General operating and

HOVA crane systems maintenance instructions

Type of crane system:

☒rail system ☐pillar-mounted slewing crane ☐wall-mounted slewing crane

☐without or on-site crane system

Type of load lifting attachment:

☒vacuum lifter for solid materials ☒incl. chain hoist ☐without chain hoist
☒electropneumatic depressurisation
☐electrical depressurisation
☐pneumatic depressurisation
☐IG lifter

☐vacuum lifter for unstable materials ☐incl. chain hoist ☐without chain hoist
☐electric depressurisation / blower

☐Chain hoist

! Assembly and service HOTLINE!

If you have any questions, please contact our customer service on +43 7258 79279
Monday - Thursday 07:00 - 16:00, Friday 07:30 - 12:00
Please have the serial number ready (see nameplate).

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 EC Declaration of Conformity
in the sense of the EC Machinery Directive 2006/42/EC

We,
HOVA Maschinenbau GmbH
HOVA Platz 1
A - 4541 Adlwang
hereby declare
that the following product:

Product name: Rail system with vacuum lifter

Type of crane system: Rail system
Type of load lifting attachment: HOVAMAT HVD 90°/90° vacuum lifter
Load capacity: 600 kg
Serial number: 2220635.03

Complies with the following applicable provisions:

EC Machinery Directive 2006/42/EC
EC Low Voltage Directives 2014/35/EU
EC Electromagnetic Compatibility 2014/30/EU

Applied harmonised standards:

EN ISO 12100:2013-10-15 Safety of machinery – General principles for design

EN 60204-1 Electrical equipment of machines

Applied standards and technical specifications:

EN 13155:2017 Load lifting attachments

Correspond to Annex V of the EC Machinery Directive:

CE mark is attached to the device.
The technical documentation is stored at the manufacturer's plant.

The EC Declaration of Conformity applies to cranes which have been erected ready for operation in accordance with the
assembly instructions and for which the proper assembly and testing have been certified. Testing of the support structure
on site is not part of this declaration.

Changes to equipment that have not been agreed with us shall void this declaration.

Adlwang, 30.09.22
Place/Date/ Manufacturer's signature
Ing. Gerhard Holzner

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 Table of contents
Operating and maintenance manual

1 General safety instructions .......................................................................................... 5

1.1 Special safety instructions ........................................................................ 6

1.2 Special hazards .......................................................................................... 6
1.3 Intended use ............................................................................................... 7
1.4 Adjusting the load lifting attachment/crossbars ..................................... 8
1.5 Guidelines for installation, maintenance and operating personnel ....... 8
1.6 Definition of the danger area ..................................................................... 8
1.7 Emissions ................................................................................................... 9
1.8 Personal protective equipment ................................................................. 9
1.9 Periodic inspections .................................................................................. 9
1.10 Warranty...................................................................................................... 9
1.11 Supplementary documents to the operating instructions ...................... 9

2 Product description .....................................................................................................10

2.1 Depressurisation ...................................................................................... 10

2.2 Suction cup............................................................................................... 10

3 Accessories (options) .................................................................................................11

3.1 Chain hoist................................................................................................ 11

3.1.1 Functional description ........................................................................ 11
3.1.2 Re-adjusting the brake ....................................................................... 12
3.1.3 Replacing the brake lining.................................................................. 13
3.1.4 Maintaining the slip clutch .................................................................. 13
3.1.5 Chain maintenance ............................................................................ 14
3.1.6 Checking the chain ............................................................................ 14
3.1.7 Replacing the chain ........................................................................... 15
3.1.8 Inspecting and maintaining the suspension elements ........................ 16
3.1.9 Bottom block ...................................................................................... 16
3.2 Electro-hydraulic rotary and swivel drive .............................................. 17
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 3.3 Flexible and pluggable version ............................................................... 18
3.4 HOVAMAT Plus + scale ........................................................................... 18
3.5 Water separator ........................................................................................ 19
3.6 Lift cut-off ................................................................................................. 20
3.7 Energy saving unit ................................................................................... 20
3.8 IG lifter version ......................................................................................... 20

4 Operating units ............................................................................................................21

4.1 HOVA Manual control unit ....................................................................... 21

4.2 HOVA operating unit ................................................................................ 22
4.3 Radio control ............................................................................................ 23

5 Operating the lifting device .........................................................................................25

5.1 Electropneumatic depressurisation ....................................................... 25

5.2 Electric depressurisation vacuum pump / vacuum blower .................. 26

6 IG lifter operation .........................................................................................................27

6.1 IG lifter large ............................................................................................. 27

6.2 IG lifter small ............................................................................................ 29

7 Power failure - warning unit and battery (only for vacuum lifter) .............................32

7.1 Warning unit (capacitor version) ............................................................ 32

8 Leak test .......................................................................................................................32

9 Troubleshooting ..........................................................................................................33

10 Maintenance .................................................................................................................34

10.1 Suction cup maintenance ........................................................................ 36

10.2 Oil-lubricated vacuum pump ................................................................... 36
10.2.1 Check the oil level.............................................................................. 38
10.2.2 Refill oil .............................................................................................. 38
10.2.3 Check the oil colour ........................................................................... 38
10.2.4 Changing the oil ................................................................................. 39
10.2.5 Air-de-oiling element .......................................................................... 40

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1 General safety instructions
1.1.1. Safety instructions and hazard warnings
The following symbols and designations are used in these operating instructions as safety instructions and hazard warnings:

WARNING! Serious personal injury or fatal accidents can result if work and operating instructions with this
symbol are not followed or are followed inaccurately.
Warnings must be strictly observed!

CAUTION! Serious damage to machinery or property can result if work and operating instructions with this
symbol are not followed or are followed inaccurately.
Cautions must be strictly observed!

NOTICE! When working and operating instructions with this symbol are followed, work can be conducted more
effectively and easily.
Notices facilitate work!

1.2. General safety regulations and organisational measures

The operating instructions must always be kept within easy reach at the place of use of the load lifting attachment. The operating
instructions must be observed.
In addition to the operating instructions, the general legal regulations for accident prevention and environmental protection must be
observed.

The operating personnel must have read and understood the operating instructions and in particular the safety guidelines before
starting work. Protective equipment for operating personnel must be provided and worn. The operator of the load lifting attachment
and his authorised representative must ensure that personnel use the load lifting attachment in accordance with the safety
instructions and hazard warnings.

1.2.1. Warnings and warning signs

Figure 1 Caution – suspended load

Figure 2 Nameplate incl. CE mark

General warning sign, Do not step under the load;
Figure 3
read operating instructions; crushing hazard
Figure 4 HOVA inspection plate

Figure 5 Electrical voltage

Figure 1 Figure 2 Figure 3

Figure 4 Figure 5

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1.1 Special safety instructions
Transporting and setting up
Carefully attach load lifting attachment, individual parts and larger assemblies to suitable and technically sound cranes with
sufficient lifting capacity (dead weight, see nameplate).
The load lifting attachment must not be operated in potentially explosive atmospheres. The ambient temperature may be between
+10°C and +40°C.
It must be connected to the power supply of the crane system or construction machine used. This ensures that it is switched on and
off with its main switch. Ensure through appropriate in-house instructions and checks that the workplace environment is always
clean and uncluttered.

Connecting
Connections should only be made by qualified personnel.

Commissioning/operation
• Perform visual inspection and prescribed checks on a daily basis before initial use.
• Only operate the load lifting attachment if the existing protective and safety devices are in place and operational.
• Immediately report any damage to the load lifting attachment or changes in its operating behaviour to the
responsible person.
• It is essential that the hook of the hoist be equipped with a fixed snap lock so as to prevent the lifting eye from
slipping out.
• • Do not place the load handling device on the suction pads! Set down the load handling device only with an
unloaded suction pad or on a transport trolley.
• Refrain from any unsafe working method
(see Section 1.5 "Intended use").

Cleaning, repairing and maintenance

• When carrying out assembly work above your head, use the climbing aids and working platforms provided for this
purpose.
• Do not use machine parts as climbing aids.
• Check electrical cables for chafing and damage.
• Ensure safe and environmentally friendly draining, collection and disposal of operating and auxiliary materials.
• Safety devices that are dismantled during assembly, maintenance and repair must be reassembled immediately after
completion of the work.
• Observe the inspection and maintenance intervals specified in the operating instructions.
• Observe the information in the operating instructions on the replacement of parts (spare parts management).
• Inform the operating personnel before the start of special and maintenance work.
• Secure a wide area around the repair area.
• Secure the load lifting attachment against unexpected switch-on during maintenance or repair work.
• Affix warning signs.
• Switch off the mains connection switch and secure it against unauthorised re-activation.
• Tighten screw connections that have been loosened during maintenance and repair work again in accordance with
regulations.
• Replace non-reusable fasteners and gaskets (e.g. self-locking nuts, gaskets).

Decommissioning/storage
• Clean and conserve (oil/grease) load lifting attachments before decommissioning and long-term storage.

1.2 Special hazards

WARNING! Since the load is held by negative pressure to the suction cups of the device, the load will drop as soon
as the negative pressure collapses.If the needle of the vacuum pressure gauge drops abruptly into the red range of
the pressure gauge, set the load down immediately!If this is no longer possible, move away from the danger area
immediately.There is a risk that the load will drop!
The device creates a very strong suction that can suck in hair and clothes. Do not look into the suction port when the device is on.
Eyes can be sucked in!

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1.3 Intended use
The load lifting attachment can be used for lifting and transporting solid materials with a clean, flat surface. The lifting device can
only be used hanging vertically.

The following points must be observed to comply with the intended use of the load lifting attachment:
• Never transport persons or animals with the load or lifting device.
• Unauthorised modifications and changes to the lifting device are prohibited for safety reasons!
• The operating, maintenance and servicing guidelines mentioned in these operating instructions must be observed.
• The maximum permissible load must not be exceeded.
• Use personal protective equipment (PPE) (see 1.8).
• Never exceed the maximum load. Never exceed the maximum load of the lifting equipment used (e.g. crane). Include
the dead weight of the lifting device. Pay attention to the payload plate.
• Do not stand under the load. Always remain outside the danger area of the load.
• Only perform work if you have a good view of the entire work area. Watch out for other people in the work area.
• Never move loads over people.
• Do not let go the operating handle of the lifting device while a load is being lifted.
• Never pull or drag loads at an angle.
• Do not use the lifting device to forcibly move loads that are stuck.
• In the event of a power failure, lower the load immediately if possible. If this is no longer possible, move away from the
danger area immediately.
• • Protect the suction cup from damage!
• • The load handling equipment must not be stored on the suction pads
• Only lift suitable loads (check inherent stability, material density and surface).
• Always keep an eye on the pressure gauge. Only lift if the pointer of the vacuum pressure gauge is in the green range. If
the pointer of the pressure gauge moves into the red range, set down the load immediately!
• Only place workpieces on an unobstructed, level surface. Otherwise they may slip when released.
• Do not release the load until it has been completely set down and is secure. Keep your hands off the load when
releasing it. Risk of crushing!
• Always distribute the load evenly across the suction area. If not all suction cups are engaged, the load capacity is
reduced proportionally to the number of unused suction cups.
• Only switch the suction cup on or off when unloaded (no load attached by suction).
• Do not let the load fall into slack chains.
• Blower lifters which manipulate unstable materials may only be used up to a maximum lifting height of 1.2 m!

CAUTION! The operator must always be able to see and observe the pressure gauge.

CAUTION! Attaching parts by suction with dirty and/or uneven surfaces is prohibited!

CAUTION! Attaching parts with damp surfaces without a water separator is prohibited. If moisture enters the vacuum
system, the device may fail.

CAUTION! The device creates a very strong suction that can suck in hair and clothes. Do not look into the suction
port when the device is turned on. Eyes can be sucked in!

NOTICE! Touch controls should be avoided. We accept no liability for any resulting damage to the device or to third
parties.

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1.4 Adjusting the load lifting attachment/crossbars
The load lifting attachment is firmly screwed to the base body. Before use, check the screw connections for tightness. If the suction
cups and crossbars are adjustable, the star knobs on the sliding shoes must open by approx. one turn for adjustment.
Set the crossbars/suction cups to the desired clearance and tighten the star knobs again. Make sure that the load lifting attachment
is always attached symmetrically.
Another securing method are locking bolts which snap in automatically. Care must be taken here to ensure that the bolt is always
fully engaged.

Arrangement of the crossbars for non-rigid parts that are longer than the main crossbar:
• Position the two outer crossbars at the ends of the main crossbar.
• Divide workpiece into 4 equal parts.
• Arrange the inner crossbars in such a way that the suction cups are the same distance from the
symmetry line = equal load distribution.

1.5 Guidelines for installation, maintenance and operating personnel

Any operating faults on the vacuum lifter which impair operational safety must be rectified immediately. This may only be done by
authorised and trained personnel.

NOTICE! We recommend that installation and maintenance work be carried out by our customer service.

CAUTION! If the operator carries out the inspection and maintenance work on their own responsibility, the type of
maintenance work and the date on which it was carried out must be recorded in the inspection logbook.

Modifications, additions and conversions to the vacuum lifter which could affect safety must be agreed with us in advance.
Unauthorised structural modifications exclude manufacturer liability in the event of damage. Material warranty claims will only be
accepted as admissible if only original spare parts of the manufacturer have been used. We expressly draw your attention to the
fact that original spare parts and accessories not supplied by us have also not been tested and approved by us.

The vacuum lifting systems may only be installed and serviced by qualified specialists, mechanics and electricians. Work on the
electronics may only be carried out by qualified electricians.

WARNING! Carry out care and maintenance work only on unloaded vacuum lifters. The main switch must be
switched off and secured against unauthorised re-activation. In addition, the compressed air supply must be
disconnected.

1.6 Definition of the danger area

The danger area is the area around the work equipment in which the safety of persons present is endangered. In the case of
vacuum lifting systems, the danger area is located under the vacuum gripper with load but also directly above the gripper.

When lifting or transporting the load, there is a possibility that the load may fall or break away from the vacuum gripper. If a load
falls, the danger area depends on the application, type of load and transport height. Loads are to be kept as close to the ground as
possible.

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1.7 Emissions
Vacuum lifting systems emit sound and hot exhaust air.
Primed media are atomised and distributed by the vacuum. Therefore, no polluted or contaminated ambient air (particle size max.
5 µm) must be primed.
The continuous sound pressure level emitted by the device is generally below 70 dB(A) (exception: blower lifter without sound
insulation box).

1.8 Personal protective equipment

Always wear suitable protective equipment when operating the vacuum lifting system:
• Safety shoes (according to EN 20345 safety class S12 or better)
• Solid work gloves (according to EN 388 safety category 2133 or better)
• Safety goggles (class F)
• Industrial helmet (according to EN 397)
• Other protective equipment appropriate to the situation or required by national and company regulations

1.9 Periodic inspections

CAUTION! Load lifting attachments and cranes must be inspected periodically by an expert. Visual and functional
inspections must carried out and the condition of components determined with regard to damage, wear, corrosion
or other changes. In addition, the completeness and effectiveness of the safety devices must be assessed.
Disassembly may be necessary to assess wear parts.

CAUTION! All periodic inspections must be arranged by the operator.

As a special service, HOVA Maschinenbau GmbH offers a service for an annual inspection
including entry in the inspection logbook.

1.10 Warranty
If no special agreements have been made, the following wear parts are excluded from the warranty: All seals of all components,
suction cup seals, pneumatic hoses, and load chains.
The warranty becomes void if the assembly, operation, testing and maintenance are not carried out in accordance with these
operating instructions.
The warranty is also void if the product is modified or if non-original spare parts are used.

1.11 Supplementary documents to the operating instructions

As a supplement to the operating instructions, the following documents must be observed by the operator:
• EC Declaration of Conformity
• Inspection logbook (optional)
• Circuit and pneumatic diagrams

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2 Product description
2.1 Depressurisation
Depending on the design, the vacuum is generated in different ways:

Depressurisation by means of pneumatic ejector

Compressed air is used to generate a vacuum based on the Venturi principle. These ejectors are available in 3 different sizes,
which can vary depending on the application. Use only with solid materials!

Depressurisation by means of oil-lubricated vacuum pump

In purely electrical systems where no compressed air is available or in vacuum lifting systems for suspension, the vacuum is
generated by means of an oil-lubricated vacuum pump. Use only with solid materials!

Depressurisation by means of vacuum blower

In the case of unstable materials such as uncoated MDF wood boards, a vacuum blower must be used to generate the vacuum.
The flywheel mass prevents the load from dropping immediately in the event of a power failure.
Max. lifting height with blower lifter: 1.8 m

2.2 Suction cup

The suction cups apply the vacuum to the load. They are used for lifting the parts to be transported. Only objects with flat, solid and
dry surfaces are suitable for lifting with vacuum.
All suction cups must always be properly seated on the workpiece in order to generate a vacuum and to be able to lift loads
(exception: devices with suction cups that can be switched off).
If suction cups are switched off, the full holding force is not reached and the maximum holding force is reduced! Optionally,
individual suction cups can be switched on and off via the ball valves on the suction cups. Suction cups that do not prime the load
must be switched off, otherwise no vacuum can build up to lift the load! The suction cups may only be switched on and off in an
unprimed state (no sucked in load). If the vacuum is switched on or off when the load is primed, the vacuum collapses abruptly and
the load falls down! If not all suction cups are switched on, the lifting capacity of the lifting device is reduced proportionally to the
number of suction cups switched off. The maximum permissible load must not be exceeded.

Before each use of the vacuum lifting device, the suction cup gaskets must be checked for wear and mechanical damage (cracks,
cuts, etc.). If the suction cup gaskets are in a critical condition, they must be replaced immediately.
The durability of the gaskets depends on the frequency of use, as well as the surface condition of the load and the ambient
temperature. We recommend that you replace the suction cup gaskets after 2 years of operation at the latest.

CAUTION! Moisture on the contact surfaces of the load or the suction cup gaskets considerably reduces the
coefficient of friction and thus the load-bearing capacity of the lifting device!
ATTENTION: Protect the suction cup from damage, do not store on the suction cup seals!

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3 Accessories (options)
3.1 Chain hoist

3.1.1 Functional description

A pole-changing three-phase-brake motor is used as the hoist motor in the chain hoist. When the motor is switched off or in the event
of a power failure, the load is held by an electromagnetic spring-applied disc brake. A short braking distance is realised by a special
electrical circuit.
The motor speed is transmitted to the chain drive via a multi-stage helical gear unit. The gearbox runs in an oil bath.
In the first gear range, a slip clutch serves as an overload control and emergency stop device, which is pre-set according to the
nominal load and the shock factors to be taken into account.
The chain is driven by a five-tooth sprocket. The chain drive is engineered and dimensioned according to DIN EN 818-7 (FEM 9.671).
Thanks to a suspension eye, which is attached to the housing with two threaded bolts, the chain hoist can be suspended from a trolley
or stationary.
In single fall operation, the load end of the chain is positively enclosed in the hook tackle and secured with a highly hardened and
tempered straight pin. In the double fall version, the chain is deflected in the bottom block by means of a sprocket and hooked onto
the housing anchor.

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3.1.2 Re-adjusting the brake
The brake cover is attached to the housing with 6 hexagon socket screws.
When the brake cover is released, the brake is located in the left side of the housing. A feeler gauge (3) can be used to measure the
air gap, which must not exceed 0.6 mm. The setting is done as follows:

• Loosen the hexagon socket screws (1).

• Screw in- or unscrew the adjusting bushes (2).
• Tighten the hexagon socket screws (1).
• Re-measure the new air gap using a feeler gauge (3).
• Repeat the procedure until the desired dimension (0.2 mm for CH1 and CH2 0.3 mm for CH3) is set.
• Tighten the hexagon socket screws (1) after adjustment.

Figure 1:Readjusting the brake

If the brake lining has been re-adjusted 2 times due to load, the complete brake disc (lining and lining carrier) must be replaced.

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3.1.3 Replacing the brake lining
To do this, loosen the fastening screws and remove the brake block. The brake disc, which is engaged with the toothing of the brake
hub, can now be removed.

Insert and secure the new brake disc in reverse order. The air gap must be adjusted after installation in the same way as described
above.

3.1.4 Maintaining the slip clutch

Under normal operating conditions, the slip clutch does not need re-adjusting. The clutch runs in an oil bath and the linings are virtually
wear-free. The slip clutch is pre-set at the factory. Re-adjustment of the slip clutch may only be carried out by authorised specialist
personnel. It is not permissible to increase the tripping torque above the factory setting.

Proper functioning of the slip clutch can be checked by whether the nominal load is lifted without delay and/or no slipping of the load
occurs during lifting. After extreme operating conditions over a long period of time, it may be necessary to re-adjust the slip clutch.

To re-adjust, proceed in this order:

• Loosen and remove the screw plug (1) on the gearbox cover (2) using an open-end spanner (size 19).
• The slip clutch is re-adjusted by turning the lock nut (size 17) clockwise.
• If the chain moves during adjustment, block it at the inlet of the chain guide.
• Check the setting by lifting / lowering the test load several times. The slip clutch must be adjusted in such a
way that 1.3 to 1.4-times the nominal load can just about be lifted.
• If the setting is not sufficient, proceed again from point 2.
• After adjustment, check the O-ring of the screw plug and replace if necessary.
• Tighten the screw plug.

Figure 2:Maintaining the slip clutch

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3.1.5 Chain maintenance
The service life of the chain is largely determined by its lubrication. Environmental influences and operating conditions affect the
necessary inspection- and maintenance intervals.

Visually inspecting the chain on a daily basis (see point 6.5) provides information about the quality of the lubrication. Accordingly,
relubrication or renewal of the lubrication must be carried out. Dirty chains must be cleaned before lubrication. Lubrication should be
carried out in an unloaded condition to ensure that the lubricant flows into the joints.

Commercially available engine oil, e.g. 20 W 50, is recommended as a lubricant.

3.1.6 Checking the chain

To determine when the chain must be discarded, the criteria
• chain length
• surface damage
• and corrosion must be taken into account.

Figure 3: Chain length

The chain length over 11 links (figure) can be measured directly or incrementally. Incremental measurement is carried out over 2 x 3
and 1 x 5 chain links. The chain must be slightly pre-tensioned during the measurement. The addition of the three determined values
L1 + L2 + L3 must not exceed the specified limit value “L”.

Maximum limits, alternative maintenance instructions if necessary, are given in the chain's instructions.

If one of the specified limit values is exceeded, the chain must be replaced. Surface damage in the form of notches or neckdowns as
well as signs of corrosion also necessitate replacement of the chain.

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3.1.7 Replacing the chain
A chain replacement may be necessary due to wear after prolonged operation or changed hook travel. Please make sure that the
new chain is lubricated before or directly after installation.

The chain is replaced by attaching the old chain to the new one. The procedure is as follows:

• Unhook the chain box and remove the chain abutment.

• Attach the new chain to the chain using a C link (Figure 15, Item 6).
• The position of the weld seam (Figure 15, Item 5) must be observed accordingly.
• Insert the new chain with the "Lower" function.
• For single fall (1/1) version open hook tackle, insert last chain link, lock with pin and refit hook tackle. The
tightening torques of the screws from Appendix D must be observed.
• In the case of the double fall (2/1) version, the chain must be guided further through the bottom block and
the last chain link fastened in the chain attachment point. To do this, unscrew the chain attachment point,
insert the last chain link into the attachment point and lock it with the pin.
• The chain must not be twisted in the process. The tightening torques of the screws for the chain attachment
point according to Appendix D must be strictly observed. The pin should be replaced every time the chain is
replaced.
• Mount the chain abutment and chain box.

Figure 4:Replacing the chain

It is essential that the chain be regularly checked for wear and that the lubrication be renewed every 100 hours of operation. Dirty
chains must be cleaned before lubrication. Commercially available engine oil, e.g. 20 W 50, is recommended as a lubricant.
Lubricate the chain when it is not under load to ensure that the lubricating film flows into the points of articulation.

Page 15 of 40
3.1.8 Inspecting and maintaining the suspension elements
The safety checks also include the inspection of the suspension elements. A regular visual inspection of the outer parts of the bump
stop, hook and hook jaw safety device is sufficient. If the bump stop shows significant cracks or deformation, it must be replaced. This
requires disassembly of the hook tackle or bottom block.

Figure 5:Widening and base height on the load hook

If the following guide values for the widening “e” and base height “f” of the load hook supplied by HOVA are not achieved, the hook
must also be replaced.

Hook size Max. widening “e” Min. base height “f”

0.12 26.4 18.1
0.25 30.8 22.8
0.5 37.4 29.9
1 44.0 38.0
Deviations are possible depending on the manufacturer.

The hook bearing is tested by turning the hook by hand with the load attached. In case of a defect,
the complete hook must be replaced.

3.1.9 Bottom block

The bottom block houses a deflection roller for the passing chain. To check the deflection roller bearing, open the bottom block by
loosening the two hexagon socket screws. Remove the chain and the hook incl. the hook bearing. By turning the deflection roller on
the bearing by hand (in one half of the bottom block), proper running can be checked. To determine any surface damage on the
bearing pin, remove the deflection roller including bearing from the pin. If one of these parts is found to be defective, the two bottom
block halves, the bearing pin and the deflection roller including bearing must be replaced. Relubricate if necessary.

Page 16 of 40
3.2 Electro-hydraulic rotary and swivel drive
In principle, the electro-hydraulic drive is a very low-maintenance component, but the oil quality and the surface seals of the drive
should be checked at least once a year. If the oil has darkened, it is essential that the oil be changed.
This is done through the oil filler plug or oil drain plug. The drive holds approx. 0.75 l. The special oil Fluit220 can be obtained from
HOVA Maschinenbau GmbH on request.
In order not to impair the service life of the drive, it is very important to check the oil level regularly with the aid of the sight glass.For
this purpose, minimum and maximum markings are integrated in the sight glass.If the oil level falls below the minimum, top up oil
immediately.
If the drive has already run dry, it must be bled.This is done via the bleed screw.

2
3

No. Description Comment

1 Oil filler/drain plug This opening allows the drive to be refilled or the oil to be changed.
2 Torque: pre-set at factory. Do not
adjust it!

3 Bleed screw The drive must be bled after every oil change.

4 Manual rotation release Turn screw counterclockwise. Drive is unlocked and can be moved
manually.

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3.3 Flexible and pluggable version
Maximum flexibility in everyday work with your HOVAMAT vacuum lifter.

With this extension, the chain hoist can be separated from the vacuum lifter and operated completely independently by means of
an external control unit.

Additionally includes:
Pluggable control unit with control cable
Eyebolt with hook block
Electrical and pneumatic plug connection on the vacuum lifter

Instructions:
The compressed air supply must be disconnected at the vacuum lifter by means of the coupling
Set down the vacuum lifter safely on an unobstructed surface (suction cups should not be primed)
Disconnect the plug-in power supply line on the vacuum lifter and unhook the hook block
Connect additional control unit to the chain hoist

3.4 HOVAMAT Plus + scale

The HOVAMAT PLUS + offers additional functions to the standard safety devices to avoid operator errors and to facilitate the
workflow.

This includes the following functions:

Load cannot be released before setting it down.

As soon as depressurisation is active, the weight is permanently monitored by means of a scale.

This ensures that depressurisation can only be stopped when the load has been set down. As a result, the load can only be
released when the load has been set down.

Lift cut-off for setting down the load

Lift cut-off is required when the load is set down. If depressurisation is stopped, lift cut-off is activated. This device prevents the
chain from slackening when the load is set down. The lowering movement is automatically stopped when the load has been set
down. The chain thus does not slacken.

Instructions:
The vacuum lifter and the logic programmed for it determine the work sequence.

Page 18 of 40
3.5 Water separator
For units with an integrated water separator, the liquid level in the sight glass of the separator must be checked before each suction
operation. If the liquid level rises near the maximum mark, the liquid must be drained.
To do this, loosen the union nut, remove the filter vessel and empty it.
Then reattach the filter vessel in reverse order.
The filter element should also be cleaned in this course.This can be done with compressed air.If the filter element is too dirty, it
must be replaced! When removing the filter element, make sure that no dirt gets into the lines!

Caution! There is a gasket on the rim of the filter vessel. It is imperative that it be re-inserted. A leak test
must then be carried out.

No. Description

1 Union nut

2 Filter element

3 Maximum marking

4 Filter vessel

Page 19 of 40
3.6 Lift cut-off
Only in combination with vacuum lifters for applications with solid materials!
For applications with solid materials, the vacuum lifting devices are equipped with an additional safety lifting function. Lifting the load is
only possible when a sufficient vacuum has been reached. This is also displayed by the red/green area on the vacuum pressure
gauge.

Check the safety lift function at the beginning of each work shift (if work is interrupted) or once a week
(in case of continuous operation)

• Start depressurisation.
• Acoustic signal sounds as long as the vacuum value is in the red range of the vacuum pressure gauge.
• Place the lifting device on a sheet metal plate or other solid surface and suck in the plate.
• The needle of the vacuum pressure gauge moves from the red to the green area.
• When sufficient vacuum (min. -0.6 bar) has been built up, the acoustic signal stops.
• The load can only be lifted when the needle of the vacuum pressure gauge is in the green area.

3.7 Energy saving unit

Only in combination with vacuum lifters for applications with solid materials!

For applications with solid materials, the vacuum lifting devices are equipped with an additional energy saving function.
Depressurisation is pre-set at the factory in such a way that the device depressurises only until a vacuum for safely lifting the load
is reached. As soon as sufficient vacuum has been reached, depressurisation is automatically stopped. This means that the on-site
compressed air network is not permanently in use, thus saving a significant amount of energy in the form of compressed air.

3.8 IG lifter version

Special vacuum lifter as support for insulating glass production with thermoplastic spacers.
For insulating glass production with thermoplastic spacers, our IG LIFTER with support is used. The first pane is held by the
vacuum plate and the rear panes are held by the mechanical support. With the mechanical support, the insulating glass can be
removed from the system immediately after completion, without prior curing of the thermoplastic mass.

Page 20 of 40
4 Operating units
Depending on the type of vacuum lifting system, there are different operating units.

4.1 HOVA Manual control unit

Is usually used in conjunction with a HOVA chain hoist. This allows an infinitely variable adjustment of the lifting speed.

The vacuum lifter is operated from the operating handle, in which all commands for proper operation are integrated.The operator's
workplace is permanently located behind the operating handle.

1
5

2
6
3
7

4 8

No. Description Colour Number Function

1 Hand lever black 1 or 2 Version with 1 piece: for swivelling the load
(optional) Version with 2 pieces: for swivelling and rotating the load
2 Emergency stop red/yellow 1 Stops all lifting and travelling movements. Depressurisation is not
button affected.
3 Selector switch black 1 Turns or rotates load
(option)
4 Control rocker green 1 Lifting/lowering to control the electric chain hoist
5 Selector switch black 1 Electric width adjustment of the suction cups
(option)
6 Illuminated push red 1 Vacuum on, locking – lights up when actuated
button
7 Push button green 1 RELEASE – vacuum off, sensing + venting of suction cups,
double actuation with No. 8 required
8 Push button red 1 Vacuum off, sensing, double actuation with No. 7 required

For devices with additional drives, the selector switches can be operated with the commands for controlling the drives.

Page 21 of 40
4.2 HOVA operating unit
Usually installed in vacuum lifting systems and blower lifters without chain hoist. The lifting movement is carried out by the on-site
chain hoist or crane.

The vacuum lifter is operated from the manual control unit, in which all commands for proper operation are integrated. The
operator's workplace is permanently located behind the operating handle.

1 2 3 4 5

1 2 3 4 5

No. Description Colour Number Function

1 Selector switch black 1 Vacuum pump ON/OFF – locking

2 Push button red 1 Release load (in combination with Item 4)

– incrementally
3 Push button black 1 Vacuum pump ON/OFF – locking

4 Push button red 1 Release load (in combination with Item 2)

– incrementally
5 Selector switch or 2 push buttons (option) black 1/2 Swivel/tilt forward/backward –
incrementally

Page 22 of 40
4.3 Radio control
The vacuum lifting system is operated by means of a radio system
Depending on the version, all commands for operation can be integrated in the radio remote control.

Turning on:

Lifting and lowering the load:

- Press LIFT button – load is lifted
- Press DOWN button – load is lowered
Light button press = slow speed / strong button press = fast speed!

Crane travel:
- Press CRANE TRAVEL FORWARD – crane moves forward
- Press CRANE TRAVEL BACKWARD – crane moves backward
Light button press = slow speed / strong button press = fast speed!

Priming and releasing loads:

- Press the VACUUM ON button – load is primed
- Press both VACUUM OFF buttons at the same time – load is released

Page 23 of 40
 The activity of the radio system can be read on the radio receiver at all times.
The receiver is attached to the hoist. The indicator turns GREEN when a transmitter is activated.

STOP button

LOWER
LIFT

CRANE FORWARD
CRANE BACKWARD

VACUUM ON
VACUUM OFF

RELEASE
APPLY

ON/OFF VACUUM OFF (1)

Caution! Audible signal always sounds as soon as the vacuum level reaches a critical value.
Please leave the danger area immediately!

Page 24 of 40
5 Operating the lifting device
Depending on the design and version of the device, there are different operating modes.

5.1 Electropneumatic depressurisation

General information on the operation of vacuum lifters with electropneumatic depressurisation
The load lifting attachment is suitable for transporting parts with solid material and flat surfaces. The max. load depends on the
number and size of the suction cups and is printed on the nameplate. Depressurisation is based on the ejector principle. For
devices with disconnectable suction cups, the max. load per suction cup must also be observed. This is also indicated on the
nameplate.
The load is lifted and lowered by means of an infinitely variable electric chain hoist from HOVA (only in conjunction with HOVA
chain hoist). Load and speed settings are optimally pre-adjusted to the respective requirement at the factory and may not be
changed without prior consultation with us.

Priming loads:
• Place the suction cup on the load to be lifted and make sure that all ball valves of the required suction cups are open.
• Press illuminated and locking push button "VACUUM ON" (illuminated) = prime load, hold.
• Vacuum rises into the green range of the vacuum pressure gauge.
• As long as the pressure gauge needle is in the red range, an acoustic warning signal sounds.
• When the acoustic warning signal stops, the load may be lifted.

WARNING! As long as the pressure gauge needle is not clearly in the green range, it is forbidden to carry out any
lifting, moving or swivelling!

WARNING! Never lift loads when an acoustic signal is sounding!

Releasing loads:
• Place the load safely on an unobstructed, level and stable surface.
• Press illuminated and locking push button “VACUUM ON” (goes off).
• Press push button “RELEASE” together with the impact button “RED” = release load.
• Press “RELEASE” push button = ventilate – release load quickly.

Power failure
The vacuum lifting device is designed in such a way that the load (solid materials) must remain attached for at least 5 min. after a
power failure by means of a reserve vacuum tank. However, this depends on many factors, including the condition of the load and
the vacuum system of the lifting device.

WARNING! In the event of a power failure, keep everyone away from the suspended load until you can safely
lower it to the ground or a stable support.
Correct any defect before resuming normal operation of the lifting device.

Page 25 of 40
5.2 Electric depressurisation vacuum pump / vacuum blower
General information on the operation of vacuum lifters with electric depressurisation
The load lifting attachment is suitable for transporting parts with solid material and flat surfaces. The max. load depends on the
number and size of the suction cups and is printed on the nameplate. The vacuum is generated by means of a high-quality electric
vacuum pump. For devices with disconnectable suction cups, the max. load per suction cup must also be observed. This is also
indicated on the nameplate.
The load is lifted and lowered using the on-site hall crane, which must be designed for the max. load plus the dead weight of the
vacuum lifter.

Operating elements (electrical depressurisation)

The vacuum lifter is operated from the operating handle, in which all commands for proper operation are integrated. The operator's
workplace is permanently located behind the operating handle.

Priming loads:
• Switch on main switch.
• Place the suction cup on the load to be lifted and make sure that all ball valves of the required suction cups are open.
• Set selector switch to "Vacuum pump ON" – depressurisation starts.
• Press "Depressurisation ON/OFF" push button – load is primed.
• Vacuum rises into the green range of the vacuum pressure gauge.
• As long as the pressure gauge needle is in the red range, an acoustic warning signal sounds.
• When the acoustic warning signal stops, the load may be lifted.

WARNING! As long as the pressure gauge needle is not clearly in the green range, it is forbidden to carry out any
lifting, moving or swivelling!

WARNING! Never lift loads when an acoustic signal is sounding!

Releasing loads:
• Place the load safely on an unobstructed, level and stable surface.
• Press "Depressurisation ON/OFF" push button.
• Press both "Release load" push buttons simultaneously – load is released.

Power failure
The vacuum lifting device is designed in such a way that the load (solid materials) must remain attached for at least 5 min. after a
power failure by means of a reserve vacuum tank. However, this depends on many factors, including the condition of the load and
the vacuum system of the lifting device.

WARNING! In the event of a power failure, keep everyone away from the suspended load until you can safely
lower it to the ground or a stable support.
Correct any defect before resuming normal operation of the lifting device.

WARNING! Not for blower lifter

The vacuum lifting device with vacuum blower is designed in such a way that the load (unstable materials) is held
in the vacuum blower by means of flywheel mass after a power failure. However, this depends on many factors,
including the condition of the load and the vacuum system of the lifting device.
Max. lifting height with blower lifter: 1.2 m

Page 26 of 40
6 IG lifter operation
6.1 IG lifter large
Supports
The vacuum lifter is equipped with additional support arms, which prevent slipping of the front glass pane (in the case of multiple
panes). The support arms are designed to be manually adjustable in depth. The height of the support arms can be adjusted electrically.

Emergency stop
button

Support arm
operation

If the emergency stop button is pressed, all electrical movements of the vacuum lifter stop immediately.

NOTICE! The clearance for the supporting jaws must be provided on the machine line.

Page 27 of 40
Lifting loads WITHOUT support
• Retract support arms (in depth).
• Start depressurisation.
• Press the lifting device lightly against the element to be lifted. Make sure that all suction cups are in contact with the
element and that the pane is picked up in the centre of gravity. Ensure that unloaded suction cups are switched off.
• Press the red "Vacuum ON" push button on the control unit. The load is primed.
• Observe the pressure gauge. As soon as -0.6 bar vacuum is reached (pressure gauge needle in the green range,
acoustic signal stops), you can lift the load. The load can only be lifted if the needle of the vacuum pressure gauge is
in the green area (for more details, see page 5).

Never lift when an acoustic signal is sounding!

Only lift if the operator is outside the danger area!

Setting down the load WITHOUT support

• Lower the load and place it securely on an unobstructed, level surface so that the load cannot slip or tip.
• Press red "Vacuum OFF (1)" and "Vacuum OFF (2)" push buttons = release load.

Lifting loads WITH support

• Retract support arms (in depth).
• Start depressurisation.
• Press the lifting device lightly against the element to be lifted. Make sure that all suction cups are in contact with the
element and that the pane is picked up in the centre of gravity.
• Ensure that unloaded suction cups are switched off.
• Press the red "Vacuum ON" push button on the control unit. The load is primed.
• Observe the pressure gauge. As soon as -0.6 bar vacuum is reached (pressure gauge needle in the green area,
acoustic signal stops) the pane is securely attached.
• Adjust the support arms depthwise according to the thickness of the pane.
• Move the support arms upwards until the jaws are in contact with the lower edge of the pane.
• The load can now be lifted. When lifting, make sure that only one item is lifted at a time. Carefully remove any other
parts adhering to the part with a screwdriver before lifting the part further. Do not release with your hands. Danger of
crushing!

Setting down the load WITH support

• Lower the load and place it securely on an unobstructed, level surface so that the load cannot slip or tip.
• Move the support arms downwards so that the load rests on an unobstructed surface.
• Retract support arms (in depth).
• Press red "Vacuum OFF (1)" and "Vacuum OFF (2)" push buttons = release load.

Page 28 of 40
6.2 IG lifter small

Operating modes
The vacuum lifter can be operated in 2 modes. The operating mode is selected via a selector switch integrated in the operating
handle.

“SUPPORT ON” operating mode

In this operating mode, the vacuum lifter is operated with the additional supports, which prevents the rear glass elements from
slipping.

“SUPPORT OFF” operating mode

In this operating mode, the vacuum lifter can be operated without the additional supports.
Switching between the two operating modes is possible using the selector switch on the device!

Select operating mode

selector button Optical display
“Rotating possible”

Optical display
“Lifting possible”

Switching between operating modes during a work cycle is prohibited!

A cycle that has already been started must be completed before switching to the other operating mode!

NOTICE! The clearance for the supporting jaws or insertion aid must be provided on the machine line!

Page 29 of 40
 Priming and lifting the load – “SUPPORT ON” operating mode
• Operate the selector switch “Raw lift” – depending on the height of the glass elements, the suction height must be preset.
• Press the control rocker down – lower the vacuum lifter onto the positioning aid (provided by customer).
• Press the vacuum lifter lightly against the glass element to be lifted.
• Press red locking push button “Vacuum ON/OFF” – load is primed.
• Acoustic and optical signal until vacuum rises into the green range of the vacuum pressure gauge.
• Press the green “Activate support” push button – support is activated – only now can the glass element be lifted!
Activation of the support is only possible when sufficient vacuum has been reached.

Caution! Before the safety forks are extended, the suction crossbar must be in horizontal
position, otherwise there is risk of collision.

➢ Lifting the element – press the control rocker upwards – the stronger the actuating pressure, the faster the element can be
lifted.
Lifting is only possible when the green light on the vacuum lifter is active.

Lowering and releasing the load – “SUPPORT ON” operating mode

• Lowering the element onto an unobstructed surface (e.g. transport rack) – press the control rocker downwards – the
stronger the actuating pressure, the faster the element can be lowered.
• Press the red illuminated push button “VACUUM ON/OFF”.
• Press the red “De-activate support” push button – depressurisation is de-activated, support is de-activated and the
element is released from the suction cups.

Press the button until the element is released from the suction cups!

Priming and lifting the load – “SUPPORT OFF” operating mode

• Press the vacuum lifter lightly against the glass element to be lifted.
• Press red locking push button “Vacuum ON/OFF” – load is primed.
• Acoustic and optical signal until vacuum rises into the green range of the vacuum pressure gauge.
• Lifting the element – press the control rocker upwards – the stronger the actuating pressure, the faster the element
can be lifted.
• Operate the “Rotate” selector switch – load can be rotated 100° to the right or left.

Caution! The support must be de-activated and the raw lift must be retracted.
Otherwise there is a risk of collision!

Page 30 of 40
Lowering and releasing the load – “SUPPORT OFF” operating mode
• Lowering the element onto an unobstructed surface (e.g. transport rack) – press the control rocker downwards –
the stronger the actuating pressure, the faster the element can be lowered.
• Press the red illuminated push button “VACUUM ON/OFF”.
• Press the red “Vacuum OFF” push button – depressurisation is de-activated.
• Press the red “Vacuum OFF” push button – the element is released from the suction cups.

Press the button until the element is released from the suction cups!

Operating handle on the vacuum

lifter

“Rotate” selector Emergency stop button

button

Push button green – Selector switch – raw lift

Activate support

Push button – “De-activate

support” or “Release”

Rocker switch –
Lift/Lower Push button locking –
“Vacuum ON/OFF”

Caution! Audible signal always sounds as soon as the vacuum level reaches a critical value.
Please leave the danger area immediately!

Page 31 of 40
7 Power failure – warning unit and battery (only for vacuum lifter)
The electric warning unit is located under the plastic cover of the electric chain hoist.
The warning unit becomes active as soon as the electrical power supply of the vacuum lifting device is interrupted (e.g. power failure).
The warning is indicated to the user by a periodically sounding horn sound.
When the horn sounds, leave the danger area immediately!

In order to guarantee the function of the electrical warning unit, the following steps must be carried out every 6 months:

• Checking the battery of the warning unit Switch on the main switch – green LED flashes for 10 seconds, then lights up
continuously. If the battery is too weak, the horn sounds at short, regular intervals – change the battery immediately, but at
least YEARLY!
• Checking the function of the warning unit: Switch on the vacuum (see Section 2.2), then switch on main switch.
The acoustic warning unit must now become active (horn sound at regular intervals). De-activating the warning tone: This
is usually only necessary if the lifting device is regularly disconnected from the power supply (e.g. power disruption at night).
• To de-activate the warning signal, please proceed as follows:
Remove the plastic cover from the chain hoist. Underneath is a control board, which is equipped with a button cell battery.
Remove the button cell battery and screw the cover back onto the chain hoist.

CAUTION! If the warning unit is de-activated, the operator does not receive any acoustic signal in the event of a
power failure – RESIDUAL RISK!

7.1 Warning unit (capacitor version)

The electrical warning unit is located under the plastic cover of the lifting unit or in the switch cabinet of the vacuum lifting device.
Proper functioning of the electrical warning unit is guaranteed when the green light flashes for 1 minute when the
unit is switched on and then changes to a steady light.
The warning unit becomes active as soon as the electrical power supply of the vacuum lifting device is disrupted while the load is
suspended (Prime button is pressed) (e.g.: power failure).
The warning is signalled to the user by a beep sounding at regular intervals. When the signal tone sounds, check the vacuum
pressure gauge immediately.
If the pointer of the vacuum pressure gauge falls, leave the danger area immediately and secure it!
If the pointer is in the green range and does not fall and there is no danger to yourself
and/or others, you can try to secure the load against falling (e.g.: move a forklift underneath).
Always make sure that the pointer of the vacuum pressure gauge is in the green area and the danger area is secured.

8 Leak test
The leak test must be carried out daily and before each use by the operating personnel.
To do this, place the device with the suction cups on a solid surface, e.g. a sheet of metal
• Switch on and prime the workpiece.
• Wait until a vacuum of approx. -0.7 bar is reached.
• Then switch off depressurisation.
• The vacuum must not drop below -0.6 bar within 5 minutes.

If the vacuum degrades faster, check:

• Suction cups/sealing lip, hose, hose connections and screw connections for damage and leaks, replace if necessary.
• Whether the vacuum filter is clogged or contaminated, if necessary clean or replace the filter (see Section 3.3.4).

! Not possible for vacuum lifters with vacuum blower!

Page 32 of 40
9 Troubleshooting
Error
Chain hoist without function
Lifting with chain hoist possible,
lowering not possible
Neither lifting nor lowering possible
Chain hoist does not lift load
Warning unit beeping
Chain rattles during lifting or lowering
No or insufficient vacuum
Suction and/or release not possible
or only partially
HOVAMAT HV 180° rotation not possible
Cause
Emergency stop pressed
Emergency stop contact block in the
manual control unit has come loose
Potentiometer adjusted or defective
Neutral conductor missing
No 230 V at the supply plug
Chain entangled
Microswitch in manual control unit
defective
Slip clutch misaligned
Load capacity exceeded
Button cell battery empty
Seal chain, chain guide or chain
sprocket shaft
Insufficient operating pressure
Compressed air supply line kinked or
broken
Damage to the vacuum system
Max. vacuum: - 0.4 bar
Leak
Filter cartridge closed and sealing ring in
position
Ejector defective or dirty
Leak
Solenoid valve or push button defective
Reversing drive cable broken
Solution
Release emergency stop
Open the manual control unit and attach
the contact block – First disconnect from
mains supply!
Adjust potentiometer
Provide connection cable with neutral
conductor
Check supply line
Dismantle chain box and untangle chain
Open the control unit and replace the
microswitch – first disconnect from
mains supply!
Adjust the slip clutch (see p. 14)
Check weight of good to be transported
Replace button cell battery in chain hoist
(see p. 33)
Check components and replace if necessary
Check compressed air; optimal
pressure: 6-7 bar
Check supply line.
Check hoses and connections
Vacuum switch defective / perform leak test
Check tightness of transport material
Open filter cartridge and check position
of O-ring
Check ejector and replace if necessary
Check suction cup for damage
Vacuum valve leaking
Loosen fastening screws of solenoid
valve, replace if no improvement
Check cable for cable break
Page 33 of 40
10 Maintenance
2. Vacuum lifter maintenance for solid materials – electropneumatic depressurisation
Type of inspection:
A: Visual inspection; check assembly for damage, deformation, corrosion
B: Mechanical inspection; check assembly for mechanical damage/failure (e.g.: tighten screws, clean)

C: Ergonomics inspection; check ease of movement and usability of product

D: Prescribed maintenance interval to ensure proper functioning of device

Type Inspection object Inspection interval Comment

D 6 12
months months
A Check base frame for damage x

A, B Check screws for tight fit, retighten if necessary x

D Check suspension points x

D Lubricate load chain (spray grease, white) and x

check wear
D Relubricate bearings and slewing rings x

A Check fasteners between trolleys and lifting x

equipment

D Replacing the button cell battery of the x

electrical warning unit
D Check oil level of electro-hydraulic swivel x
drive, top up if necessary
A Check the toothed segments of the lifting scissors x
for wear, relubricate if necessary (option)
A, B Check all hoses and pneumatic fittings for x
cracks or tight fit and damage, replace if
necessary
A, B Function test of solenoid valves x

A Function test of optical displays, vacuum x

pressure gauge
A Function test of audible warnings x

A, B Perform leak test x

D Check suction cup gaskets for wear, clean and x

replace if necessary
A, B Clean vacuum filter x

A Power supply – check all cables for chafing or x

other damage
A Check energy chains for damage x

A, B Check energy chain carriers for tight fit and x

damage
A, B Check lifting guide elements for wear, readjust x
or replace if necessary
A, B Water separator, visual check whether marking x
has been reached, empty if necessary

The intervals listed apply to normal operating hours and are highly dependent on individual operating conditions. They must be
shortened if the load is above average and if unfavourable conditions (dust, heat, vapours, etc.) occur during operation.

Page 34 of 40
3. Vacuum lifter maintenance for solid materials – electrical depressurisation
Type of inspection:
A: Visual inspection; check assembly for damage, deformation, corrosion
B: Mechanical inspection; check assembly for mechanical damage/failure (e.g.: tighten screws, clean)
C: Ergonomics inspection; check ease of movement and usability of product
D: Prescribed maintenance interval to ensure proper functioning of device

Type Inspection object Inspection interval Comment

D 6 12
months months
A Check base frame for damage x

A, B Check screws for tight fit, retighten if x

necessary
A, B Check suspension points x

D Lubricate load chain (spray grease, white) and x

check wear
A Relubricate bearings and slewing rings x

D Replacing the button cell battery of the x

electrical warning unit
A, B Check the level and colour of the oil x

D Clean fan guard, fan impeller, fan grille and x

cooling fins
D Service vacuum pump x In case of multi-shift
operation every 6 months.
D Check all hoses and pneumatic fittings for x
cracks or tight fit and damage, replace if
necessary
A, B Function test of solenoid valves x

A Function test of optical displays, vacuum x

pressure gauge
A Function test of audible warnings x

A, B Perform leak test x

D Check suction cup gaskets for wear, clean and x

replace if necessary
A, B Clean vacuum filter x

A, B Water separator, visual check whether marking x

has been reached, empty if necessary

The intervals listed apply to normal operating hours and are highly dependent on individual operating conditions. They must be
shortened if the load is above average and if unfavourable conditions (dust, heat, vapours, etc.) occur during operation.

Page 35 of 40
10.1 Suction cup maintenance
Remove adhering objects and dirt such as glue, adhesive, chips, dust, etc. from the sealing lips at least once a week. Use glycerine
for cleaning.
Immediately replace damaged or worn suction cups/sealing lips (cracks, holes, corrugation).
Use cold cleaning agents to clean the device (no petroleum ether or corrosive liquids).
This would cause the feed hose to leak or be destroyed).

NOTICE! Only original HOVA suction cups may be used. Otherwise the manufacturer's warranty will be voided!

The suction cups must be in the air during storage and must not be loaded with the dead weight of the load handling device for a
long period of time!

3.3.4 Vacuum filter

Check filter at least once a week and blow out filter cartridges (from the inside to the outside). Change the filter cartridge if it is very dirty.
When removing the filter cartridge, make sure that no dirt gets into the lines.

10.2 Oil-lubricated vacuum pump

Any operating faults on the vacuum lifter which impair operational safety must be rectified immediately.This may only be
done by authorised and trained personnel.

NOTICE! We recommend having the vacuum pump serviced by our customer service as part of the annual
inspection.

CAUTION! The surface of the vacuum pump can reach temperatures of over 70°C during operation. Risk of
burns!

CAUTION! If the operator carries out the maintenance work on their own responsibility, the type of maintenance
work and the date on which it was carried out must be recorded in the inspection logbook.

Page 36 of 40
Page 37 of 40
10.2.1 Check the oil level

• Make sure that the vacuum pump is switched off, secured against switching on and that the oil has collected at the bottom
of the oil separator (d)
• Read oil level at sight glass (h)
When the level has dropped below the 50% mark on the sight glass:
• Refill oil
When the level is above the 75% mark on the sight glass:
• Unacceptable dilution with condensates – change the oil and check the process
• If necessary, retrofit a gas ballast (HOVA customer service)
If despite proper use of the gas ballast the level is above the 75% mark on the sight glass:
• Replace the filter

10.2.2 Refill oil

NOTICE! Normally, it should not be necessary to add oil within the recommended change intervals. A clear drop
in the fill level indicates a malfunction. Please contact our customer service.

NOTICE! The air-de-oiling element becomes saturated with oil during operation. A slight drop in the fill level is
thus to be expected.

CAUTION! Filling oil through the suction port (g) will cause the slider to break, thus destroying the vacuum pump.
Oil may only be filled in through the filler opening (c).

CAUTION! The oil separator is filled with hot, pressurised oil mist during operation.
Risk of injury from hot oil mist when the filler opening is open.
Risk of injury if screw plug (c) comes off because it was inserted too loosely. The screw plug (c) may only be
removed when the vacuum pump is not running. The vacuum pump may only be operated with the screw plug (c)
firmly inserted.

• Make sure that the vacuum pump is switched off and secured against accidental re-activation.
• Remove the screw plug (c).
• Top up oil until the level reaches the 75% mark on the sight glass (h).
• Ensure that the sealing ring is inserted in the screw plug (c) of the filler opening and is undamaged, replace if necessary
• Tighten the screw plug (c) of the filler opening with the sealing ring again.

10.2.3 Check the oil colour

NOTICE! The oil should be light in colour and either clear, slightly frothy or slightly cloudy.A milky discoloration
that does not disappear after the oil has settled indicates contamination with foreign matter.Dark discoloured oil is
burnt.Oil contaminated with foreign matter or burnt oil must be changed.

If despite proper use of the gas ballast the oil appears to be contaminated with water or other condensates:
• Replace filter

Page 38 of 40
10.2.4 Changing the oil
Draining the used oil
NOTICE! No more than 20 minutes should elapse between switching off a vacuum pump at operating temperature
and draining the oil (the oil should still be warm when draining).
• Make sure that the vacuum pump is switched off and secured against accidental re-activation.
• Make sure that the vacuum pump is vented to atmospheric pressure.
• Place a collecting vessel under the drain opening (i).
• Remove the screw plug (i) and drain the oil.
• When the oil flow decreases:
• Replace the screw plug of the drain opening (i).
• Switch on the vacuum pump for a few seconds.
• Make sure that the vacuum pump is switched off and secured against accidental re-activation.
• Remove the drain plug (i) of the drain opening and drain the remaining oil.
• Make sure that the sealing ring on the screw plug is inserted and undamaged, replace if necessary.
• Firmly re-insert the screw plug (i) with the sealing ring.
• Dispose of the used oil in accordance with the applicable regulations.

Flushing the vacuum pump

• Ensure that the used oil is completely drained off.
• Prepare 0.45 litres of flushing agent from 50% oil and 50% petroleum or diesel/heating oil.
• Make sure that the screw plug of the drain opening (i) is firmly inserted.
• Remove the screw plug (c) of the filler opening.
• Pour in the flushing agent.
• Tightly insert the screw plug (c) of the filler opening.
• Close the suction line.
• Operate the vacuum pump for at least half an hour.
• Drain the flushing agent and dispose of it in accordance with the applicable regulations.

Fill up with fresh oil

• Keep 0.45 litres of oil ready according to the manufacturer's instructions (the quantity indicated is a guide value; the mark
on the sight glass is decisive for the quantity to be filled in (h)).
• Make sure that the drain plug (i) is firmly inserted.
• Remove the screw plug (c) of the filler opening.
• Fill in approx. 0.45 litres of oil.
• Make sure that the level is at approx. the 75% mark on the sight glass (h).
• Make sure that the sealing ring of the screw plug (c) of the filler opening is inserted and undamaged, replace if necessary.
• Tightly re-insert the screw plug (c) of the filler opening with the sealing ring.

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10.2.5 Air-de-oiling element
Checking during operation
• Make sure that the vacuum pump is in operation.
• Check that the power consumption of the drive motor is within the normal range.
• Check that the exhaust air is free of oil.
Assessment
NOTICE! Air-de-oiling element cannot be successfully cleaned.Clogged air-de-oiling elements must be replaced
with new ones.

The air-de-oiling element must be replaced if:

• The current consumption of the drive motor is lower than normal, or
• The exhaust air contains oil

Removing the air-de-oiling element

• Make sure that the vacuum pump is switched off and secured against accidental re-activation.
• Before disconnecting the connections, make sure that the connected lines are ventilated to ambient pressure.
• If necessary, remove the exhaust duct.
• Remove the exhaust cover (f) from the oil separator (d).
• Loosen the screw in the centre of the filter spring, but do not remove it.
• Push the filter spring out of the recess and rotate it.
• Remove the filter spring from the oil separator (d).
• Pull the air air-de-oiling element out of the oil separator (d)).

Inserting the air-de-oiling element

• Ensure that the new air-de-oiling element is fitted with a new O-ring.
• Insert the air-de-oiling element in such a way that its opening is seated in the oil separator (d) in the correct position.
• Ensure that the tip of the screw in the centre of the filter spring protrudes approx. 2-5 threads from the filter spring.
• Insert the filter spring so that its ends are secured against slipping off by the lugs in the receptacles of the oil separator (d)
and the tip of the screw is engaged in the recess of the air-de-oiling element.
• Tighten the screw in the filter spring until the screw head touches the spring plate.
• Ensure that the gasket under the exhaust cover (f) is clean and undamaged, replace with a new gasket if necessary.
• Fasten the exhaust cover (f) to the oil separator (d) with gasket and hexagonal bolts.
Connect the exhaust duct if necessary.

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