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WIRE ROPE HOIST INSTRUCTION MANUAL

CONTENT
FOREWARD
NOTES BEFORE INSTALLATION
2-1 General Examination
2-2 Insulation
2-3 Rail
2-4 The notes of power feed system installation
2-5 Distribution of the control box
INSTALLATION OF HOIST
3-1 Mono rail
3-2 Double rail
3-3 Lifting hoist (Cargo elevator)
TESTING
4-1 Confirmation before running
4-2 Confirmation before un-loading running
4-3 Confirmation before full loading running
4-4 Confirmation after testing
IMPROPER OPERATION
5-1 Correct Operation
5-2 Improper Operation
5-3 Operated by two peoples
MAINTENANCE
6-1 Notes when maintenance
6-2 Limitations of Use
6-3 Items examined daily
6-4 Items examined monthly
6-5 Items examined quarterly
6-6 Items examined yearly
TROUBLESHOOTING AND MAINTENANCE
7-1 Notes of Maintenance
7-2 Mechanism
Circuit Diagram
Annex

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I FOREWARD
Dear Customers:
Now you are the master of FITOP Electric Wire Rope Hoist, and we believe that it will
meet your expectation. It is a best tool of automation for carriage purpose, and is
produced by us under careful design and strict quality control. Before leaving the factory,
every set is tested to be qualified to meet CNS regulation for domestic and overseas
markets. It is surely safe.
However, in order to perform it with the maximum function, this manual is prepared by
us to let you fully understand the operation and maintenance. Please read carefully
before operation, and we will serve you with satisfactory instructions. The prosperity and
development of your business is our happiness!

IINOTES BEFORE INSTALLATION


2-1. General Examination
2-1-1. Examine if the specifications are in compliance with the requirements?
2-1-2. Examine if the hoist is damaged in the process of carrying?
2-1-3. Examine if all parts below are enclosed:
(1) Button switch (2) Fuse (3) Structural drawing
(4) Circuit Diagram (5) Wire rope (6) other specific demands

2-2. Insulation
Examine the resistance of insulation system: Use of 500V high- impedance Meter to
measure if the resistance of each individual part is above 1.

2-3. Rail
2-3-1. Stop device shall be set on the rail.
2-3-2. The gap between each rail connection shall not over 0.8 cm.
2-3-3. The installation of rail shall be complied with the regulation and be sure to keep
level at transversal and horizontal direction to avoid any unstable condition
when operating.

2-4. The notes of power feed system installation


2-4-1. Cable type
(1) Keep the ring of cable smoothly.
(2) Towing arm shall be welded on the hoist and against the end of electrical
power cable.
(3) When collecting the cable, be careful not hooked up with any extrusion from
runway.
-1-

2-4-2. T-rail type:


(1) T-rail shall be welded firmly and keep connection be smooth.
(2) For flat cable, the loop shall be smooth. (As the below drawing)
(3) Same as cable type (2).
(4) Same as cable type (3).
(5) The connection can be welded at A point. Dont weld B point. (As the
below drawing)

2-4-3. Safety rail type


(1) The fixing clamp shall be in the same line and level.
(2) The welding of towing arm shall be formed as square iron stick.
(3) Fix square bar shall be in parallel with the surface of safe rail, and the
distance is 70+10 mm.

2-5. Distribution of the control box:


Standard specifications refer to circuit diagram Fig. 1, 2, 3, 4, 5, and 6. The others shall
refer to the circuit diagram inside the control box.

III INSTALLATION OF HOIST


3-1. Mono rail
3-1-1. The width of I / H beam girder should be >= (the base width of trolley
wheel + 2~4 mm gap) shown as below fig.

Gap

3-1-2. When one end of girder is opened, the hoist and trolley could be combined and
install them from the opening end.
3-1-3. When both ends of grider are closed or the end of girder cant be opened to
cause hoist to fail to enter in, please release the trolley plates than install it.
-2-

3-2. Double rail


After hoist and trolley has been combined, set it on the traversing rail directly.
Remark: There is an eccentricity self-regulator device for the axle of double rail hoist, so
the movement of the trolley wheel can keep evenly on the rail.
However, when main hoist has no loading, the four trolley wheels may not touch to the
rail simultaneously. After having loading, this situation wont be happened anymore.

3-3. Lifting hoist (Cargo elevator)


Lifting cabin shall be elevated to the top end. Move the hoist to keep the center of
gravity of hook be same as the vertical line of lifting box, then fix the hoist horizontally
correctly.

IV TESTING
4-1. Confirmation before running
4-1-1. The auxiliary supporting line of the button switch should be tie firmly and
correctly, to avoid the cable being deformed under force.
4-1-2. The position of button switch shall at 1 M distance from the floor.

4-2. Confirmation before un-loading running


4-2-1. Testing the button switch
When testing, press the UP button first, never press the DOWN button first.
After pressing the UP button, the hook will be lifted up. So, it is no problem. If
the hook moves downward, the power connection wire of hoist is not correct
(error phase sequence). So, please change two wires of R, S, T, alternatively, and
repeat the above steps until this problem has been solved.
If the hoist is used under the wrong wire connection (error phase sequence), the
limit switch will be invalid and it may be caused the wire rope broken or serious
damage of the hoist, etc. accidents. Therefore, be careful to pay attention to this
condition.
4-2-2. Press the button switch to keep the hook lifting up, when hook reaches to the
position of up limit, the limited switch will be started to stop the hook
automatically. Then press DOWN button, to make sure if the hook is moved
downward.
4-2-3. Let hoist load 100 kg-200 kg loading and move full distance up and down.
When the moving, please check the below list:
(1). Is the rail proper?
(2). Is any interference for cable?
(3). are there enough spaces between hook and building?
(4). If the hoist could be touched the building?
-3-

4-3. Confirmation before full loading running


4-3-1. First test lifting up and down action, and check the sliding is appropriate or not
after the brake?
4-3-2. Is it stable or not, when hoist is moving?
4-3-3. When hoist is moving, test the voltage of trolley, the voltage should not more 7%
the voltage of motor that show in motor nameplate.

4-4. Confirmation after testing


4-4-1. After hoist testing, please check the rope press block on the drum, if that is loosen
or not?
4-4-2. Check the traversing and runway rail, if they are loosen or not?
4-4-3. Check the temperature of motors, if they are normal or not?

V IMPROPER OPERATION
5-1. Correct Operation
5-1-1. When hoisting, be sure the wire rope is fastened at correct position for safety
purpose. Otherwise, loosened hook, the cargo hoisted will be fallen down to
cause damage.
5-1-2. Gradually loosen the tight wire rope; on the contrary, the loose wire rope shall be
tightened by gradual process.
5-1-3. Before hoisting, please make sure the wire rope orderly.
5-1-4. A sharp angle would be damaged wire rope, make use of a smooth object to
protect the wire rope at that position.
5-1-5. Keep opening of hooks wire rope degreed within at 60 shown as below fig.

Max. 60

5-1-6. When operation, be careful not to impact to the cargo , to avoid loading falling
down.
5-1-7. Lift one cargo by two hoists, please pay attention to keep a balance for the center
of gravity.

-4-

5-2. Improper Operation


5-2-1. The hoisting weight is over the rated weight.
5-2-2. When hoisting, the slant degree of wire rope is over big (shall not over 8 degree) or
push the hoisted loading to another side.
5-2-3. Weld hoisted object, Using the hoist to connect ground.
5-2-4. Keep the hook at the top end.
5-2-5. Often used the limit switch.
5-2-6. Put the sheave on the ground then the wire rope on the drum will be loosened.
The wire rope may be damaged when not place it in the correct glove.
5-2-7. When ascending or descending the cargo by hoist, operator does not see clearly
the wire rope and the situation of floor.
5-2-8. Carrying the cargo over the head of the workers.
5-2-9. When not hoisting, still lift loading off the ground.
5-2-10. Using the hoist to dismantle the stable and fixed object.

5-3. Operated by two peoples


5-3-1. Conductor and operator shall leave the hoisting district for a safe place.
5-3-2. Signal shall be acknowledged correctly before hoisting.
5-3-3. All operations shall be conducted by the same person.
5-3-4. Below is the instruction drawing for gesture:

Prepare
Raise arm over the head,
open five fingers,
Palm forward not moving

Lifting
Raise arm over the
head
forefinger point sky ,
and Draw a circle
horizontal rotation

Stop
Extend the arm , let palm
down, not moving .

Descending
Lower the arm,
forefinger point
ground and Draw a
circle horizontal
rotation

-5-

Emergency Stop
(at emergency condition)
Quickly stretch out both arms,
not moving.

Runway Moving
Arm protrusion,
open palm and
Move hand back
and forth to the
desired direction.

Traversing
Palm up and clench
fist ,
Thumb point to the
desired direction

VI MAINTENANCE
6-1. Notes when maintenance
6-1-1. Periodically clean the rail of trolley.
6-1-2. Periodically check the function of limit switch.
6-1-3. Periodically lubricate. Please refer the the below table for the
recommendation lubricant applied.

Standard lubricant
Lubricating
Place

Lubricating
Method

Interval
(Temp.10-60)

Recommended
CPC
www.cpc.com.tw

Lubricant
JIS
Standard

Gear box

Oil bathing

Every year

Gear oil #90

K-2219(1983)
Gear oil

Wire Rope

Smearing

Check it monthly,
Apply lubricant, If
necessary

GEAR
COMPOUND

K-2220(1980)
Grease

Bearing

Oil filling

Every year

Grease for
Ball bearing

K-2220(1980)
Grease

Opened gear

Smearing or
spraying

Check it monthly ,
Apply lubricant, If
necessary

GEAR
COMPOUND

k-2220(1980)
Grease

Oil filling

Check it monthly ,
Apply lubricant, If
necessary

GEAR
COMPOUND

Oil filling

Check it monthly ,
Apply lubricant, If
necessary

GEAR
COMPOUND

Up sheave &
shaft

sheave &
shaft

-6-

K-2220(1980)
Grease

K-2220(1980)
Grease

6-2. Limitations of Use


6-2-1. Wire rope
The wearing of wire ropes O. D. shall not over 7%, otherwise, a replacement
is necessary.
(a) Wrong measuring

(b) Correct measuring

The broken thread number shall not over 10% of total thread number in one
unit.
One Unit

6-2-2. Hook

H1

H2
Normal Hook opening

Serious opening
(Dont use it)

6-2-2-1. If the hook is cracked or deformed, dont use it.


6-2-2-2. The Wear and tear limitation of H value is under 5% standard
thickness.
6-2-2-3. If the opening width (B) has been deformed, replace it immediately
for safety purpose.

-7-

6-2-3. Sheave
The wear and tear limitation of cast iron sheave is under 30% of wire ropes
O. D., but the wear and tear limitation of inner wall of sheave shall depend
on it condition.

6-2-4. Gear
The wear and tear limitation of gear depends on thickness above the pitch
circle.
Thickness
Blank
diameter
Pitch circle
diameter

Wearing

Gap

Dedendum
diameter

6-2-4-1. The wear and tear limitation of driving gear for trolley is at 40%.
6-2-4-2. The part of winding up shall not over 30% of original size.
6-2-4-3. The first section of gear shall not over 10% of original size.
6-2-4-4. Shaft coupler shall not over 20% of its original size.
6-2-5. The wear and tear condition of electrical connection shall be below 65% of
original thickness.
6-2-6. The wear and tear of lining shall not over 50% of original thickness.
6-2-7. Wheel
6-2-7-1. The wear and tear limitation of flange thickness is 50% of original size.
6-2-7-2. The wear and tear limitation of wheel groove is 5% of original dia.
6-2-7-3. The tolerance of roundness on groove dia. Shall not over 1mm
6-2-7-4. the tolerance of Left/right dia.:
Driving (Active) wheel shall not over 0.2%.
Follow (Passivle) wheel shall not over 0.5%.
6-2-8. The wear and tear of lining shall not over 50%. (The original thickness:
3.5mm)

-8-

6-2-9. The SOP of Brake Disk Replacement and Brake Gap Adjustment
6-2-9 -1. The SOP of 6HP Motor Brake Disk Replacement and Brake Gap Adjustment
The steps of release as below:
1 (pay attention to brake line and
Step 1 - Remove the the end cover of brake
spring)
2
Step 2 - Remove the brake plate
3
Step 3 - Remove the brake disk
4
Step 4 - Remove the Brake plate
6 and brake column
5 if they have any
Step 5 - Check the brake seat
loosened.
The steps of installation as below:
4
Step 1 - Install the Brake plate
3
Step 2 Install the brake disk
2
Step 3 Install the brake plate
Step 4 Mesure the gap of brake. (The gap about 0.5mm)
.
1 (pay attention to brake line and
Step 5 Install the the end cover of brake
spring) and Test and check the function of brake in normal.

-9-

6-2-9-2. The SOP of 10HP Motor Brake Disk Replacement and Brake Gap
Adjustment the steps of release as below:
1
Step 1 - Remove the fan cover
2
Step 2 - Remove the nut
3 (pay attention on brake line and spring)
Step 3 - Remove the brake coil assembly
4
Step 4 - Remove the nut
5
Step 5 - Remove the brake plate
6
Step 6 - Remove the first of brake disk
7
Step 7 - Remove the retaining ring
8
Step 8 - Remove coupler
9
Step 9 - Remove the Brake plate
10 if it has been broken or missed.
Step 10 - Check the washer
11 and brake column
12 if they have any loosened.
Step 11 - Check the brake seat
The steps of installation as below:
9 (put the washer between brake seat
11 and
Step 1 - Install the Brake plate
9 )
brake plate
8
Step 2 - Install the coupler
7
Step 3 - Install the retaining ring
6
Step 4 Install the brake disk
5 and nut
4 at the right position (the plane side of nut
Step 5 - Install brake plate
face up).
3 and nut
2
Step 6 - Install brake coil assembly
.
Step 7 - Using adjustment plate to adjust the gap of brake. (The gap between coil
column and brake plate is 0.5mm)
.
Step 8 Reverse the screw tight and fix the brake coil seat. Test and check the
function of brake coil. If the brake discs have been engaged and released
averagely, be sure if the gap of brake is appropriate.
1
Step 9- Install the fan cover

- 10 -

6-2-9-3. The SOP of 15HP Motor Brake Disk Replacement and Brake Gap
Adjustment the steps of release as below:
1
Step 1 - Remove the fan cover
2
Step 2 - Remove the nut
3 (pay attention on brake line and spring)
Step 3 - Remove the brake coil assembly
4
Step 4 - Remove the washer and nut
5
Step 5 - Remove the brake plate
6
Step 6 - Remove the first of brake disk
7 and coupler
8
Step 7 - Remove the retaining ring
Step 8 - Check the teeth of coupler, if the teeth have been abraded, if so, we
strongly suggest the brake disc and coupler should be replaced together,
otherwise the brake disc will have big problem.
9
Step 9 - Remove the middle brake plate
10
Step 10 - Remove the second of brake disk
11
Step 11 - Remove the Brake plate
12 if it has been broken or missed.
Step 12 - Check the washer
13 and brake column
14 if they have any loosened.
Step 13 - Check the brake seat
The steps of installation as below:
11
Step 1 - Install the Brake plate
8 and retaining ring
7
Step 2 - Install the coupler
10
Step 3 Install the second of brake disk
9
Step 4 - Install the middle brake plate
6
Step 5 - Install the first of brake disk
5
Step 6 - Install the brake plate
Step 7 - Install the nut
4 at the right position (the plane side of nut should be up).
3
Step 8 - Install the washer and brake coil assembly
2 and use the retaining ring
15 to adjust the brake gap.
Step 9 - Install the nut
(The gap between coil column and brake plate is 0.5mm)
Step 10 - Reverse the screw tight and fix the brake coil seat. Test and check the
function of brake coil. If the brake discs have been engaged and released
averagely, be sure if the gap of brake is appropriate.
1
Step 11 - Install the fan cover

- 11 -

6-3. Items examined daily


Check
Wire rope

Item
Prolonged
Worn out
Deformed
Corroded
Broken

Judgment Standard
Abnormal prolong condition.
The thread wiring is over the limitation.
Visible for continuous deformation.
Clearly to see corroded part.
Over the limitation for broken.

Hook

Widen opening
Deformed
Other damaged
defects
Performing
Safe latch

The opening is become wide.


It is curved & deformed.
Cracked, Scared or other defects.

Up limited switch

Up and upper
limited switch
assembly

When the loading touch the Up limited switch,


then hoist power off.

Motor

The function of
hoist, Trolley and
end carriage

Is the function normal or not, any noise?

Brake

The function of
hoist, Trolley and
end carriage

Checkthe brake function without


Sliding down condition, without noise?

Push Button

Outlook and
Operation

If the outer shell is damaged or deformed.


All hoist movmtion in normal.
The move directions of hoist are all the same
signs shown on push button.

Hanging tool

Wear and tear


Deformed

Check if any abnormal wear and tear deformed


and cracked, etc. condition exists or not?

Smooth performance when move up and down.


If the safe latch has been loosened?

Daily checking point form as the Annex 1.

- 12 -

6-4. Items examined monthly


Refer to the monthly examination table for checking the items one by one.
6-4-1. Structure & Mechanism
Examine
No.

Place

Main hoisting

Sub-hoisting

Inspected by

Charged by

Crane No.

Date of inspection

Span

Lift

Operator

Safety supervisor

Area

Sidewalk

Traveling
mechanism
device

Item examined

Good
Bad

Area

Item examined

1. Mount on the bolt, gap


plate, & washer.
2. Mounting of soft start.
3. Is walking path smooth
without caught down,
step down, slipping,
etc. situation.

Gear Device
12. Abnormal sound, heating,
vibration, and lubricating.
13. Loose condition of bolt
mounting for gear box.
14. Gear cover and bolt
deformed, damaged.

Shaft coupler
4. Mounting of bolt, key,
non-turn.
5. Loosen or deformed
washer, rubber
cushion.
6. Lubricating & oil
leaking of gear, shaft
coupler

Bearing
15. Cracked, damaged,
deformed or loosened
bolt.
16. Lubricating condition.
Traveling motor
17. Loosened bolt
Traveling
mechanism
device

Brake
7. Performance.
8. Wear and tear
condition of brake
lining.
9. Contact condition, gap
between brake lining
and brake body when
starting.
10. Contact condition, gap
between brake lining
and brake body when
braking.
11. Suitable gap for brake.

Wheel
18. Wear and tear or
deformed wheel base.
19. Wear and tear of wheels
groove surface.
20. Cracked wheel.
21. Noisiness or lubricating
Wheels bearing.

Examination form as the Annex 2.

- 13 -

Good
Bad

Area

Item examined

Good
Bad

Area

Gear Device
41. Abnormal sound,
heating, vibration, and
lubricating.
42. Loose condition of bolt
43. Mounting for gear box.
Gear cover and bolt
deformed, damaged.

Shaft coupler
22. Mounting of bolt, key,
non-turn.
23. Loosened or deformed
washer, rubber
cushion.
24. Lubricating & oil
leaking of gear, shaft
coupler
Hoisting motor
25. Loosened bolt

Hoisting
Mechanism
device

Item examined

Brake
26. Performance.
27. Wear and tear
condition of
brake lining.
28. Contact condition, gap
between brake lining
and brake body when
starting.
29. Contact condition, gap
between brake lining
and brake body when
braking.
30. The slide is too much.
31. Wear and tear, broken,
and dusted surface of
brake Body.
32. The condition of brake
torque adjustment
device.
33. Performance of
electro-magnet brake
magneto and abnormal
sound.
34. Drum type brake oil
pipe leakage
35. The status of Electric
hydraulic disc brake.
36. Electric hydraulic brake
disc , oil leakage and
the oil volum
37. Rod, bar, pin, screws
and other parts of
operating mechanism.
38. All pins of the
lubrication.
39. Piping, joints of oil
spills
40. Abnormal noise,
abnormal vibration,

Hoisting
Mechanism
device

- 14 -

Bearing
44. Cracked, damaged,
deformed or loosened
bolt.
45. Lubricating condition.
Winding drum
46. Crack.
47. Gear of winding drum,
loosened condition of
bolt.
48. Winding drum groove.
49. After rope is fallen off.
50. Deformation, loosened
condition of key plate,
shaft.
51. Bearing.
Wire Rope
52. Wire rope.
53. Knotted.
54. Lubricant & surface
polluted.
55. Other contacts and intercontacts point.
56. Thread cut.
57. Disordered & curved
part.
58. Caved, grooved, swelled
and corroded.
59. Rope end processing,
rope end parts, fixing
condition.
60. Knitted part.
61. Wear and tear and
broken condition of
equilibrium sheave.
62. After replacement of
wire rope.check that
monthly.

Good
Bad

Area

Item examined

Good
Bad

Sheave

Gear
84.

68.

Condition of return-run
Damaged, cracked flange.
Wear and tear condition
of sheave groove.
Crack of spider hub.
Wear and tear and
deformation of Bearing
chain plate, locking Pin.
Proper sheave groove and
Rope dia.

85.

86.

69.
70.
71.
72.

73.

74.

87.

Traveling
mechanism
device

Damaged condition of
hook.
Loosened condition of
screw thread.
Falling protective device
of hook nut.
Deformed, loose
condition of key plate,
locking pin.
Deformed, loose
condition of bolt, nut,
splitting pin, etc.
Cracked, wearing,
damaged condition of
side plate.

77.

80.

81.
82.

83.

Cracked, damaged,
deformed, loosen condition
of bolt.
Lubricating condition.

Traversing Wheel
90.
91.

92.

Wearing, deformation of
Flange.
Wearing of wheels pedal
Face.
Crack of wheel.
Abnormal lubricating of
Wheels bearing.

93.
94.
95.

Bolt, key, non-turn device.


Deformed, loose
condition of washer
rubber cushion.
Lubricating, leaking
condition of gear, shaft
coupler

Security
check

Brake, etc.
78.
79.

88.
89.

Shaft coupler
75.
76.

Noise, heating, vibrating &


lubricating conditions.
Loose bolt for gear box.
Deferment, damaged
Condition of opened Gear
cover, bolt mounded.

Bearing

Hook

Traveling
mechanism
device

Item examined

63.
64.
65.
66.
67.

Hoisting
Mechanism
device

Area

Performance
Wearing of brake lining,
etc.
Contact, gap between
brake Lining & brake body
when starting.
Equable contact of brake
Lining & brake body when
braking, wearing, cracked,
dusted, Condition of
brake body surface.
Stroke distance is too long

Safety ladders are secure.


Handrails are secure.
Check the overload device
movement is normal.
96. The anti-wind device is
functioning correctly.
(outdoor gantry crane)
97. Safety sidewalk is clean or
rust.
98. Over winch (upper and
lower limit) action is
normal.
99. Runway and Trolley limit
switch are normal.
100. Runway and Trolley
stopperdevice is normal.
101. Runway warning lights and
alarm devices are working
properly.

102. Check the valid period.

Others

- 15 -

Good
Bad

6-4-2. Electrical device


Examine No.

Place

Crane No.

Date of
inspection

Area

Electric motor

Main hoisting

Sub-hoisting

Hook path

Lift

Item examined

Good
Bad

1. The motor wire


damage? Is insulation
good?
2. Terminal wires are
loosened?
3. Any abnormal noise
during hoist running.
4. Three-phase current
balance in full loading.

Control panel
or
Distributor

5. Fixing screw of panel.


6. Fixing of contactor &
transformer.
7. Steel core of the
absorbent surface,
Enameled wire,
Abnormal sound
8.
Contact slice surface.
Electromagnetic
9.
The wear and tear
contactor
conditions of Contact
point.
10. The action status of
Contactor.

Interior wiring

Push button
station
(pendant)

Area

Power
feed
system

11. Fix the terminal of


Contactor
12. Internal wiring and
insulation.
13. Mounting bolts.
14. Conduction device.

Inspected by

Operator

Charged by

Safety supervisor

Item examined
Safe rail
21. Wear and tear of safe
rail.
22. End tension device.
23. Anti-conduction
device.
24. Abnormal insulating
object & insulation.
Current Collector
25. Wear and tearof
collector.
26. Oiler mechanism.
27. The status of
insulation.
28. Fix terminal, bolt and
screw.
Power-supply cable
29. Wear and tear of
exposed insulation.
30. Expansion of cable.
31. Terminal, Bolt and
screw tightly.
32. Performance of cable
leading mechanism.
Signal lamp
33. Fixing part of terminal.
Lightening device
34. Fix the terminal.
35. Mounting part &
break proof bulb.

15. Contact slice surface.


16. keep the the contact
depth of Contact point
17. the status of
Movement direction
18. Power cable input.
19. The condition of box
and cover.
20. The Protection
condition of the wire
rope.

Other
devices

- 16 -

Limit switch
36. Contact point of
contactor.
37. The spring of
contactor point.
38. Limit lever deformed?
39. Performance & its
position.
40. Bolt mounting.

Good
Bad

6-5. Items examined quarterly


6-5-1. Check the insulation of cable wire and cable.
6-5-2. Check all nuts & bolts of connecting part.
6-5-3. Check control cable of push button station.
6-5-4. Check all bolts on the trolley wheel and motor.

Examination table as the Annex 2.


6-6. Items examined yearly
1. Check and fill lubricant oil of every part of the hoist after it is operated for one year.
2. Check gear box of hoist.
Check the wear condition of gear, the function of ball bearing, and the tightness of
locking bolt.
3. Check brake
Check the wear of lining, brake plate, linings motion, and test its function.
4. Examine if electromagnetic device is in good condition.
5. Examine motor
Examine if abnormal sound appears when motor runs to see if the ball bearing is in
good condition.
6. Inspect limit switch
Check the wear of contact point, tightness of bolt and test for switchs function.
7. Sheave and wire rope shall be examined monthly.
8. Check Trolley wheels & end carriage wheels.
Inspect the wearing condition of wheel surface, ball bearing and gear.
9. If every part inspected is in normal condition, hoist goods 10-20cm high and lower
them 10-20cm repeatedly. If nothing wrong, ordinary motion can be started again.

Examination form as the Annex 2.

- 17 -

VII. TROUBLESHOOTING AND MAINTENANCE


7-1. Notes of Maintenance
7-1-1. Before the maintenance work of runway beam and hoist, you must cut off the
power supply and remove lead away. In addition the work should be posted notice
of Note
7-1-2. Dont maintain or repair machine when power supply is on.
7-1-3. After maintenance is finished, close all doors or covers.
7-1-4. After maintenance is finished, dont leave any tools or master unit on the trolley or
rail.

7-2. Mechanism
Trouble
1. Steel wire rope is not in
the drum groove when
rolling.

Possible cause
(1)

(2)

When lift load and made Wire


rope rock movement, cause
wire rope to jump rope groove
or overlap.
Wire rope wear or
deformation.

Troubleshooting
(1)

Roll wire rope down and re-roll


wire rope up

(2)

Replaced with new wire rope

2. Loud noise.

Reducer excessive wear.

Change new parts.

3. Disc brakes loose motion


is too slow.

(1)

(1)

Adjust gap.

(2)

Pull pin out and repair it.

(1)

Pull pin out and repair it.

(2)
4. Disc brake takes too long
time to function.

(1)

Too big gap between Lining and


disc.
The hole of folding part Rusts
or is burned.

(2)

Clean the folding part.

(3)
(4)

The hole of folding partRusts or


is burned.
Dirty object sticks to the
Folding part of disc.
Manual loose bolt is working.
Lining on the disc breaks down.

(3)
(4)

Loosen bolt.
Change lining.

5. Main hoisting slide down

(1)
(2)
(3)

The brake gap is too big.


Brake Lining wear and tear.
The brake spring loosened.

(1)
(2)
(3)

Adjust brake gap.


Replace lining.
Replace brake springs.

6. Trolley will slide

(1)

The brake adjustment screw is


not tightening.
The lining wear and tear.
The brake spring lossened.

(1)

To fix the crew at right


tightness.
Replace lining.
Replace brake springs.

(2)

(2)
(3)
7. End carriage will slide
and running un- even

(1)
(2)
(3)

The brake adjustment screw is


not tightening.
The lining wear and tear.
The brake spring lossened.

- 18 -

(2)
(3)
(1)
(2)
(3)

To fix the crew at right


tightness.
Replace lining.
Replace brake springs.

Trouble
8. Noise & abnormal
vibration produced when
wheel is running.

Possible cause
(1)
(2)
(3)

9. No working

(1)

(2)
(3)
(4)
(5)
(6)

(7)
(8)
(9)
10. Hoisting up doesnt work

(1)
(2)
(3)
(4)
(5)

11. Hoisting down doesnt


work

(1)
(2)
(3)

12. Hoisting up and down


doesnt work
(motor stopping)
13. Trolley cant move EAST

(1)
(2)
(3)
(1)
(2)
(3)
(4)

Troubleshooting

Bearing bush is worn.


Deficient lubrication for
bearing.
Burned object sticks to the
shaft.
The main power supply of end
carriage, trolley or main hoist
isnt on.
Stop at up or dwon limited
switch.
Control circuit is off.
Push button malfunction.
Main power contactor have
problem or does not work.
Runway power feed, R or Tphase current collector have
taken off.
The main fuse has broken.
The Movable power cable and
connection point have trouble.
Voltage of power supply
dropping down.
check up limited switch

(1)
(2)

Change new ones.


Oil filling.

(3)

Clean it.

(1)

Check the current collector and


other power connections.

(2)

the up current of hoisting has


broken
Motor is too hot,
Push buttom UP malfunction.
Contactor of up function
malfunction.
the down current lood of
hoisting havs broken
Push buttom DOWN
malfunction.
Contactor of DOWN function
malfunction.
The fuse 10A has broken.
The brake of hoisting motor
doesnt open.
Burned-out Hoisting motor.
check up east limited switch
The east current of hoisting
has broken.
Push buttom EAST
malfunction.
Contactor of EAST function
malfunctions.

(2)

Move up and upper limited


switch to normal position.
Check the MT main loop.
Replace Push Button station.
Check up limit switch and the
fuse of main contactor circuit.
Identify the reasons for power
off and recovery of current
collector
Replace the main fuse.
Tie loose lead tightly, change
control cables if necessary.
Check the reason why voltage
dropping.
If limited switch malfunction or
stop
Check the break point of current.

(3)
(4)
(5)

Fix or isolate high temperature


Replace new Push buttom
Replace new UP contactor

(1)

Check the break point of current.

(2)

Replace new Push buttom

(3)

Replace new DOWN contactor

(1)
(2)
(3)
(1)
(2)

Replace new fuse


Check the current of brake and
lining.
Replace new hoisting motor
Replace east limited switch.
Check the break point of current.

(3)

Replace new Push buttom

(4)

Replace new EAST contactor

- 19 -

(3)
(4)
(5)
(6)

(7)
(8)
(9)
(1)

Trouble
14. Trolley cant move
WEST

15. Trolley cant move EAST


and WEST
(Trolley motor stopping)
16. End carriage cant move
South

Possible cause
(1) check up west limited switch
(2) The west current of hoisting has
broken.
(3) Push buttom WEST malfunction.
(4) Contactor of WEST function
malfunctions.
(1) The brake of trolley motor doesnt
open.
(2) Burned-out trolley motor.
(1) Check South limited switch
(2) The SOUTH current has broken.

(4)

Replace South contactor.

(1)
(2)
(3)

Replace the north limit switch.


Check the failed circuit point
failure.
Replace it.

(4)

Replace north contactor.

(1)

(2)
(3)

Check the brake circuit or


replace the brake coil.
Replace motor.
To adjust and balance the both
sides break gap of the motors.
Check and solve it.
Replace motor.

Three-phase power have twophase short-circuit.


Any phase and ground short
circuit. (electric leakage)

(1)

Check the circuit of power.

(2)

Check the reason of electric


leakage

(1)

Battery no power

(1)

(2)
(1)

The fuse of Receiver burned


The frequency of the remote
control is similar to the other
remote control.
Any phase of control cable with
common line short circuit.
The direction of the contactor is
bound.
The direction of the push button
failure.

(2)
(1)

If the red light on, that mean


indicating need to replace
battery.
Replace the fuse
Change the frequency of
remote control.

(1)
(2)
(3)
(4)

19. End carriage's start and


stop unbalance

(1)
(2)
(1)
(2)
(3)

20. The main power failed


(No fuse breaker)

(1)
(2)

21. Push button doesnt


work

22. Hoist movement


without operator

(2)
23. Releave push button
but hoist doesnt stop

(1)

(3)

(4)

18. End carriage move


uneven

(1) Replace west limited switch.


(2) Check the break point of
current.
(3) Replace new Push buttom
(4) Replace new WEST contactor
Check the brake circuit and
lining.
Replace motor.
Replace the south limit switch.
Check the failed circuit point
failure.
Replace it.

(3)

17. End carriage cant move


South

Troubleshooting

(1)
(2)

Push buttom SOUTH


malfunction.
Contactor of south function
malfunction.
check north limited switch
The north current has broken.
Push buttom NORTH
malfunction.
Contactor of north function
malfunctions.
One of motors' brake is not open
or failed
One of motors burned.
The gaps of both sides motor are
not adjusted well.
One of motors brakes is not open.
one of motors burned

- 20 -

(2)
(1)
(2)

(2)
(1)

(2)

Check and solve it.

(1)

Replace the direction of the


contactor
Replace the direction of the
push button.

(2)

Trouble
24. Motor burned
(main hoist , trolley end
carriage)

Possible cause
(1)

3 phase sequence are not correct


(a phase contactor point of
failure)
Short circuit (motor wiring error).
Overload (lifting heavy loading,
and overtime).
Insulation damage caused by
overheating, and made short
circuit between phases (over
duty cycle).
Bearing trouble.
The planetary gear or Inner gear
is worn.
The gear shaft is bent or
deformed.

(1)

Replace the contactor

(2)

(7)

Check the circuit of contactor


and replace it.
Dont overload and overtime or
change high duty cycles hoist.
Dont over duty cycle, inch
movement or change high duty
cycle hoist and use low speed to
instead of inch movement.
Replace the bearing.
Replace planetary gear or Inner
gear.
Replace gear shaft.

(1)

The bearing wear and tear.

(1)

Replace the bearing.

(1)

The bearing of trolley wheel is


worn (active wheels or Passive
wheels) .
The front and rear wheel has not
in the same line.
The trolley rail bent or deformed

(1)

Replace the bearing.

(2)
(3)

Make the straight line test of the


wheel while assembling.
Check the rail and fix it.

(1)

Replace the bearing.

(2)

Make the straight line test of the


wheel while assembling.
Loading can't exceed rated load.

(1)

The bearing of end carriage


wheel is worn (active wheels or
Passive wheels) .
The front and rear wheel has not
in the same line.
Deformed span or girder, cause
the loading is over heavy.
The specification of rail is not
meet for example (5) Tons hoist
use rail for 3 tons hoist
Seal hardened or deformed

(2)

The oil seal is assembled badly.

(2)

(3)

The groove of gear box is too


deep

(3)

(1)

Driver seat loosened.

(1)

(2)

Connection shaft broken.

(2)

(2)
(3)
(4)

25. Abnormal sound of the


gear box

(5)
(6)
(7)

26. Abnormal sound of the


motor
(main hoist, Trolley and
end carriage)
27. Abnormal sound
when the trolley is
traversing

(2)
(3)
28. Abnormal sound
when the end carriage is
traveling

(1)

(2)
(3)
(4)

29. leak oil from gear box

30. Drun cant be rolled

Troubleshooting

- 21 -

(3)
(4)

(5)
(6)

(3)
(4)

The rail specification should


meet host specification.

(1)

Replace the oil seal able to bear


the high-temperature material.
Examine and look at the oil seal
to damage, rebuild.
Replace and seal and the cover
of gear box.
Check the reason of loosened
drive seat and fix the screw
tightly.
Replace connection shaft.

Circuit Diagram 1.

- 22 -

Circuit Diagram 2.

- 23 -

Circuit Diagram 3.

- 24 -

Circuit Diagram 4.

- 25 -

Circuit Diagram 5.

- 26 -

Circuit Diagram 6.

- 27 -

Annex 1.

(Company Name) Hoist Examine form for Daily checking point


Date:

Year

month

Hoist serial number:

Manager:

Date
Item

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

1.UP Limited switch


2.Over load device
3.Brakes
4.Wire rope
5.Hook
6.Control function
7.Runway and Trolley rail
8.Note

Examine person and sign

Remarks:
Inspection result, the good one is marked ' ', no need to check mark ' /' ,bad one is marked '' and note in item 8.

25

26

27

28

29

30

31

Annex 2.

Hoist /Crane Regular Examination Maintenance Form


Department:

Hoist serial No.:

Hoist type and capacity:

Check item

Monthly

Girder, End carriage and the other traveling mechanism


1. Any loosened bolt in Girder and end carriage
Girder

2. The wear and tear condition of trolley rail.

and

3. Fixing Trolley stopper.

End

4. The lubrication of Gear and shaft

carriage

5. Any damage on trolley wheels


6. Any damage on gear surface
1. Rail wear and tear more than 10% original size,
2. Any loosened bolt

Rail
3. Any crack on the welding
4. Any damage on stopper or buffer
1.

The brake device has nay deformation or bolt loosened.

2. The bolts of gear motor have loosened


3. The lubrication of bearing
Traveling
device

4. Does the driven shaft become flexible and wear


5. The surface of wheel is flawless
6.

Flange thickness wear and tear is more than 50% of


original.

7. The bearing have noise


Push

1. The outlook is good and no crack

button

2. Each button function is normal


3. Bolts for Wiring or ground line has been loosened
4. Is every contact point good?
5. Does the control cable break?

- 29 -

Quarterly

Yearly

Hoist /Crane Regular Examination Maintenance Form


Check item

Monthly

1. Check the action


2.
Electromagnetic
Brake

Any noise or vibration? any oblique or irregular


movement

3. Is the gap of brake normal


4.

Brake lining wears more than the original


thickness 50%.

5. A good ability of braking


6. Any wear on the surface of brake drum or disc
7. Check all Bolts, nuts and springs
1. Any obvious deformation or corrosion
2. Normally Contact with pulley
3. Is there cable wire oil of coating

Wire
rope

4.

The broken thread number shall not over 10% of


total thread number in one unit.

5. Diameter less than 7% of the nominal diameter


6. The end side join with drum properly
1. Drum cracks or groove wears.
2. Wire rope with drum with properly
Drum
3. Drum have deformation
4. Any noise from bearing seat when drum is rolling.
1. Wearing situation
2.
Chain

The size of the chain exceeds the demarcation


line of the specification

3. The chain obvious deformation


4. The chain add the oil to lubricate

- 30 -

Quarterly

Yearly

Hoist /Crane Regular Examination Maintenance Form


Check item

Monthly

1. Any crack
2. Visual check and find deformation
3. Opening width same as original size.
4. Opening width under 5% as standard
Hook

5. Any wear and tear on nut or screw thread


6. Any anti-all device
7. The condition of spreader
8. the condition of operating
1. Any obvious crack or wear and tear on sheave

Sheave
groove

2. Any obvious crack or wear and tear on bearing or shaft


3. Key , pin and bolt do not loosened

Hoist case

1. Any cracks
1. The states of gearbox

Lubrication

2. Any crack or obvious wearing


3. Any noises when the running
1. Fixed control box

Inner
power
cable

2. Power cable damage


3. Screw all bolts tightly
4. The condition of insulation

Power
feed
Current
Collector

1. Current Collector wearing


2. Any damage or fall off
3. Keep in touch or not
4. Is the spring damaged or tired
1. The condition of insulation
2. Coil burnt?

Motor

3. Check any loosened bolts?


4. Any noise when the running

- 31 -

Quarterly

Yearly

Hoist /Crane Regular Examination Maintenance Form


Check item

Safety
device

Contactor

Cable

Monthly

1.

Safety ladder fixed

2.

Handrail is firmly

3.

Check overload device

4.

Check anti-wind device

5.

the cleaned sidewalk

6.

Up or down limited switch normal

7.

South and north limited switch normal

8.

East or west limited switch normal

9.

The warning light

10.

Loudspeaker

11.

Lighting

1.

Action confirmed

2.

Check contact point

3.

Fixed terminal

1.

Any damage or crack

2.

The condition of rolling

Quarterly

Yearly

and
Cable reel

The state expresses symbols: Good O , Normal , Bad X , Doesnt have that device N

Suggestion

Checking Company / department:

Manager :

Inspector 1:

Inspector 2:

- 32 -