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A series-built hoist is designed for a defined service life. How much of it has been used can be estimated from mechanism group, load spectrum and running time – and with it, when the general overhaul is due.
Limits of the calculator. The estimate follows the method of FEM 9.755 and does not replace the determination by a competent person as part of the periodic inspection. The information in the manufacturer’s operating manual is binding.
Gearbox, brake and motor of a series-built hoist are not designed for unlimited running time but for a number of operating hours under an assumed loading. The classification is expressed by the mechanism group – 1Bm, 1Am, 2m, 3m, 4m to FEM, M3 to M7 to ISO. The higher the group, the longer the service life under full load: from 400 hours for 1Bm to 6,300 hours for 4m.
Hardly any hoist lifts its maximum load all the time. The load spectrum accounts for this with a factor: 0.125 for light, 0.25 for medium, 0.5 for heavy and 1.0 for very heavy duty. Actual use in a year is that factor times the running time of the hoist times a factor for the method of recording.
Running time here is only the time the hoist is lifting or lowering. At an assembly workstation that is often just minutes per shift – which is why a correctly classified hoist can last decades and one classified too low reaches its limit after a few years.
Once the theoretical service life is reached, a general overhaul is due: the components on which the design was based are inspected and replaced as specified by the manufacturer; a new period of use then begins. Determining the service life used is part of the periodic inspection and is documented.
For the decision between general overhaul, upgrade and replacement, this figure is the starting point – not the year of manufacture.
On the rating plate or in the operating manual, stated to FEM (for example 2m) or ISO (M5). If it is missing, the manufacturer can provide it from the serial number.
It can be estimated from average lifting height, number of work cycles and lifting speed. Because an estimate is less certain than a measurement, the method applies an additional factor for it.
It applies to series-built hoists classified in a mechanism group. For equipment without that classification, the operating manual states the criteria for replacing components.
Recurring inspection under German BetrSichV and DGUV rules – chain hoists, rope hoists, balancers, manipulators and jib cranes.
View service ServiceRepair of lifting equipment and manipulators of any make – from a brake change to a full overhaul.
View service ServiceAdapting existing lifting equipment to a new task – gripper, control, reach, capacity.
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