialist.
The manufacturer shall not be liable in the event of false
or incomplete records.
CAUTION: Hoists and cranes must be tested from
time to time by an industry specialist. Basically, this is a
visual and functional inspection where the condition of
components is examined for damage, wear and tear,
corrosion and other changes. In particular, the presence
and functioning of safety systems must be examined.
Disassembly may be required to determine the wear
and tear of some parts.
CAUTION: Lifting accessories must be examined
along their entire length, including concealed parts.
CAUTION: All periodic inspections must be
demanded by the user.
1.5.2. Guarantee
– The guarantee shall not apply if installation, operation,
inspection and maintenance are not carried out in
accordance with these operating instructions.
– Repairs and troubleshooting under the guarantee
shall only be carried out by qualied personnel after
consultation with the manufacturer/supplier and as
ordered by it. The guarantee shall not apply if the
product is modied and non-original spare parts are
used.
1.6. Appropriate use
Electric chain hoists from the TT/TTR range are
classied according to their lifting force. They may be
used both in stationary and mobile applications. Electric
chain hoists are designed and built according to the

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latest technical and safety criteria and are subjected to
a safety test by the manufacturer.
Electric chain hoists are approved by the approval
bodies (BG, etc.).
The electric chain hoists of the aforementioned range
are to be used only in perfect technical condition, for
the work for which they are intended and by trained
personnel, in accordance with safety regulations.
General conditions of use:
– ambient temperature: -15°C to +50°C
– ambient humidity: max. 80% relative humidity
– type of protection: IP65
When tralift™ TT/TTR chain hoists are used outdoors,
the addition of a roof for protection from the weather
is recommended; alternatively, store the chain hoist,
trolley and drive carriage under a shelter when not in
use. Special conditions of use may be agreed with the
manufacturer in particular cases. Based on the enquiry,
an optimised and appropriate conguration of the
equipment and important information for safe operation
with reduced wear and tear can be provided. Proper
use of electric chain hoists also entails the application
of the operating, maintenance and repair conditions
provided by the manufacturer.
Due to the excellent corrosion resistance of the
components located on the load line, chain hoists
of the tralift™ TTR range are specially designed for
applications in the food industry and in clean rooms,
and also in aggressive environments with salt water
or dust. Cathodic dip painting of aluminium parts
guarantees high colour fastness and very e󰀨ective
protection from corrosion. The grease used in the
gearbox is a food grade grease. These hoists use a
stainless steel lifting chain. As these chains are not as
strong as standard chains, the safe working loads of
these hoists are reduced.
The following are not considered to be in accordance
with the intended purposes:
– exceeding the maximum permissible load;
– pulling loads at an angle (maximum tilt angle 4°, see
Figure 1-6);
– snatching loads, pulling them or dragging them on the
ground;
– transporting personnel;
– moving loads over people;
– being under suspended loads (see Figure 1-7);
– pulling the control cable;
– diverting the chain over edges;
– failure to supervise the loads at all times;
– dropping the load with the chain slackened;
– use in an explosive environment.
Also see section 1.3.
Figure 1-6
Figure 1-7

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Avoid operating the equipment in jogs, allowing the
chain to slacken and starting against limit switches. The
supplier shall not be liable for damage to the equipment
or to third parties as a result of improper use.
2. Description
General:
The tralift™ TT series consists of the following models:
TT, TTK, TTS, TTHK, TTHTD, TTR.
2.1. Working conditions
Classication according to elds of application:
Electric chain hoists and trolleys are classied in a
usage group according to the following criteria:
– DIN EN14492-2 (A5= 125000 cycles)
– DIN 15401 (load hook)
– ISO 4301-1: D (M5) = 1600 h
– Information on general overhauls (see Section 4)
Specic and di󰀨erent values apply to the usage groups
and they must be observed in practice.
CAUTION: The trolley will have the same
classication of mechanisms as the electric hoist.
RECOMMENDATION: The usage group of the
electric chain hoist is indicated on the specications
plate of the hoist.
The manufacturer guarantees safe and long-lasting
use only when the hoist is used in accordance with the
values corresponding to its usage group.
Prior to commissioning, the owner of the machine must
assess which of the four load types is applicable for the
use of the electric chain hoist during its entire service
life using the characteristics in Table 2-1. Table 2-2
provides the guidance values for the operating
conditions in number of cycles/day depending on the
classication and the load condition.
Denition of the appropriate use of an electric chain
hoist:
To determine the appropriate use of an electric chain
hoist, evaluate the number of cycles or the expected
load condition.
CAUTION: Prior to commissioning the electric
chain hoist, dene the load condition according to
Table 2-1 - Load conditions. The selected load condition
(Q) must remain unchanged over the entire service life
of the equipment and, for safety reasons, must not be
changed under any circumstances.
Example 1: Dene the permissible operating time of an
electric chain hoist:
A class A4 electric chain hoist must be used at medium
speed throughout its service life. That corresponds
to load condition Q4 heavy> (see Table 2-1 - Load
conditions). According to the guidance values in
Table 2-2 - Working conditions, the electric chain hoist
may not be in e󰀨ective service more than 60 cycles per
day.
Example 2: Dene the appropriate load condition:
A class A5 electric chain hoist may be operated with
approximately 400 cycles per day over its entire service
life. In that case, the equipment must be operated in
the light Q2> regime (see Table 2-1 - Load conditions).

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Table 2-1 - Load conditions
Load type Q2
light
Q < 0.50
Q = 0.50
Load type Q3
medium
0.50 < Q < 0.63
Q = 0.63
Load type Q4
heavy
0.63 < Q < 0 80
Q = 0.80
Load type Q5
very heavy
0.80 < Q < 1.00
Q = 1.00
% of load capacity
% of operating time
% of load capacity
of operating time
% of load capacity
of operating time
% of load capacity
of operating time
Only exceptionally at full load;
otherwise mainly at reduced
load
Often at full load, otherwise
reduced load operation
Frequently at full load,
operation with medium load
Regularly at full load
Q = Load condition (loading)
Table 2-2 - Working conditions
Classication according to
DIN EN 14492-2 (ISO 4301-1) A3 (M3) A4 (M4) A5 (M5) A6 (M6) A7 (M7)
Load condition Number of cycles per working day
(lifting classes Dh2 - Dh5, lifting speed 8 m/min)
Q2 - light Q < 0.50 120 240 480 960 1920
Q3 - medium 0.50 < Q < 0.63 60 120 240 480 960
Q4 - heavy 0.63 < Q < 0.80 30 60 120 240 480
Q5 - very heavy 0.80 < Q < 1.00 15 30 60 120 240

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2.2. Overall description
Figure 2-1, tralift™ TT range
1
2
3
4
5
6
7
8
Control box with 1 fall with 2 falls
1. Control unit
2. Rotor shaft
3. Motor
4. Casing
5. Brake
6. Electrical control
7. Reducer
8. Limit switch

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Figure 2-2, tralift™ TTR range
Control box with 1 fall with 2 falls
The electric chain hoist complies with the EU Machinery
Directive and the EN standards used.
The casing and cover of the electric chain hoist are
made of die-cast aluminium. Cooling ns located near
the motor ensure optimum cooling. The chain box may
be fastened to the compact casing. Two holes have
been provided for screwing in the mains connection
cable and the control cable. The eye or hook suspension
is fastened to the ange.
Tractel electric chain hoists are driven by asynchronous
motors. Two-speed models are equipped with a polarity
switching motor.
The braking system consists of a DC magnetic
brake. When the power to the system is switched o󰀨,
compression springs provide braking torque.
The slip joint is mounted upstream from the braking
system and incorporated into the rotor shaft. It protects
the chain hoist from overloads and serves as an upper
and lower limit switch.
An upper and lower limit switch is used to limit hook
travel. Downstream forced-disconnecting emergency
stop contacts are available as an option.
Electric chain hoists are equipped as standard with a
42 V contactor control system. The standard emergency
stop switch switches o󰀨 the three main phases of the
mains when the red button is pressed.
The chain of TT series hoists is made of high-strength
proled steel and complies with the DAT quality class
(8SS) according to DIN EN 818-7. The chain wheel is
hardened. The load hook according to DIN 15401 has
a safety catch.
Straight spur gears with two or three closed stages are
usually helical gears. The gears are mounted on roller
bearings and lubricated with grease.
The electric chain hoist is equipped as standard with a
control box (moving up/down with the emergency stop).

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3. Commissioning
WARNING: Mechanical adjustments may only be
carried out by authorised specialists.
CAUTION: Users must read the operating
instructions carefully and carry out all tests before the
electric hoist is put into operation for the rst time. The
equipment may only be put into operation once safe
operation has been guaranteed. Unqualied individuals
may not be allowed to operate or work with the hoist.
The owner of the electric chain hoist must open
the logbook when the hoist is commissioned. The
logbook contains all technical data and the date
of commissioning. It serves as a logbook for all
maintenance and service work.
3.1. Transport and assembly
Follow the safety instructions (see section 1.3) during
transport and assembly.
Electric chain hoists must be installed by experts in
accordance with accident safety regulations (see
section 1.2). The electric chain hoist must be stored
under a shelter before assembly. When the electric
chain hoist is used outdoors, the addition of a weather
protection roof is recommended.
The hoists should preferably be transported in
their original packaging. The delivery must be fully
inspected and the packaging material disposed of in an
environmentally friendly manner. It is recommended to
have the electric chain hoist installed and commissioned
by competent individuals.
3.2. Connection
3.2.1. Electrical connection
WARNING: Electrical adjustments may only be
carried out by authorised specialists.
To connect the electric chain hoist to the mains, the
mains cable, mains fuse and main switch must be
provided by the customer.
A four-conductor cable with PE earthing is required as a
power cable for the connection of three-phase models.
For single-phase models, a three-conductor cable with
earthing is su󰀩cient. The length and cross-section must
be selected according to the current consumption of the
electric chain hoist.
– Before connecting the electric chain hoist, check that
the operating voltage and frequency indicated on the
rating plate correspond to the mains voltage.
– Remove the cover on the electrical side.
– Insert the power supply cable with the M25 × 1.5
screw type cable gland into the side hole and connect
it to terminals L1, L2, L3 and PE according to the
connection diagram included in the delivery (see
Figure 3-1).
– Insert the control cable with the M20 × 1.5 screw
type cable gland into the hole on the lower part of the
housing and connect it to terminals 1, 2, 3, 4, 10 (see
Figure 3-2).
– Install the strain relief on the housing (see Figure 3-3).
CAUTION: The control switch must be suspended
from the strain relief cord, not from the cable.
Figure 3-1 Figure 3-2 Figure 3-3
L3
L2
L1
PE
4
3
1
2
1
0
1
2
3
4
10
NA
1 speed
4
2
3
1
4
4
1 speed
3
3
3
4
2 speed
2 speed
2
red
21
red
1
2 1 10 4 3
WARNING:
– inspect the direction of rotation: if the direction of
movement of the lifting hook does not match the
button symbols on the control box, the supply wires
L1 and L2 must be reversed.

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– when the cover is removed, pay attention to the
rotating fan rotor (ref. 1, gure 3-3b).
RECOMMENDATION: Opening of the terminal
used as shown in Figure 3-3c.
Figure 3-3b
Figure 3-3c
3.2.2. Lifting chain
CAUTION: Use only original chains.
– The welds of the chain links must be on the inside
(see Figure 3-4).
– When inserting the chain by pulling, the limit switch
must be mechanically deactivated, see chapter 3.2.3.
The entire length of the lifting chain must be coated with
oil before commissioning and during use. Gearing and
friction parts must always have oil. Lubrication is carried
out using penetrating gear oil (type SAE 15W-40), by
immersing the chain in an oil bath or with the help of
an oil can.
The end of the chain must be attached to a exible
wire (1) and inserted through the chain nut (2) into the
electric chain hoist. The chain (3) shown in Figure 3-4
is inserted in small jogs.
The lifting height must be selected so that in its lowest
position, the hook rests on the ground.
Figure 3-4
3
2
1
One-fall operation:
The load hook (1) is connected to the chain by means
of the clamping piece (2). For power transmission, it is
important to t the pin (3) (see Figure 3-5 for TT range
hoists and Figure 3-5b for TTR range hoists).
CAUTION:
• make sure that the suspension is positioned
correctly (dimension k1):
– TT125 single phase : symmetric
– TT250/500 k1= 41 mm (gure 3-6)
– TT1000 k1= 43 mm (gure 3-6)
– TT1600 k1= 53 mm (gure 3-6)
– TT2500 k1= 87 mm (gure 3-6b)
• Grease the bearings adequately.

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Figure 3-5
3
1
2
Figure 3-5b
3
1
2
Figure 3-6
k1
Figure 3-6b
Two-fall hoist:
Connect the carrying end of the chain with the chain
holder (3) and x it in the guide rail of the housing.
Attach the reeving jaw (2) to the load hook (1) as shown
in Figure 3-7 for TT series hoists and Figure 3-7b for
TTR series hoists.
CAUTION:
• make sure that the suspension is correctly
positioned (dimension k2):
– TT250/500 k2= 52 mm (gure 3-8)
– TT1000 k2= 62 mm (gure 3-8)
– TT1600 k2= 73 mm (gure 3-8)
– TT2500 k2= 130 mm (gure 3-8b)
• Avoid twisting the chain lengthwise (see
Figure 3-9).
• Grease the bearings adequately.

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Figure 3-7
2
1
4
3
Figure 3-7b
3
1
2
Figure 3-8
k2
Figure 3-8b
Figure 3-9
3.2.3. Limit switch
The electric chain hoist is equipped with an integrated
limit switch as standard. That switch is also suitable as
a regular nal limit switch with high switching accuracy.
The function of the limit switch (extreme positions of the

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hook at the top and bottom) must be checked during
commissioning.
Four di󰀨erent increasing gears adapted to the height
are available:
TT 125
increasing
gear Colour one-fall lifting height [m] two-fall lifting height [m]
i = 1:1 black 14 -
i = 1:1.5 red 21 -
i = 1:3 yellow 42 -
i = 1:6 blue 90 -
TT 250/500
increasing
gear Colour one-fall lifting height [m] two-fall lifting height [m]
i = 1:1 black 19 9.5
i = 1:3 yellow 57 28.5
i = 1:6 blue 114 57
TT 1000
increasing
gear Colour one-fall lifting height [m] two-fall lifting height [m]
i = 1:1 black 30 15
i = 1:1.5 red 45 23
i = 1:3 yellow 90 45
i = 1:6 blue 102 96
TT 1600
increasing
gear Colour one-fall lifting height [m] two-fall lifting height [m]
i = 1:1 black 34 17
i = 1:1.5 red 51 25.5
i = 1:3 yellow 102 51
i = 1:6 blue 204 102
TT 2500
increasing
gear Colour one-fall lifting height [m] two-fall lifting height [m]
i = 1:1 black 42 21
i = 1:1.5 red 63 31.5
i = 1:3 yellow 126 63
i = 1:6 blue 252 126
Description of the adjustment (see Figure 3-10):
– Before inserting the chain or while changing the chain,
the travel switch must be mechanically deactivated by
locking the rocker (1).
– Provision only with model TT 125: Loosen screws
(1+2) and turn clamping strp (3) away (see gure
3-10 bis)
– Insert the chain.
– Raise the hook to the highest position, turn the red
control wheel (2) (on the front) of the switch cam of the
upper limit switch (3) (turn clockwise for a high hook
position and anticlockwise for a low hook position).
– Engage the rocker, lower the hook to the lowest
position, turn the green control wheel (4) (at the back)
of the switch cam of the lower limit switch (5) (turn
anticlockwise for a high hook position and clockwise
for a low hook position).
– Engage the rocker (it must snap into the control
wheel).
– Check the operation of the limit switch device; the
limit switch stop and the hook assembly must not
touch the casing.
Figure 3-10
3
1
2
5
4
Figure 3-10 bis
3.2.4. Chain box or bag
– Pull the chain out on the load side until the limit switch
trips.
– Install the free end of the chain on the box or bag (see
Figure 3-13).
– Install the chain box and feed in the chain (see
Figure 3-11).

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WARNING: All sheet steel chain boxes must be
secured with an additional steel cable of at least 2 mm
diameter (see Figure 3-12).
Note: for TT125 see gure 3-12 bis
Figure 3-11
Figure 3-12
Figure 3-12 bis
Figure 3-13
4. Care and maintenance
Malfunctioning electric hoists that are unsafe to use
must be put out of service immediately.

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4.1. General instructions for maintenance
and repair work
CAUTION: Maintenance and service work on the
electric chain hoist may only be carried out by suitably
qualied and trained personnel.
CAUTION: If the owner carries out maintenance
work on the electric hoist under its own responsibility,
the work and the date of intervention must be recorded
in the service logbook.
Any modications and additions to the electric hoist that
could have an e󰀨ect on safety must rst be approved
by the manufacturer. In the event of an accident,
the manufacturer shall not be liable if the hoist has
undergone unauthorised modications.
The equipment guarantee will only be valid if original
manufacturer’s spare parts are used.
The customer must particularly note that original spare
parts and accessories not supplied by the manufacturer
are not tested or approved by the manufacturer.
General:
Care and maintenance work are required to ensure
the safe and proper working of electric chain hoists.
Failure to observe maintenance frequencies can lead
to malfunctioning and damage.
Inspections and maintenance must be carried out from
time to time according to the operating instructions (see
Table 4-1 - Overview of inspections and maintenance
and Table 4-2 - Overview of maintenance work).
Follow the requirements of safety regulations
(section 1.3) and take precautions to prevent injuries
and accidents (section 1.4).
WARNING: All inspections and maintenance work
may only be carried out when the hoist is not under load
and is out of service. The main switch must be switched
o󰀨. The block or the hook must be placed on the oor or
on the service platform.
Inspections and maintenance include visual inspections
and cleaning work. Maintenance work also includes
operating inspections. During operating inspections,
inspect all fasteners and electrical cable terminals.
Cables must be inspected, in particular for dirt, cuts,
wear, colour change and possible e󰀨ects of calcination.
In case of damage, replace them with original parts.
CAUTION: Dispose of and store industrial oils (oil,
grease, etc.) in accordance with environmental
protection regulations.
Care and maintenance work is to be carried out at the
following frequencies:
t: daily
3 M: every 3 months
12 M: every 12 months
Care and maintenance frequencies should be increased
if the electric chain hoist is subjected to extraordinary
loads or if it is often used in unfavourable conditions
(e.g. dust, heat, humidity, steam, etc.).
4.2. Care and maintenance
4.2.1. Overview of inspections and maintenance
Table 4-1 - Overview of inspections and maintenance
Term Daily test Activity Notes
1. Lifting chain X
X
Visual inspection for damage
Clean and lubricate if necessary
2. Hoist and trolley X
X
Sound inspection: check for unusual noises
Seal inspection
3. Power cable X Visual inspection
4. Limit switch X Operating inspection See section 3.2.3
5. Braking system X Operating inspection
6. Retainer cable of the pendant
control electrical cable X Visual inspection See picture 3.3

17
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4.2.2. Overview of maintenance work
Table 4-2 - Overview of maintenance work
Term Annual
inspections Activity Notes
1. Seal X Visual inspection
2. Lifting chain X
X
grease
measure wear See sections 3.2.2 / 4.2.4
3. Braking system X Slip resistance test with load See section 4.2.3
4. Electrical connections X Operating inspection
5. Safety screws on suspended
parts and lifting hook with
accessories
X
X
Crack detection
Screw play inspection See section 4.2.8
6. Limit switch X Control of switching elements See section 3.2.3
7. Slip friction clutch X Overload test See section 4.2.7
4.2.3. Braking system
The spring brake is an electromagnetically actuated
single disc brake with two friction surfaces. The braking
force is provided by pressure springs. Braking torque is
generated when the system is switched o󰀨. Release is
electromagnetic.
The brake must be able to hold the rated load when the
power is switched o󰀨.
CAUTION: The voltage of the brake coil must
necessarily match the operating voltage.
4.2.4. Lifting chain
Lifting chain wear must be measured from time to time.
4.2.5. Limit stop
CAUTION: If the stop plate at the bottom of the
casing is defective, it must be replaced.
Check the screw connection at the end and the block
assembly and, if necessary, tighten to the recommended
torque. Guidance values in section 4.2.8.
4.2.6. Gear
The reducer gears are permanently lubricated. The
reducer casing must not be opened.
4.2.7. Friction coupling
The friction clutch is factory set at 125% of the maximum
working load.
4.2.8. Suspension pieces
All parts under static loads are considered to be load-
bearing parts. The bearing surfaces of swivelling
suspension pieces must be greased periodically.
Tightening torques for class 8.8 screws to DIN ISO 898:
M 4 M 5 M 6 M 8 M 10 M 12
3.3 Nm 6 Nm 10 Nm 24 Nm 48 Nm 83 Nm
Data for ordering spare parts can be found on page 3.
Table 4-3: Wear values for suspension pieces
Suspension piece TT 125 TT 250 TT 500 TT 1000 TT 1600 TT 2500
Load hook H [mm] 18.0 28.0 28.0 35.5 35.5 35.5
min. h [mm] 17.1 26.6 26.6 33.8 33.8 33.8
Suspension hook H [mm] 18.0 28.0 28.0 35.5 35.5 35.5
min. h [mm] 17.1 26.6 26.6 33.8 33.8 33.8
Hanging eye H [mm] 11.0 15.0 15.0 20.0 20.0 20.0
min. h [mm] 10.5 14.3 14.3 19.0 19.0 19.0
Hook opening L [mm] 24.0 34.5 34.5 42.6 44.6 44.6
min. l [mm] 26.4 37.9 37.9 46.8 49.0 49.0

18
GB
Figure 4-4
5. Measures for safe working
Special risks, which can for instance occur due to
fatigue and ageing, must be eliminated under the health
and safety requirements of EC directives.
Thus, the owner of standard lifting equipment is required
to determine its actual service life. That is determined
by the after-sales service department as part of the
annual inspection. When the total theoretical number
of work cycles under load has been reached or no later
than after 10 years of service, a general overhaul must
be carried out.
All inspections and general overhauls must be carried
out at the request of the owner of the lifting equipment.
For electric chain hoists classied according to DIN
EN14492-2, the total number of load cycles depending
on the load condition is shown in table 5-1.
5.1. Determination of actual use S
The actual use depends on the daily operating time and
the load conditions.
The determination of the operating time is based on
the owner’s information or logged by an operating
data counter. The load conditions are determined in
accordance with Table 2-1 - Load conditions. From
these two pieces of information, the annual usage
time shown in Table 5-2 - Annual Usage Time can be
deducted.
For electric hoists equipped with a BDE
(Betriebsdatenerfassungs-Gerät = operating data
logging device), the actual use can be read out directly
by our competent employee.
CAUTION: The values calculated or read from time
to time must be entered in the service logbook.
5.2. General overhaul
A general overhaul must be carried out when the
theoretical limit of the total number of cycles under load
is reached, or no later than after 10 years if there is no
work data recording system. In that case, the hoist is
refurbished to enable it to be used safely for a second
period of use. The components are tested and changed.
Testing and approval for a future period of use must be
carried out by a person skilled in the area and authorised
by the manufacturer or by the manufacturer itself.
The specialist denes:
– the new theoretical usage value,
– the maximum operating time until the next general
overhaul.
The data are recorded in the service logbook.
Table 5-1: Total number of work cycles under load
Classication according to
DIN EN 14492-2 (ISO 4301-1) A3 (M3) A4 (M4) AS (M5) A6(M6) A7 (M7)
Load condition Number of load cycles over the entire service life
Q2 = 0.50 250,000 500,000 1,000,000 2,000,000 4,000,000
Q3 = 0.63 125,000 250,000 5,000,000 1,000,000 2,000,000
Q4 = 0.80 63,000 125,000 250,000 500,000 1,000,000
Q5 = 1.00 31,500 63,000 125,000 250,000 500,000

19
GB
Table 5-2: annual usage (208 workdays/year)
Number of cycles per
working day
<= 15
(15)
<= 30
(30)
<= 60
(60)
<= 120
(120)
<= 240
(240)
<= 480
(480)
<= 960
(960)
<= 1920
(1920)
Load condition Annual usage in full load cycles
Q2 = 0.50 400 800 1600 3150 6300 12,500 25,000 50,000
Q3 = 0.63 800 1600 3150 6300 12,500 25,000 50,000 100,000
Q4 = 0.80 1600 3150 6300 12,500 25,000 50,000 100,000 200,000
Q5 = 1.00 3150 6300 12,500 25,000 50,000 100,000 200,000 400,000
6. Appendix
Table6-1:Specicationsofthree-phaseTTmodels
DIN EN (ISO)
classication
A3 (M3)
15 C/d
(25% ED)
A4 (M4)
30 C/d
(30% ED)
A5 (M5)
60 C/d
(30% ED)
A6 (M6)
120 C/d
(50% ED)
A7 (M7)
240 C/d
(60% ED)
A7 (M7)
240 C/d
(60% ED)
Lifting
speed
50 Hz
Lifting
speed
60 Hz
Type of
motor Number of falls Dead weight 3m lift
stroke
Mains
connection
fuse (400 V,
time lag)
Series Load capacity [kg] [m/min] [m/min] [kg] [A]
TT250 1 fall 400 320 250 200 160 125 8/2 9.6/2.4 80 B 8/2 1 24 6
400 320 250 200 160 125 8 9.6 80 B 2 1 24 6
TT500 2 falls - 630 500 400 320 250 4/1 4.8/1.2 80 B 8/2 2 25 6
- 630 500 400 320 250 4 4.8 80 B 2 2 25 6
TT500 1 fall 800 630 500 400 320 250 8/2 9.6/2.4 80 B 8/2 1 26 6
800 630 500 400 320 250 8 9.6 80 B 2 1 26 6
TT1000 2 falls - 1250 1000 800 630 500 4/1 4.8/1.2 80 B 8/2 2 28 6
- 1250 1000 800 630 500 4 4.8 80 B 2 2 28 6
TT1000 1 fall 1600 1250 1000 800 630 500 8/2 9.6/2.4 100 B 8/2 1 58 10
1600 1250 1000 800 630 500 8 9.6 100 B 2 1 57 10
TT2000 2 falls - 2500 2000 1600 1000 1000 4/1 4.8/1.2 100 B 8/2 2 62 10
- 2500 2000 1600 1000 1000 4 4.8 100 B 2 2 61 10
TT1600 1 fall 2500 2000 1600 - - - 8/2 9.6/2.4 100 C 8/2 1 93 16
2500 2000 1600 1250 1000 - 4 4.8 100 AL 4 1 88 16
TT3200 2 falls - 4000 3200 - - - 4/1 4.8/1.2 100 C 8/2 2 102 16
- 4000 3200 2500 2000 - 2 2.4 100 AL 4 2 97 16
TT3200 1-fall - 3200 - - - - 6.4/1.4 7.8/1.9 100 C 8/2 1 100 16
TT2500 1 fall - - 2500 - - 8/2 9.6/2.4 100 C 8/2 1 100 16
TT3200 1-fall - 3200 - - - - 3.2 3.4 100 AL 4 1 95 16
TT2500 1 fall - - 2500 - - 4 4.8 100 AL 4 1 95 16
TT6300 2 falls - 6300 - - - - 3.2/0.8 3.8/1 100 C 8/2 2 117 16
TT5000 2 falls - - 5000 4000 - - 4/1 4.8/1.2 100 C 8/2 2 117 16
TT6300 2 falls - 6300 - - - - 1.6 1.9 100 AL 4 2112 16
TT5000 2 falls - - 5000 4000 - - 2 2.4 100 AL 4 2112 16

20
GB
Table6-2:SpecicationsTT(single-phasemodels)
DIN EN (ISO)
classication
A3 (M3)
15 Z/d
(25% ED)
A4 (M4)
30 Z/d
(30% ED)
A5 (M5)
60 Z/d
(40% ED)
A5 (M5)
60 Z/d
(40% ED)
A5 (M5)
60 Z/d
(40% ED)
A5 (M5)
60 Z/d
(40% ED)
Lifting
speed
50 Hz
Lifting
speed
60 Hz
Type of
motor Number of falls Own
weight
3 m lift
Mains
connection fuse
(230 V, time lag)
Series Load capacity [kg] [m/min] [m/min] [kg] [A]
TT125 1 fall - - 125 100 80 - 8 9.6 71 A 4 1 17 10
TT250 1 fall - - 250 200 160 125 8 9.6 80 A 4 1 24 10
TT500 2 falls - - 500 400 320 250 4 4.8 80 A 4 2 25 10
TT500 1 fall - - 500 400 320 250 4 4.8 80 A 4 1 26 10
TT1000 2 falls - - 1000 800 630 500 2 2.4 80 A 4 2 28 10
TT1000 1 fall - - 1000 800 630 500 4 4.8 90 B 4 1 56 16
TT500 1 fall - - 500 400 - - 8 9.6 90 B 4 1 56 16
TT2000 2 falls - - 2000 1600 1250 1000 2 2.4 90 B 4 2 60 16
TT1000 2 falls - - 1000 800 - - 4 4.8 90 B 4 2 60 16
Table6-3:TTelectricalspecications(three-phasemodels)
Series Type of
motor Number of poles PNnNMin./max. currents and starting current
3 × 400 V, 50 Hz 3 × 230 V, 50 Hz
IN 380 IN 415 Imax. IA/IN 415
power
factorN
IN 220 IN 240 Imax. IA/IN 240
power
factorN
[kW] [1/min] [A] [A] [A] [A] [A] [A]
TT250 1 fall/
TT500 1 fall
TT500 2 falls/
TT1000 2 falls
80 B 8/2 8 0.18 665 1.4 1.9 2.2 1.45 0.51 2.4 3.1 3.5 1.45 0.51
2 0.72 2745 2.4 3.4 3.7 2.75 0.77 3.2 4.3 4.7 2.75 0.77
80 A 4 4 0.55 1420 1.3 1.9 2.2 1.65 0.68 2.6 3.2 4.1 1.65 0.68
80 B 2 2 0.72 2745 3.2 3.4 3.7 2.75 0.77 5.6 5.9 6.2 2.75 0.77
TT1000 1 fall/
TT2000 2 falls
100 B 8/2 8 0.57 675 3.8 4.3 5.1 1.45 0.58 7.1 7.4 9.0 1.45 0.58
2 2.3 2790 5.3 6.2 7.8 2.75 0.77 8.2 9.3 10.7 2.75 0.77
90 B 4 4 1.5 1430 3.4 3.8 4.2 1.65 0.76 6.1 6.5 7.4 1.65 0.76
100 B 2 2 2.3 2790 6.2 7.3 8.6 2.75 0.77 10.4 13.2 15.8 2.75 0.77
TT1600 1 fall/
TT2500 1 fall
TT3200 2 falls/
TT6300 2 falls
100 C 8/2 8 0.93 685 4.8 6.0 6.5 2.35 0.53 8.2 9.7 11.0 2.35 0.55
2 3.7 2820 9.8 9.7 10.5 4.95 0.82 15.8 15.2 16.5 4.95 0.82
100 AL 4 4 2.2 1415 5.3 5.7 6.1 1.65 0.80 7.6 7.8 10.5 1.65 0.80
100 C 2 2 3.7 2820 10.4 10.8 11.7 4.95 0.82 17.8 18.5 19.8 4.95 0.82
Table6-4:TTelectricalspecications(three-phasemodels)
Series Type of
motor Number of poles PNnNMin./max. currents and starting current
3 × 460 V, 60 Hz
IN 380 IN 415 Imax. IA/IN 415
power
factorN
[kW] [1/min] [A] [A] [A]
TT250 1 fall/
TT500 1 fall
TT500 2 falls/
TT1000 2 falls
80 B 8/2 8 0.22 815 1.2 1.5 1.9 1.45 0.50
2 0.86 3345 2.3 2.8 3.2 2.75 0.76
80 A 4 4 0.66 1720 1.4 1.5 2.0 1.65 0.67
80 B 2 2 0.86 3345 3.2 3.4 3.7 2.75 0.76
TT1000 1 fall/
TT2000 2 falls
100 B 8/2 8 0.68 825 3.8 4.1 4.7 1.45 0.57
2 2.8 3390 5.3 5.8 7.3 2.75 0.76
90 B 4 4 1.8 1730 3.4 3.8 4.2 1.65 0.75
100 B 2 2 2.8 3390 6.2 6.5 8.1 2.75 0.76
TT1600 1 fall/
TT2500 1 fall
TT3200 2 falls/
TT6300 2 falls
100 C 8/2 8 1.15 835 5.1 5.3 5.9 2.35 0.54
2 4.5 3420 9.4 9.6 10.2 4.95 0.81
100 AL 4 4 2.7 1715 5.3 5.7 6.1 1.65 0.79
100 C 2 2 4.5 3420 10.4 10.8 11.7 4.95 0.81