Original Operating Instructionsludwigsystem.com/wp-content/uploads/2017/08/BA... · Supply 1 - 2 LUDWIG HOOK XL / Ludwig System GmbH & Co KG: 83435 Bad Reichenhall / Tel.: +49 8651

Original Operating Instructions

Ludwig System GmbH & Co KG, Am Kraftwerk 3, 83435 Bad Reichenhall

Tel.: +49 8651 7656730, [email protected], www.ludwigsystem.com

Remote-controlled slinging equipment

Reference: 20170629_Rev01_DE

Preface

We thank you for your decision to acquire remote-controlled slingingequipment from Ludwig System GmbH & Co KG.

We would ask you to read the following operating instructions and to observethe listed items in order to guarantee problem-free, and primarily safe,operation.

• You should use the load slinging equipment in accordance with the oper-ating instructions.

• The load slinging equipment should be serviced and cleaned at regular in-tervals.

Copyright

The operating instructions are the intellectual property of Ludwig SystemGmbH & Co KG. It must not be copied, neither completely or partially asextracts, published or used in any other way for exploitation.

Modifications

We retain the right to make modifications in the course of designdevelopments without having to correct these operating instruction at thesame time.

Issue date: 17.7.17

Content

1 - 1LUDWIG HOOK XL / Ludwig System GmbH & Co KG; 83435 Bad Reichenhall / Tel.: +49 8651 7656730

1 Delivery 1-11.1 Scope of supply for the LUDWIG HOOK XL Systems . . . . . . . . . . . . . . . 1-1

1.1.1 Standard1-11.1.2 Options1-2

1.2 Identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2 Safety 2-12.1 Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 Use range/Limitations to use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32.3.1 Foreseeable misuse....................................................................2-3

2.4 Areas of application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42.4.1 Direct tension ..............................................................................2-42.4.2 Indirect tension............................................................................2-4

2.5 Three-stage safety concept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42.5.1 Two-button actuation...................................................................2-42.5.2 Opening safety device.................................................................2-42.5.3 Power failure ...............................................................................2-42.5.4 Load table - Direct tension ..........................................................2-52.5.5 Load table - Indirect tension........................................................2-5

2.6 Organizational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52.6.1 Operating instructions .................................................................2-52.6.2 Legal note ...................................................................................2-6

2.7 Personnel selection and qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2.8 Notes concerning normal operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72.8.1 Take safety measures.................................................................2-72.8.2 Carry out function check .............................................................2-72.8.3 Barrier-free environment for radio remote control .......................2-82.8.4 Check radio frequency ................................................................2-82.8.5 Manufacturer's data.....................................................................2-92.8.6 Maintaining safety distance.........................................................2-9

2.9 Information concerning special types of danger . . . . . . . . . . . . . . . . . . . 2-102.9.1 Residual dangers ......................................................................2-10

2.9.1.1 Latch...........................................................................2-102.9.1.2 Locking pin .................................................................2-112.9.1.3 Danger of fire/damage from deep discharge..............2-12

2.10 Liability exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

3 Product 3-13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13.2.1 LUDWIG HOOK XL.....................................................................3-1

Content

1 - 2LUDWIG HOOK XL / Ludwig System GmbH & Co KG: 83435 Bad Reichenhall / Tel.: +49 8651 7656730

3.2.2 Radio remote control .................................................................. 3-2

4 Charging process 4-14.1 Chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Charging process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14.2.1 Charging mobile charger ............................................................ 4-2

4.2.1.1 Charging conditions mobile charger ............................ 4-34.2.1.2 Charging conditions charging table ............................. 4-34.2.1.3 Adding extra charging tables (option) .......................... 4-4

4.2.2 Charging LUDWIG HOOK XL..................................................... 4-54.2.2.1 Mobile charger installation ........................................... 4-64.2.2.2 Charging conditions (LED)........................................... 4-7

4.2.3 Charging battery of radio remote control .................................... 4-74.2.3.1 Removing the antenna................................................. 4-74.2.3.2 Inserting charging cable............................................... 4-84.2.3.3 Inserting the charger into the mains socket ................. 4-94.2.3.4 Installing the antenna................................................... 4-9

5 Operation 5-15.1 Load types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1.1 Single strand load ....................................................................... 5-15.1.1.1 Single strand load (90°) ............................................... 5-1

5.1.2 Two strand load .......................................................................... 5-25.1.2.1 Two strand load (75-90°) ............................................. 5-25.1.2.2 Two strand load (45-75°) ............................................. 5-35.1.2.3 Two strand load (30-45°) ............................................. 5-3

5.1.3 Permissible load on latch............................................................ 5-4

5.2 Slinging types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55.2.1 Direct tension.............................................................................. 5-55.2.2 Indirect tension ........................................................................... 5-6

5.3 Choker hitch with lifeline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

5.4 Before starting work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-85.4.1 Radio remote control preparation ............................................... 5-8

5.4.1.1 Installing the antenna................................................... 5-85.4.1.2 Carrying out checks ..................................................... 5-85.4.1.3 Chest belt (option) ....................................................... 5-95.4.1.4 Rubber protection sleeve (option)................................ 5-9

5.4.2 Preparing LUDWIG HOOK XL.................................................. 5-105.4.2.1 Slinging from crane hook ........................................... 5-105.4.2.2 Carrying out function check ....................................... 5-11

5.5 Suspending the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-145.5.1 Closing the latch manually........................................................ 5-145.5.2 Suspending the load in the latch............................................... 5-16

5.6 Lifting the load - operating conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Content


5.7 Putting down the load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

5.8 Releasing the load by radio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-195.8.1 Single actuation.........................................................................5-195.8.2 Group actuation.........................................................................5-20

5.9 After completing work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-215.9.1 Suspended from crane..............................................................5-215.9.2 In extreme weather ...................................................................5-21

5.10 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

6 Disposal and recycling 6-16.1 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.3 Battery recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26.3.1 Note concerning the battery statute ............................................6-2

7 Maintenance/problem treatment 7-17.1 Maintenance by operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1.1 Lubrication/cleaning ....................................................................7-17.1.2 Function check and cleaning.......................................................7-2

7.2 Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.3 Maintenance/testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37.3.1 Annual maintenance ...................................................................7-37.3.2 Testing ........................................................................................7-3

7.4 Problem treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

8 Technical data 8-18.1 Technical data - general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.2 Technical data - electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.4 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8.5 Environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-38.5.1 Operation ....................................................................................8-38.5.2 Charging......................................................................................8-38.5.3 Storage........................................................................................8-38.5.4 Operation/storage charger ..........................................................8-3

9 EU-Declaration of Conformity 9-1

Content


Supply


1 Supply

1.1 Scope of supply for the LUDWIG HOOK XL Systems

1.1.1 Standard

Scope of supply

Item Name Number

1 Radio remote control with integrated battery 1 off

2 Antenna radio-control 1 off

3 LUDWIG HOOK XL 1 off*

4 Mobile charger 1 off*

5 Adapter for mobile charger 1 off*

6 Charging table for mobile charger 1 off*

7 Mains unit for radio remote control 1 off

8 Mains cable for mains unit charging table 1 off

9 Mains unit charging towel 1 off

10 Original operating instructions (not shown) 1 off

11 Transport case (not shown) 1 off

* Number as per customer request

Fig.: 1-1 Standard scope of supply

Supply


1.1.2 Options

1.2 Identification plate

* Serial Number: see chap. 9 “EC Declaration of Conformity” on page 9 - 1

Options

Item Name Number

1 Chest strap 1 off*

2 Rubber protection sleeve 1 off*

3 Lifeline 1 off*

* Number as per customer request

Identification plate

Item Name

1 Type*

2 Serial Number*

3 Year of manufacture*

4 Min./Max. Load

5 Manufacturer's address

6 CE marking

7 TÜV marking

Fig.: 1-2 Identification plate

A

Safety


2 Safety

2.1 Symbols usedThe following names and characters are used for particularly important detailsin the operating instructions.

Details and instructions and prohibitions to protect persons or pre-vent extensive material damage.

Danger

Particular details and instructions and prohibitions for damage pre-ventions.

Caution

• Particular details concerning economic use.

Safety


2.2 Area of use/limits to useThe area of use of the LUDWIG HOOK XL provides for use in combi-nation with crane applications indoors and outdoors.

The LUDWIG HOOK XL has been constructed in accordance with state-of-the-art technology and the recognized safety-related regulations.Nevertheless, its use can generate dangers to the life and limb of the user orthird parties and impairment of the LUDWIG HOOK XL and other materialassets.

Use is not permitted in:• an explosive environment• a gaseous environment• a salty environment• an acidic environment• a basic environment• an underwater environment

Danger

Use the LUDWIG HOOK only in: • a technically perfect condition • and with intended use, with safety and danger awareness • with consideration of the operating instructions!

Faults, in particular those that impair safety, must be eliminated im-mediately. Danger

The maximum number of load cycles must not be exceeded!

(see chap. 8 “Technical data - general” on page 8 - 1)

Danger

Safety


2.3 Intended useThe LUDWIG HOOK XL is a hook from which loads up to 5.3 to can besuspended.

The LUDWIG HOOK XL can be unlocked using remote control, where the loadis released without the need for anyone to approach the load, and to unhookit manually. Release is only possible when the load is put down. When thehook is under tension, the power supply to the opening mechanism is switchedoff and the hook is then in a safe condition.

2.3.1 Foreseeable misuse

The slinging tackle (lifting straps, chains, shackles, etc.) used in connectionwith the LUDWIG HOOK XL must meet the requirements of the lifting processand must be approved for the particular application.

• Intended use also includes the observance of the operating instruc-tions and the compliance with the inspection and maintenance condi-tions.

The LUDWIG HOOK XL is not suitable for the lifting of persons!• The LUDWIG HOOK XL must only be used for the lifting of loads

within its payload limit. There is a table for this purpose that shows the max. payload according to the type of slinging and the number of LUDWIG HOOK XLs (see chap. 5 “Load types” on page 5 - 1).

Danger

Fig.: 2-1 Person transport NOT permitted

Safety


2.4 Application areasHere we can differentiate between two significant areas of application:

• the slinging of a load in direct tension • (see chap. 5 “Direct tension” on page 5 - 5)• (see chap. 5 “Choker hitch with lifeline” on page 5 - 7)

• the slinging of a load in indirect tension• (see chap. 5 “Indirect tension” on page 5 - 6)

2.4.1 Direct tensionThe load is fixed directly onto the LUDWIG HOOK XL.

In this application, a shackle is attached to the hole in the cap on the LUDWIGHOOK. This can then, in turn, be attached to a load hood. The load itself isfixed directly onto the hook of the LUDWIG HOOK XL.

2.4.2 Indirect tensionA second strand (in the form of a chain, lifting strap) is attached to the loadhook, alongside the LUDWIG HOOK XL.

The second strand is placed around the load or threaded through an eye onthe load and then hung back into the LUDWIG HOOK XL.

2.5 Three-stage safety concept

2.5.1 Two-button actuationThe fact that two buttons always need to be pushed in the correct sequencemeans that, as far as possible, inadvertent actuation of the remote control isexcluded.

2.5.2 Opening safety deviceOpening safety device” with (residual) loads over 17.5* kg by spring force. If,nevertheless, actuation of the release mechanism on the LUDWIG HOOK XLoccurs, and the locking pin moves upwards, the special geometry of theLUDWIG HOOK XL ensures that the hook does not open far enough, withloads in excess of 17.5* kg, to release the load. The load will remain hangingfrom the unlocked LUDWIG HOOK XL.

* see chap. 2 “Load table - direct tension” on page 2 - 5

2.5.3 Power failurePower failure with (residual) loads over approx. 32* kg. Actuation of the remotecontrol at this point in time has no effect. The load continues to hang safelyfrom the locked LUDWIG HOOK XL.

* see chap. 2 “Load table - direct tension” on page 2 - 5

Safety


2.5.4 Load table - direct tension

2.5.5 Load table - indirect tension

2.6 Organizational measures

2.6.1 Operating InstructionsThe original operating instructions are a constituent part of the LUDWIGHOOK XL. It must be retained and maintained during the entire service life.

The owner and/or user is responsible for the original operating instructions:• being accessible for consultation at all times.• is continuously availability at the site of use of the LUDWIG HOOK XL .• will be forwarded to each subsequent owner.

.

Three-stage safety concept “direct tension”

Residual load 2-Button radioOpening

safety device

Power

failureSuspension 0 kg X - -When lifting / putting down

0-17.5 kg X - -17.5-32 kg X X -over 32 kg X X X

Load travel over 50 kg X X X

Three-stage safety concept “indirect tension”

Residual load 2-Button radioOpening

safety device

Power

failureSuspension 0 kg X - -When lifting / putting down

0-35 kg X - -35-70 kg X X -

over 70 kg X X XLoad travel over 100 kg X X X

Safety


2.6.2 Legal instructionsThe generally-applicable legal and other binding regulations for accidentprevention and for environmental protection must be observed and instructedalongside and supplementary to the operating instructions!

Obligations of this type can apply, for example, to the making available/wearing of personal protection equipment.

Supplementing the operating instructions with instructions includingsupervision and reporting obligations for consideration of operationalspecialties, e.g. with regard to work organization, working sequences,personnel deployed.

The safety and danger aware working of the personnel with consideration ofthe operating instructions must be checked at least occasionally!

2.7 Personnel selection and qualificationAny work on the LUDWIG HOOK XL must only be performed by reliable expertpersonnel. Use only trained or instructed personnel. The responsibilities of thepersonnel for operating and maintenance must be clearly laid down.

• The personnel tasked with activities on the LUDWIG HOOK XL must be made familiar with the safety-relevant parts of the operating instructions (verifiable) and to convince themselves that they have understood the content. This applies particularly to the personnel only active on the LUDWIG HOOK XL occasionally.

Do not make any modifications or make any attachments on, or con-versions to, the LUDWIG HOOK XL without approval by the supplier/manufacturer!

Danger

Make sure that only appointed personnel act on the LUDWIG HOOK XL!

Safety


2.8 Instructions for normal operation

2.8.1 Take the safety measures

Depending on the application, additional safety regulations may have to becomplied with (see chap. 2 “Legal instructions” on page 2 - 6).

2.8.2 Carry out a function checksee chap. 5 “Carry out a function test” on page 5 - 11

• Wear protective gloves!• Wear a safety helmet!• Wear eye protection!• Wear safety shoes!

Fig.: 2-2 Take the safety measures

Safety


2.8.3 Barrier-free environment for radio remote control

2.8.4 Check radio frequency

Establish radio contact!

Radio contact between the remote control and the LUDWIG HOOK XL must be ensured at all times.

Measures:

Ensure a fault-free and barrier-free environment

Caution

Fig.: 2-3 Establish radio contact

The user is obligated to perform a test before commissioning the LUDWIG HOOK XL from the closest distance to make sure that var-ious different devices do not use the same radio frequency.

This applies particularly when using two LUDWIG HOOK XL sys-tems close together.

If mutual release takes place, the user is obligated to make contact with the supplier/manufacturer immediately.

Caution

Safety


2.8.5 Create visual contact

2.8.6 Maintain a safe distance

We need to point out that the operator must always have an unre-stricted view of the load to be released and the slinging equipment, including the LUDWIG HOOK XL.

Fig.: 2-4 Create visual contact

Do not stand or work under a suspended load!

Measures:

Use only suitable and technically perfect lifting equipment having adequate carrying capacity! Danger

Maintain a safe distance!• In addition, the required safety distance for the application is defini-

tive. This, in turn, is produced from the crane being used and the load being moved.

Safety


2.9 Notes concerning specific types of danger

2.9.1 Residual dangers

2.9.1.1 Latch

Danger of finger injury!

When the release takes place via radio remote control, the latch opens quickly under spring force!

Measures:

Adequate distance to be maintained to the hook being opened quickly by spring force!

Wear protective gloves!

Caution

Fig.: 2-5 Opening latch - finger injury!

Safety


2.9.1.2 Locking pin

Function impairment locking pin!

Loads must not be suspended if the locking pin does not come out of the housing completely!

Measures:

Clean the area around the locking pin in the event of dirt contamination

If that does not resolve the the problem:

LUDWIG HOOK XL send to the manufacturer!

Caution

Fig.: 2-6 Locking pin

Safety


2.9.1.3 Danger of fire/damage caused by deep discharge

2.10 Exclusions of liabilityThe manufacturer of the LUDWIG HOOK XL declares itself free from liabilityfor damage to persons or property, at the operator or third parties, if

• the LUDWIG HOOK XL has been used not as intended.• the operating personnel has not read and understood the existing instruc-

tions.• the operating personnel is not adequately qualified.• the LUDWIG HOOK XL was operated under conditions that fall outside the

stated threshold values.

Danger of fire/damage caused by deep discharge of LiIO battery.• Mobile charger

There is a danger of fire if LiIO batteries are charged after deep dis-charge!

Measures:

Lithium ion batteries should not be exposed to heat or cold for extended periods.

Charge batteries regularly (always ensured by charger at storage area.

Caution

Damage caused by deep discharge of NiMH battery.• Ludwig Hook• Radio remote control

NiMH batteries must not be charged after deep discharge!

Measures:

NIMH batteries should not be exposed to heat or cold for extended periods.

Charge the batteries regularly.

Caution

Product


3 Product

3.1 General pointsThe specific properties and design characteristics of the LUDWIG HOOK XLare the intellectual property of Ludwig System GmbH & Co KG.

3.2 Main components

3.2.1 LUDWIG HOOK XL

Fig.: 3-1 LUDWIG HOOK XL front

LUDWIG HOOK XL front

Item Name

1 Housing

2 Charging module including LED (status display)

3 Cap

4 Safety latch

5 Latch

6 “Unilock” shackle

7 Antenna window

8 Antenna window

Product


3.2.2 Radio remote control

Fig.: 3-2 Radio remote control front

Radio remote control

Item Name

1 Operating button

2 Group button (release button of all LUDWIG HOOK XLs)

3 Release button LUDWIG HOOK XL red

4 Release button LUDWIG HOOK XL blue

5 Release button LUDWIG HOOK XL green

6 Release button LUDWIG HOOK XL yellow

7 Radio antenna

Charging process


4 Charging process

4.1 ChargersUse the chargers provided to charge the batteries (see chap. 1 “Scope ofsupply for the LUDWIG HOOK XL Systems” on page 1 - 1).

4.2 Charging process

• Battery LUDWIG HOOK XL (1)• Battery mobile charger (2)• Battery radio remote control (3)

The batteries must be charged before commissioning for the first time and after being in storage for an extended period ( see chap. 2 “Danger of fire/damage caused by deep discharge” on page 2 - 12)!

Caution

Fig.: 4-1 Initial charge

Charging process


4.2.1 Charging the mobile chargerWe use a mobile charger to prevent the LUDWIG HOOK XL having to beremoved from the load hook for charging.

This mobile charger ...• ... Is charged fully in the charging table.• ... transfers the charge energy to the LUDWIG HOOK XL by plugging it in.

Connect the D-SUB cable (1) on the mains unit to the charging table (3)

Insert the mobile charger (2) into the charging table (3)

Fig.: 4-2 Charging the mobile charger

Charging process


4.2.1.1 Charge levels of mobile charger

4.2.1.2 Charge levels charging table

Mobile charger LED (2)

Color Explanation

LED off No LUDWIG HOOK XL connected, unit is switched off.

Continuous orange light LUDWIG HOOK XL battery being charged.

Continuous green light LUDWIG HOOK XL battery fully charged, charging pro-cess complete.

Charge duration:• Charge duration: up to 8 hours (depending on discharge level)

Charging table LED (3)

Color Explanation

LED off LUDWIG HOOK XL not on charging table.

Continuous green light Internal LiIo battery fully charged, charging process complete.

Continuous orange light Internal LiIo battery being charged.

Green/yellow flashing al-ternately

Internal LiIo battery missing or defective.

Charging process


4.2.1.3 Adding extra charging tables (option)

Fig.: 4-3 Adding extra charging tables and screwing together with connecting plates

The mains unit can charge a maximum of 5 mobile chargers!

Fig.: 4-4 Charger position extended charger table

Charging process


4.2.2 Charging LUDWIG HOOK XL

ATTENTION: Charge the battery of the LUDWIG HOOK XL only in the opened (unlocked) condition!

Caution

Fig.: 4-5 Opened condition of the latch

The LUDWIG HOOK XL is being charged with a mobile charger.

The charging of the LUDWIG HOOK XL always takes place in 2 steps:

Charging the mobile charger in the charging table (see chap. 4 “Charging the mobile charger” on page 4 - 2).

LUDWIG HOOK XL charging with mobile charger (see chap. 4 “Installing the mobile charger” on page 4 - 6).

Charging process


4.2.2.1 Installing the mobile charger

• Insert the charged mobile charger (3) and adapter (1) between the right-hand retainer on the LUDWIG HOOK XL (2)!

Fig.: 4-6 Installing the mobile charger

Fig.: 4-7 LED charge level display

Charging process


4.2.2.2 Charge levels (LED)

4.2.3 Charging the radio remote control battery

4.2.3.1 Removing the antenna

• Removing the antenna (1) from the radio remote control (2) • (push antenna together with thumb and finger and turn

through 90° counter-clockwise!)

Charge duration:• Charge duration: up to 5 hours (depending on discharge level)• Possible charge cycles: up to 3 charging cycles

LED mobile charger

Color Explanation

Continuous orange light

LUDWIG HOOK XL Battery being charged.

Continuous green light

LUDWIG HOOK XL Battery fully charged, charg-ing process complete.

No light No LUDWIG HOOK XL connected

Fig.: 4-8 Removing the antenna

Charging process


4.2.3.2 Inserting the charger cable

• Inserting the charger cable (3) to the radio remote control

Fig.: 4-9 Charger cable installing

Charging process


4.2.3.3 Inserting the charger into the mains socket

• Inserting mains plug (5) into 220 V plug socket

4.2.3.4 Fitting the antennaFit the antenna back on the radio remote control again after the chargingprocess.

Fig.: 4-10 Inserting the mains plug

LED

Color Explanation

Continuous yellow light

Standby (ready)

Flashing yellow Pre-charge

Rapid flashing green Main charge (rapid charge)

Flashing green Recharge (maintain)

Rapid flashing yellow Error

Continuous green light

Ready

Flashing yellow and green

Wait

Charge duration/operating duration:• Charge duration: 1-5 hours (depending on discharge condition)

Charging process


Operation


5 Operation

5.1 Load types

5.1.1 Single-strand loading

5.1.1.1 Single-strand loading (90°)

Fig.: 5-1 Single-strand loading (90°)

Operation


5.1.2 Two-strand loadingWith multiple hangers always only 2 strands to be considered as carrying. Thenumber of carrying strands can be increased by using a balancing device!

5.1.2.1 Two-strand loading (75-90°)

Fig.: 5-2 Two-strand loading (75-90°)

Operation






Operation


5.1.3 Permissible loading on the latch

The latch on the LUDWIG HOOK XL must only be loaded with ONE sling per slinging point!

There is a danger of the latch breaking in the event of non-obser-vance.

Danger

Fig.: 5-5 Permissible loading on the latch: ONE sling

Fig.: 5-6 Prohibited loading on the latch: SEVERAL slings

Operation


5.2 Types of slinging equipment

5.2.1 Direct tension

• Load (1) directly on the hook• LUDWIG HOOK XL (2)• Shackle (3)• Load hook (4)

Fig.: 5-7 Slinging type “direct tension”

Operation


5.2.2 Indirect tension

Hook the end of the chain (A) on the load hook (1).

LUDWIG HOOK XL Hook (2) on the load hook (1).

Guide the chain (3) through the eye or around the load (4).

Push in the safety latch (5) and suspend the load (4) INDIRECTLY via chain end (B) on the LUDWIG HOOK XL (2) or latch.

Fig.: 5-8 Max. 40° angle

Fig.: 5-9 Load indirectly on Ludwig HOOK

Operation


5.3 Choker hitch with lifelineIn order to sling a load with a choker hitch, we recommend using a lifeline (notincluded). Provided that the lifting strap is to be carried by the crane afterreleasing the LUDWIG HOOK XL and not left on the load.

Place the lifting strap (2) around the load (4) as shown in the figure and suspend from the latch on the LUDWIG HOOK XL (1).

Suspend the lifeline (3) end to a bracket on the LUDWIG HOOK XL.

Suspend the other end of the lifeline from the lifting strap (see illustra-tion).

Fig.: 5-10 Securing the slinging equipment

ATTENTION: The lifeline (X) must always be longer that the distance between the latch and the load(Y). The fracture load of the lifeline is of the order of 5% of the transported payload or carries max. 100 kg.

Caution

Fracture load lifeline

Load (example) Max. fracture load lifeline

200 kg 10 kg

800 kg 40 kg

2000 kg 100 kg

5300 kg 100 kg

Operation


5.4 Before starting work

5.4.1 Prepare radio remote control

5.4.1.1 Fitting the antenna

5.4.1.2 Carry out tests (see chap. 2 “Barrier-free environment for radio remote control” on

page 2 - 8).

see chap. 2 “Check radio frequency” on page 2 - 8

Possible electronic damage!

Operation without connected antenna on the radio remote control is not permitted!

Measures:

Always fit the antenna to the radio remote control before operating!

Caution

Fig.: 5-11 Fitting the antenna

Operation


5.4.1.3 Chest strap (option)

With the optional chest strap you will have the radio remote control:• held securely on your upper body (both hands free)• to operate without having to pick it up• always available as a result of the Velcro fastening

5.4.1.4 Rubber protection sleeve (option)

With the optional rubber protection sleeve, the radio remote control is• protected all round from impact• always to hand on your body using the shoulder strap

Fig.: 5-12 Fitting chest strap

Fig.: 5-13 Rubber protection sleeve

Operation


5.4.2 Preparing the LUDWIG HOOK XL

5.4.2.1 Fitting to the crane hook

The crane hook or its linkage/crossbeam must be lowered so that the LUDWIGHOOK XL can be mounted at chest height.

Observe the fundamental information!• see chap. 5 “Load types” on page 5 - 1• see chap. 5 “Types of slinging equipment” on page 5 - 5

Fig.: 5-14 LUDWIG HOOK XL on the load hook

Operation


5.4.2.2 Carry out a function test

Turn the latch (1) in the housing up to the stop and ...

... wait for approx. 2 seconds until the green LED lights up.

Fig.: 5-15 Closing the latch manually

Fig.: 5-16 Green LED lights up

Operation


Load the latch with more than 17 kg and check that the LED changes to blue.

Reduce the load on the latch to less than 17 kg rand check that the LED changes to green again.

Fig.: 5-17 Blue LED lights up


Operation


Open the latch using the radio remote control.

see chap. 5 “Releasing the load by radio” on page 5 - 19

Fig.: 5-19 Open the latch again

Operation


5.5 Suspend the load

5.5.1 Closing the latch manually Turn the latch (1) in the housing up to the stop and ...

Fig.: 5-20 Closing the latch manually

Operation


... wait for approx. 2 seconds until the green LED lights up.


If the locking pin does not move to a position of “safe lock” within 2 secs., it moves back to the starting position, for safety reasons, causing the LUDWIG HOOK XL to open.

Measures:

In this case, repeat the locking process. If you cannot achieve safe locking, contact the manufacturer or send in the LUDWIG HOOK XL.

Caution

Operation


5.5.2 Suspending the load from the latch Push in the safety latch (2) and suspend the load (1).

Fig.: 5-22 Pushing in the safety latch

Operation


5.6 Lifting the load - operational conditionsThe operational conditions of the LUDWIG HOOK XL are determined by thepossible positions of the locking pin.

The current operational conditions are displayed on the LUDWIG HOOK XLby the lighting up of the LEDs.

Error conditions: see chap. 7 “Problem treatment” on page 7 - 4

Fig.: 5-23 LudwigHOOK XL locking pin

Normal conditions

LED color Explanation

none Latch is “open” (unlocked rest position)

GREEN Latch is “unloaded” and can be actuated by the transmitter.

BLUE Latch is ”loaded” and cannot be triggered, since re-ceiver not powered.

ATTENTION: The load can only be suspended when the green LED lights up!

Caution

Operation


5.7 Setting down the load

Lower the load until max. 17 kg pulls on the latch on the LUDWIG HOOK XL.

Fig.: 5-24 Lowering the load

On the LUDWIG HOOK XL the LED changes from blue to green. Only now can you release the load by means of the radio remote control.

Operation


5.8 Releasing the load by radio

5.8.1 Single actuation

Hold down the operating button (A) and, within 0.5 sec., push one of the 4 desired actuation buttons.

• Red LUDWIG HOOK XL (1)• Blue LUDWIG HOOK XL (2)• Green LUDWIG HOOK XL (3)• Yellow LUDWIG HOOK XL (4)

Result: The latch on the color assigned LUDWIG HOOK XL releases the load with a delay of approx. 2 secs.

Fig.: 5-25 Single actuation

Actuation in the reverse sequence (i.e. first actuation button (1-4) and then operating button (A) or simultaneous actuation of both buttons) will result in no radio signal being sent to the LUDWIG HOOK XL. This condi-tion is indicated by a flashing red LED.

Remedy:

Wait until the LED goes out and carry out correct actuation again.

Operation


5.8.2 Group actuation

Push the operating button (A) and then the group button (5) within 0.5 secs.

Result: All the latches on the LUDWIG HOOK XL release the load with a delay of approx. 2 secs.

5.9 After finishing work

5.9.1 Carry out suspended from the craneThe following steps must be taken at break times and after finishing work:

• Open LUDWIG HOOK XL by radio. No power is consumed in this condition and the service life of the battery will be increased considerably!

• Charge LUDWIG HOOK XL with mobile charger• Clean LUDWIG HOOK XL and spray locking pin with WD 40!

5.9.2 In extreme weatherExtremely cold temperatures will reduce the service life of the batteries.

• Open LUDWIG HOOK XL by radio.• Remove LUDWIG HOOK XL from crane or load slinging equipment.• Charge LUDWIG HOOK XL with mobile charger.• Clean LUDWIG HOOK XL and spray locking pin with WD 40.• Store LUDWIG HOOK XL and radio remote control in a heated room.

Fig.: 5-26 Group actuation

Operation


5.10 Storage

see chap. 2 “Danger of fire/damage caused by deep discharge” on page 2 -12

• Before storage: Fully charge LUDWIG HOOK XL and remote control! Storage in the discharged state can lead to damage to the batteries.

• If the LUDWIG HOOK XL is stored under tension, there is a danger of deep discharge of the batteries.

• The batteries must be charged every 4 months with long periods on non-use.

Operation


Disposal and recycling


6 Disposal and recycling

6.1 Environmental ProtectionDuring all work on LUDWIG HOOK XL all legal regulations regarding wasteavoidance and correct disposal / recycling must be observed!

During maintenance work, water-damaging materials such as lubricants andoils must not be released into the ground or allowed to enter the sewagesystem! These substances must be kept, transported and disposed of insuitable containers.

6.2 DisposalIf the LUDWIG HOOK XL is finally decommissioned, the laws and regulationsapplicable at the time of disposal must be observed and followed.

Always establish which materials can be forwarded for recycling. These mustthen be recycled by a suitable waste disposal company.

Disposal and recycling


6.3 Battery recycling

6.3.1 Note concerning the battery statuteSince we sell equipment that contains batteries and rechargeable batteries,we are obligated, according to the batteries statute (BattV), to advise you ofthe following:

• Batteries and rechargeable batteries must not be disposed of in the house-hold waste, and you are legally obligated to return used batteries and re-chargeable batteries.

• You can either return the batteries to us after use or you can return to local trade locations or communal collection points free of charge.

• Batteries and rechargeable batteries contain toxic materials that exceed the legal thresholds in accordance with § 17 Para. 3 BattG, are marked with the crossed out trash container symbol and the chemical symbol of the individ-ual toxic material

The abbreviations mean: • Cd (Cadmium)• Li (Lithium) / Li-Ion (Lithium ions)• Ni (Nickel)• Mh (Metal hydride)• Pb (Lead)• Zi (Zinc)• Hg (Mercury)•

Corresponding marking must be made by the manufacturer if the followingthreshold values are exceeded:

Hg = Mercury > 0.0005 mass percent

Cd = Cadmium > 0.002 mass percent

Pb = Lead > 0.004 mass percent

Pb = Lead > 0.004 mass percent

Maintenance/problem treatment


7 Maintenance/problem treatment

7.1 Maintenance by the operator

7.1.1 Lubrication/cleaning

Fig.: 7-1 Lubrication

Lubrication

Item Name Interval

1 Lubricate locking pin* monthlyCleaning if necessary

* use penetrating oil (e.g.: WD 40)



7.1.2 Function check and cleaning

At least once per deployment:• check for detectable external damage and faults! • Carry out a function check!

Immediately report any changes (including battery behavior) to the department/person responsible! Faults must be eliminated immedi-ately!

Fig.: 7-2 Function check

Function check and cleaning

Item Name Interval

1 Mechanism locking pin dailya) By pressing the operating button and the actuation button in the correct sequence on the radio remote control (locking pin moves in the housing), the LUD-WIG HOOK XL opens up.b) Check movements of the locking pin (1) by loading the latch (3).

see chap. 5 “Lifting the load - operational conditions” on page 5 - 17

2 Check the movement of the safety latch (2) daily3 Check the movement of the latch (3) daily4 LUDWIG HOOK XL clean as required daily



7.2 Replacing the batteryThese batteries are checked during the annual inspection, and replaced onrequest:

• Battery LUDWIG HOOK XL• Battery radio remote control• Battery mobile charger

7.3 Maintenance/checking

7.3.1 Annual maintenanceMaintenance and repair must be carried out 1x per year exclusively by themanufacturer or an authorized service partner.

• Function check (and testing the carrying elements)• Maintenance• Repair• Premature replacement of wear parts (e.g. actuator, locking pin, axle,

batteries)

7.3.2 Test

ATTENTION!

Observe residual dangers from latch and locking pin: see chap. 2 “Notes concerning specific types of danger” on page 2 - 10

Caution

Battery recycling• see chap. 6 “Battery recycling” on page 6 - 2

Yearly maintenance!• The manufacturer will provide information about an upcoming annual

maintenance!

The annual maintenance does not replace the country-specific regula-tions concerning regular testing of load slinging equipment.

The user is obligated to obtain information concerning the regulations ap-plicable to him and to appoint a capable service provider to carry out this test!



7.4 Problem treatment

Problem treatment

Problem Possible cause Remedy

LED on LUDWIG HOOK XL flashing red.

- Error: flat battery Charge battery!

LED on LUDWIG HOOK XL flashing red/blue.

- Error in monitoring the actuator. Send to the manufacturer!

LED on LUDWIG HOOK XL flashing red/green.

- Incorrect operation User needs to re-hang the Ludwig Hook!

LUDWIG HOOK XL will not open.

- flat battery (LUDWIG HOOK XL )

- flat battery (radio remote control)

Charge battery!

- LUDWIG HOOK XL out of range. Reduce the distance!- Load suspended from hook.

(Unlocking block)

Lower the load further!

- defective LUDWIG HOOK XL.

- defective radio remote control.

Send to the manufacturer!

Locking pin does not come out of the hous-ing.

- Linear motor defective.

- poor lubrication.

Immediately take out of service and send to manufacturer!

Hook does not turn or moves only with difficul-ty.

- Spring defective/jammed.

- poor lubrication.


Bad range of one or all LUDWIG HOOK XL.

- flat battery (transmitter or receiv-er).

Charge battery!

- Radio transmitter/antenna defec-tive.


- Radio receiver/antenna defec-tive.


Rapid flashing of all LEDs on radio remote control.

- Incorrect operation Push buttons within 0.5 secs!

Rapid flashing of the LED operating button radio remote control.

- flat battery. Charge battery!

Technical data


8 Technical data

8.1 Technical data - general

* Provided the angle < 40° between the strands (see chap. 5 “Indirect tension”on page 5 - 6).

Technical data - general

Minimum load (direct/indirect tension)

50/100 kg

Maximum carrying capacity (direct tension)

5.3 t (minimum load 50 kg)

Maximum carrying capacity (indirect tension)

10 t (minimum load 100 kg)

Safety level C (Performance Level)

Category 3

Service life 7 years

Max. permissible load cycles < 20,000

Technical data


8.2 Technical data - electrical

Standards complied with

EN 55011, EN 55022/B, FCC 47 Part 15, EN 61000-3-2,

EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, EN 61000-4-5,

EN 61000-4-6, EN 61000-4-11, DIN EN 60204-32

Fulfills Class II SELV for the following applications:

IEC 60601-1, IEC 60335-2-29, UL 1310, VDE, CE-Marking, CSAl

8.3 Dimensions

Technical data - electrical

Battery type LUDWIG HOOK XL NiMH 4.8 V

Battery type mobile charger LiIO 3.7 V

Battery type radio remote control NiMH 4.8 V

Operational radio range 50 m

Radio frequency 868.3 MHz

Transmitter output power 25 mW

Charger type Friwo FW 7219/NI4-10NTC

Input voltage charger 100 to 240 V (± 10%)

Input current 0.25 – 0.3 A

Frequency 50-60 Hz

Efficiency 75% typ. Full load

Dimensions

LUDWIG HOOK XL

Width 154 mm

Height (without shackle) 308 mm

Depth 179 mm

Radio housing

Width 80 mm

Height 180 mm

Depth 42 mm

Technical data


8.4 Weight

8.5 Ambient conditions

8.5.1 Operation

8.5.2 Charging

8.5.3 Storage

8.5.4 Operation/storage charger

Weight

LUDWIG HOOK XL approx. 6.7 kg

Remote control approx. 0.7 kg

Operation

Cold -15°C

Dry heat +60°C

Protection rating (water) IP 65

Charging

Humidity max 70 %

Temperature 0 - 40°C

Storage

Cold -20° C

Dry heat +70° C

Operation/storage charger

Operating temperature 0 - 40°C

Storage temperature - 20 to 70° C

Humidity 5% to 95% non-condensing

Technical data


EC Declaration of Conformity


9 EC Declaration of Conformity

pursuant to:

EC Machinery Directive 2006/42/EC

EC-EMC Directive 2004/108/EC

Product: Remote-controlled slinging equipment

Product designation: LUDWIG HOOK XL

Year of manufacture: 2017

has been developed, designed and manufactured in compliance with the above EC directives, with the sole responsibility of the company:

Ludwig System GmbH & Co KG

Am Kraftwerk 3

83435 Bad Reichenhall

Tel.: +49 8651 7656730

Fax: +49 8651 7688472

Currently applicable standards with content and validity on date of issue:

DIN EN ISO 12100; 2010: “General structural principles risk assessment and risk reduction”

DIN EN 13155; 2009-08: “Cranes - safety - loose load slinging equipment”

EN ISO 13857; 2008-06: “Safety of machines - safety distances against reaching danger areas with the upper and lower limbs”

DIN EN 349; 2008-09: “Safety of machines - minimum distances for preventing crushing of body parts”

DIN EN ISO 13849-1; 2012: “Safety of machines – safety-relative parts of control systems – Part 1: General points

Structural principles”

DIN EN ISO 13849-2; 2012: “Safety of machines – safety-relative parts of control systems – Part 2: Validation”

DIN EN 60204-32; 2009-03: “Safety of machines – electrical equipment of machines – Part 32: Requirements for lifting equipment”

Complete technical documentation is available. The operating manual for the machine is available.

Person, resident in the Community, and authorized to collate the technical documents

(documentation officer): Peter Ruf

Special documentation requested on justifiable grounds by specific government centers is submitted in hard copy form and via postal ser-vice.

Bad Reichenhall, 17.7.17

Peter Ruf

Technical Management

EC Declaration of Conformity


Ludwig System GmbH & Co KG, Am Kraftwerk 3, 83435 Bad Reichenhall

Tel.: +49 8651 7656730, [email protected], www.ludwigsystem.com

Dealer’s Stamp

Documents

Original Operating Instructionsludwigsystem.com/wp-content/uploads/2017/08/BA... · Supply 1 - 2 LUDWIG HOOK XL / Ludwig System GmbH & Co KG: 83435 Bad Reichenhall / Tel.: +49 8651