LK 4ESZ - Hoists Holzmann - Free user manual and instructions

Product Type	Electric Trolley for Hoists
Brand	Holzmann
Model	LK 4ESZ
Voltage	230 V / 50 Hz
Motor Power	200 W
Maximum Payload	999 kg
Moving Speed	16 m/min
Minimum Curve Radius	1 m
Protection Mode	IP 54
Weight	14.5 kg
Operating Mode	S3 (25% duty cycle: 2.5 min on, 10 min cycle)
Intended Use	Lifting and moving fixed loads along I-beam track
Switch Control	Left/right movement with emergency stop
Limit Switches	Left and right limit switches for travel end
Safety Features	Emergency stop, thermal motor protection, limit switches
Maintenance	Regular check of limit switches and emergency stop; keep clean and dry
Spare Parts Availability	Original HOLZMANN spare parts recommended

Frequently Asked Questions - LK 4ESZ Holzmann

What is the maximum load the LK 4ESZ can lift?

The maximum payload is 999 kg. Never exceed this limit.

Can the trolley be used outdoors?

It has IP54 protection, making it suitable for outdoor use with protection against dust and water splashes, but avoid extreme weather.

How do I install the trolley on an I-beam?

Measure the flange width of the I-beam. Ensure a 2 mm gap between flange and roller track ring. Internal dimension = flange width + 4 mm. Tighten all bolts firmly.

What does the emergency stop do?

Pressing the emergency switch immediately stops all movement. Turn it clockwise to unlock after use.

How often should I maintain the trolley?

Regularly check the function of limit switches and the emergency stop. Clean after each use and store in a dry location.

Can I use the trolley with any hoist?

The trolley is designed for use with hoists like chain pulley blocks or electric cable pulls. Ensure the hoist weight does not exceed the maximum payload.

What is the operating mode S3 mean?

S3 means intermittent duty: the machine can run for 2.5 minutes out of a 10-minute cycle (25% duty cycle). Do not run continuously.

What should I do if the trolley stops during operation?

It may be due to thermal overload. Let it cool down for about 5 minutes before restarting. If problem persists, check for obstructions or contact service.

Is it allowed to lift people or animals?

No, lifting people or animals is explicitly forbidden. The machine is only for lifting fixed loads.

Where can I find spare parts?

Use only original HOLZMANN spare parts. Order via the service form in the manual or contact your dealer. Provide machine type and part number.

USER MANUAL LK 4ESZ Holzmann

Industrial machine with red and yellow components, no visible text or symbols

LK 4ESZ

1 INHALT /INDEX

12.1 Intended Use.... 14
12.2 Security instructions....15

13 ASSEMBLY 16

13.1 I-steel track dimensions ..... 16

14 OPERATION 17

14.1 Operation instructions.... 17

14.2 Operation....17

15 MAINTENANCE 18

15.1 Maintenance plan.... 18
15.2 Cleaning.... 18
15.3 Disposal 18

16 SCHALTPLAN / WIRING DIAGRAM 19

17 ERSATZTEILE / SPARE PARTS 20

This manual contains information and important instructions for the installation and correct use of the electric trolley for ESZ LK4ESZ.

Following the usual commercial name of the device (see cover) is substituted in this manual with the name "machine".

This manual is part of the product and shall not be stored separately from the product. Save it for later reference and if you let other people use the product, add this instruction manual to the product.

Please read and obey the security instructions!

Before first use read this manual carefully. It eases the correct use of the product and prevents misunderstanding and damages of product and the user's health.

Due to constant advancements in product design, construction pictures and content may diverse slightly. However, if you discover any errors, inform us please.

Technical specifications are subject to changes!

Please check the product contents immediately after receipt for any eventual transport damage or missing parts.

Claims from transport damage or missing parts must be placed immediately after initial product receipt and unpacking before putting the product into operation.

Please understand that later claims cannot be accepted anymore.

Copyright

© 2016

This document is protected by international copyright law. Any unauthorized duplication, translation or use of pictures, illustrations or text of this manual will be pursued by law. Court of jurisdiction is the Landesgericht Linz or the competent court for 4170 Haslach, Austria!

Customer service contact

1	Motor	6	Arbor fixing screw
2	Driven wheel	7	Limit switch
3	Hook plate	8	Controller
4	Balance wheel	9	Switch left / right
5	Driven wheel	10	Emergency switch

11.2 Technical details

Voltage	230 V / 50Hz
Motor power	200 W
max. payload	999 kg
Moving speed	16 m/min
Radius min.	1 m
Protection mode	IP 54
Weight	14,5 kg

12 SAFETY

12.1 Intended Use

The machine must only be used for its intended purpose! Any other use is deemed to be a case of misuse.

To use the machine properly you must also observe and follow all safety regulations, the assembly instructions, operating and maintenance instructions lay down in this manual.

All people who use and service the machine have to be acquainted with this manual and must be informed about the machine's potential hazards.

It is also imperative to observe the accident prevention regulations in force in your area.

The same applies for the general rules of occupational health and safety.

The machine is used for:

Lifting and moving of fixed loads.

Any manipulation of the machine or its parts is a misuse, in this case HOLZMANN-MASCHINEN and its sales partners cannot be made liable for ANY direct or indirect damage.

WARNING

• The motor of the machine is protected with a thermal fuse. When the thermal fuse responses, the machine stops. The machine can be used again only after cooled down (app. 5 minutes).
• The machine is suitable for operating mode S3 (25% operating time: 2,5 min at 10 min) and not for continuous operation.

Ambient conditions:

The machine may be operated:

humidity

max. 70%

temperature

+5°C to +40°C

The machine shall not be operated in areas exposed to increased fire or explosion hazard.

Prohibited use:

• The operation of the machine outside the stated technical limits described in this manual is forbidden.
• The operation of the machine without provided protective devices is prohibited
• The use of the machine not according with the required dimensions is forbidden.
• Any manipulation of the machine and parts is forbidden.
• The use of the machine for any purposes other than described in this user-manual is forbidden.
• The unattended operation on the machine during the working process is forbidden!
• It is explicitly prohibited that persons stayed or walked under or in the immediate vicinity of the suspended load!
  • To lift loads connected to earth is forbidden!
• Swinging with the hung load is forbidden!
• Lifting of loads hung outside of axis of gravity is forbidden!
  • To lift people or animals is explicitly forbidden!

W AR N U NG

Never exceed the maximum payload. When lifting and transporting the center of gravity should be in the same area with "I" steel beams. Otherwise the machine must not be operated. If the construction is abnormal during lifting and transport stop the operation immediately and eliminate the problem. "I" steel which is deformed, bent or cracked, does not conform to the standard, or has other defects, must not be used as a track of the machine.

12.2 Security instructions

Missing or non-readable security stickers have to be replaced immediately!

The locally applicable laws and regulations may specify the minimum age of the operator and limit the use of this machine!

To avoid malfunction, machine defects and injuries, read the following security instructions!

NOTICE

In this machine following protective equipment is in effect:

• Emergency-switch on controller
- Limit switch left and right

• Keep your work area dry and tidy! An untidy work area may cause accidents. Avoid slippery floor.
  • Make sure the work area is lighted sufficiently
  • Always stay focused when working. Reduce distortion sources in your working environment. The operation of the machine when being tired, as well as under the influence of alcohol, drugs or concentration influencing medicaments is forbidden.
• Never reach under the housing of the machine while the machine is running! The rotating rollers of the machine can lead to severe cuts or severing of body parts
• Only one person shall operate the machine.
• The machine must be operated only by trained persons (knowledge and understanding of this manual), which have no limitations of motor skills compared with conventional workers.
  • Make sure there is nobody present in the dangerous area. The minimum safety distance is 10 m
• Use personal safety equipment: safety shoes S1, work wear when working with or on the machine!
• Never leave the machine running unattended! Before leaving the working area switch the machine off and wait until the machine stops.
  • Always disconnect the machine prior to any actions performed at the machine!
• Do not use the machine with damaged switch
• The plug of an electrical tool must strictly correspond to the socket. Do not use any adapters together with earthed electric tools
  • Each time you work with an electrically operated machine, caution is advised! There is a risk of electric shock, fire
• Protect the machine from dampness (causing a short circuit)
• Check the cable regularly for damage
• Do not use the cable to carry the machine or to fix the load
• Protect the cable from heat, oil and sharp edges
• Avoid body contact with earthed components
• Keep any machine that is not being used out of reach of children

A first aid kit should always be readily available for a possible accident. Initiate the violation in accordance with the necessary first aid measures. When requesting support, provide the following details::

1. Place of accident

2. Number of injured people

3. Type of accident

4. Injury type(s)

13 ASSEMBLY

Please check the product contents immediately after receipt for any eventual transport damage or missing parts. Claims from transport damage or missing parts must be placed immediately after initial machine receipt and unpacking before putting the machine into operation. Please understand that later claims cannot be accepted anymore.

ATTENTION

• Ensure conscientious assembly of the machine.
  • Measure the flange width of the track carrier and ensure compliance
• Install the machine in accordance with the width of the carrier and the intended lifting variant (chain pulley train or electric cable pull).
• There must be a gap of 2mm between the carrier flange and the track ring of the rollers. Internal dimension = flange width + 4mm.
• Tighten firmly all bolts, using washers and snap rings.
• At regular intervals, please check the fastening clamps for any damage, cracks, etc.
• Ensure that the support, where the machine will be mounted is securely mounted.
• Never exceed the maximum payload!
• The operator is responsible for selecting and dimensioning the appropriate supporting structure

13.1 I-steel track dimensions

Machine to be operated in a perfect state only. Inspect the device visually every time it is to be used. Check in particular the safety equipment, electrical controls, electric cables and screwed connection for damage and if tightened properly. Replace any damaged parts before operating the device.

14.1 Operation instructions

W ARNI NG

Perform all machine settings with the machine being disconnected from the power supply!

NOT I CE

• In addition to these operating instructions also read the operating instructions of the hoists used! (Pulley block or electric cable pull)
• Inspect the machine visually before each use.
  • It is to check the end stops are present so that the machine can not crash
• Before using the machine, ensure that there are no contamination contours or obstacles on the carrier and along the track
• In particular, check the perfect state of the snap hooks preventing any unintentional release of the lifting hook from slings (ropes, rings, transportation eyes, etc.).
• All lifting work is only allowed when appropriate fixing elements (ropes, rings, transport loops, etc.) are used and when in accordance with appropriate provisions and standards valid in the workplace.
• The machine can only be used for lifting of loads whose weight does not exceed the maximum payload specified by the producer in technical data and on the type label of the machine.
• Attach the load correctly.
• Lifted loads may only be lifted in a vertical position! Never pull and lift in an inclined position!

14.2 Operation

• Check, whether the emergency switch (10) is pressed. For unlocking, turn the emergency switch clockwise.
• For moving the machine, press the left/right switch (9).
• In the emergency case press the emergency switch immediately. The machine stops.

15 MAINTENANCE

ATTENTION

Perform all maintenance machine settings with the machine being disconnected from the power supply!

Serious injury due to unintentional or automatic activation of the machine!

The machine does not require extensive maintenance. If malfunctions and defects occur, let it be serviced by trained persons only.

NOTICE

Clean your machine regularly after every usage – it prolongs the machines lifespan and is a prerequisite for a safe working environment.

Repair jobs shall be performed by respectively trained professionals only.

Check regularly the condition of the security stickers. Replace them if required.

Check regularly the condition of the machine!

Store the machine in a closed, dry location.

15.1 Maintenance plan

- Check regularly the correct function of the limit switches and the emergency switch.

15.2 Cleaning

HINWEIS

The usage of certain solutions containing ingredients damaging metal surfaces well as the use of scrubbing agents will damage the machine surface!

Never spray water on the machine or submerge it to any liquid.

15.3 Disposal

Do not dispose the machine in residual waste. Contact your local authorities for information regarding the available disposal options. When you buy at your local dealer for a replacement unit, the latter is obliged to exchange your old.

16 SCHALTPLAN / WIRING DIAGRAM

graph LR
    A["Capacitor"] --> B["7μF"]
    B --> C["Control cord"]
    C --> D["Stop switch"]
    D --> E["Thermal Cut-out Switch"]
    E --> F["~230V 50Hz"]
    G["Switch"] --> H["Motor"]
    I["Microswitch"] --> J["Control cord"]
    K["Motor"] --> L["Control cord"]

17 ERSATZTEILE / SPARE PARTS

With original HOLZMANN spare parts you use parts that are attuned to each other shorten the installation time and elongate your products lifespan.

I MP OR T AN T

The installation of other than original spare parts voids the warranty!

So you always have to use original spare parts

When you place a spare parts order please use the service formular you can find in the last chapter of this manual. Always take a note of the machine type, spare parts number and partname. We recommend to copy the spare parts diagram and mark the spare part you need.

You find the order address in the preface of this operation manual.

No.	PARTS NAME	QTY.	No.	PARTS NAME	QTY.
1	DRIVEN WHEEL WALLBOARD	1	23	CONNECTING HOUSING SPACER	1
2	DRIVEN WHEEL	2	24	CONNECTING HOUSING (DOWN)	1
3	INNER OIL SPACER	4	25	LIMIT PLACE STAFF	1
4	BEARING(6204-2RS)	4	26	LIMIT PLACE SPRING	2
5	CIRCLIP FOR SHAFT Φ20	4	27	LIMIT PLACE SUPPORTING	2
6	OUTER OIL SPACER	4	28	SLOTTED THIN HEX NUT M6*1.5	4
7	CIRCLIP FOR BORE Φ47	4	29	FIXED SCREW ARBOR	2
8	ACTION WHEEL	2	30	HOOK PLATE	1
9	ACTION WHEEL WALLBOARD	1	31	BALANCE WHEEL	1
10	GEAR SHAFT	1	32	BALANCE SHAFT	1
11	BEARING(6204-ZN)	4	33	POSITIVE AND NEGTIVE SWITCHES	1
12	Big GEAR	1	34	EMERGENCY STOP SWITCH	1
13	BEARING(61900)	1	35	THREE-CORE PLUG	1
14	FRONT COVER	1	36	CAPACITOR	1
15	BEARING(6000-2RS)	2	37	HANDLE COVER	1
16	ROTOR	1	38	MICROSWITCH	2
17	STATOR	1	39	CONNECTING HOUSING	1
18	SPRING	1	40	PLACES TERMINAL BLOCK	1
19	BRAKE HOOP	1	41	Four CORE CABLE	1
20	GEAR COVER	1	42	HANDLE BASE	1
21	FAN BLADE	1	43	LIMIT ATTACHMENT LINK ESZ1000D:290, ESZ250D/500D:180	2
22	FAN HOOD	1

18 EU-KONFKORMITÄTSERKLÄRUNG / CE-CERTIFICATE OF CONFORMITY

CE	Inverkehrbringer / DistributorHOLZMANN MASCHINEN® GmbH4170 Haslach, Marktplatz 4, AUSTRIATel.: +43/7289/71562-0; Fax.: [phone]www.holzmann-maschinen.at
Bezeichnung / name
ELEKTRISCHE LAUFKATZE FÜR ESZ/ ELECTRIC TROLLEY FOR ESZ
Typ / model
LK4ESZ
EG-Richtlinien / EC-directives
•2006/42/EG; •2014/30/EU, •2011/65/EU
Angewandte Normen / applicable Standards
•EN 14492-2+A1/AC:2010, •EN 60204-32:2008, •EN 61000-6-1:2007, •EN61000-6-2:2005,•EN 61000-6-3:2007+A1, •EN 61000-6-4:2007+A1, IEC 62321:2008

Hereby we declare that the above mentioned machines meet the essential safety and health requirements of the above stated EC directives. Any manipulation or change of the machine not being explicitly authorized by us in advance renders this document null and void.

Please consult our troubleshooting section for initial problem solving. Feel free to contact your HOLZMANN reseller or us for Customer Support!

Warranty claims based on your sales contract with your HOLZMANN retailer, including your statutory rights, shall not be affected by this guarantee declaration. HOLZMANN-MASCHINEN grants guarantee according to following conditions:

A) The guarantee covers the correction of deficiencies to the tool/product, at no charge, if it can be verified adequately that the deficiencies were caused by a material or manufacturing fault.
B) The guarantee period lasts 12 months, and is reduced to 6 months for tools in commercial use. The guarantee period begins from the time the new tool is purchased from the first end user. The starting date is the date on the original delivery receipt, or the sales receipt in the case of pickup by the customer.
C) Please lodge your guarantee claims to your HOLZMANN reseller you acquired the claimed tool from with following information:

Original Sales receipt and/or delivery receipt

Service form (see next page) filed, with a sufficient deficiency report

for spare part claims: a copy of the respective exploded drawing with the required spare parts being marked clear and unmistakable.

D) The Guarantee handling procedure and place of fulfillment is determined according to HOLZMANNs sole discretion in accordance with the HOLZMANN retail partner. If there is no additional Service contract made including on-site service, the place of fulfillment is principally the HOLZMANN Service Center in Haslach, Austria.

Transport charges for sending to and from our Service Center are not covered in this guarantee.

E) The Guarantee does not cover:

• Wear and tear parts like belts, provided tools etc., except to initial damage which has to be claimed immediately after receipt and initial check of the product.
• Defects in the tool caused by non-compliance with the operating instructions, improper assembly, insufficient power supply, improper use, abnormal environmental conditions, inappropriate operating conditions, overload or insufficient servicing or maintenance.
  • Damages being the causal effect of performed manipulations, changes, additions made to the product.
  • Defects caused by using accessories, components or spare parts other than original HOLZMANN spare parts.
• Slight deviations from the specified quality or slight appearance changes that do not affect functionality or value of the tool.
• Defects resulting from a commercial use of tools that - based on their construction and power output - are not designed and built to be used within the frame of industrial/commercial continuous load.

F) Claims other than the right to correction of faults in the tool named in these guarantee conditions are not covered by our guarantee.

G) This guarantee is voluntary. Therefore Services provided under guarantee do not lengthen or renew the guarantee period for the tool or the replaced part.

SERVICE

After Guarantee and warranty expiration specialist repair shops can perform maintenance and repair jobs. But we are still at your service as well with spare parts and/or product service. Place your spare part / repair service cost inquiry by filing the SERVICE form on the following page and send it:

via Mail to [e-mail]

or via Fax to: [phone]

21 PRODUKTBEOBACHTUNG PRODUCT EXPERIENCE FORM

We observe the quality of our delivered products in the frame of a Quality Management policy.

Your opinion is essential for further product development and product choice. Please let us know about your:

• Impressions and suggestions for improvement.
• experiences that may be useful for other users and for product design
• Experiences with malfunctions that occur in specific operation modes

We would like to ask you to note down your experiences and observations and send them to us via FAX, E-Mail or by post:

Erworben von / purchased from:

E-Mail/ e-mail:

service inquiry spare part inquiry guarantee claim

Please describe amongst others in the problem: What has cause the problem/defect, what was the last activity before you noticed the problem/defect? For electrical problems: Have you had checked you electric supply and the machine already by a certified electrician?

3. Bitte beachten

Additional information

INCOMPLETELY FILLED SERVICE FORMS CANNOT BE PROCESSED! FOR GUARANTEE CLAIMS PLEASE ADD A COPY OF YOUR ORIGINAL SALES / DELIVERY RECEIPT OTHERWISE IT CANNOT BE ACCEPTED. FOR SPARE PART ORDERS PLEASE ADD TO THIS SERVICE FORM A COPY OF THE RESPECTIVE EXPLODED DRAWING WITH THE REQUIRED SPARE PARTS BEING MARKED CLEARLY AND UNMISTAKABLE. THIS HELPS US TO IDENTIFY THE REQUIRED SPARE PARTS FASTLY AND ACCEL- ERATES THE HANDLING OF YOUR INQUIRY.