OPERATION AND MAINTENANCE MANUAL. FOR 10 TONS X 11.5m SPAM SINGLE GIRDER E.0.T. CRANE FOR TENAGA NATIONAL BHD, 132/33/11 KV GIS, PANDAN MESRA, SEKSYEN 15, BDR . AMPANG.© Max Power Electric Hoist Instructions On Maintenance Servicing And Operation Lih Yeh Hoist Co, , Ltd.Dear Consumer, ‘Thank you for your purchase of this product. To gin careful understanding and ‘optimal performance ofthis product, please read these instructions carefully before use. and keep this manual in safe place as reference for regular maiatenance and inspection. CONTENTS. 1, Precautions for opeaion of electrical hoist, 2. Machine inspection and method 3. Inspection of electrical pats. 4. Troubleshooting of eect al hoist 5, Adjustment of brake clearance in electrical hoist 6, Bleetie hoist circuit diagram (single speed) 7. Bletic hoist cireuit diagram (dual speed) 8. Electric Hoist main unt setional view 9. Electric hoist motor lly sectional view (monorail ype) 10 Elec hoist motor toley sectional view (double-al type) Hook black setonal view 12, Dual speed reduction gear sectional VieW page 1 page? page 3 page 3 soo age 4 page 5 page 6 page 7 page 8 age 9 page 10 so age 1‘A. Precautions in operation of electrical hoist 1) Precautions in operatcn of electrical hoist, 1. An olectcal st must be operated only by a designated, trained opemtor: no person but the assigned operator shall be allowed to operate the hoist, or it may result in accident and personal injury. 2. No overload is alowed: Make sure to operate the hoist under ated load, 50 aso ensure the performance and working ie ofthe hoist, 43. No inelined hosing shall be allowed: Normal operation ofthe hoist stall be vertical lining position. inclined hoisting may result in fretion and wear, tangling up or breaking ofthe stel cable, or swinging of work piece. causing coll ‘human ite snd damage to objects, on and danger to 4. Safety device: Mike sure to conduct regular inspection of limit switch anda ypes of bake devices, ete, witch shall ot be dismantled, ‘Do not release the work pee by moving the electrical hoist 5. The operatr ofthe hoist shall no eave his working position during hosing operation. ‘After operation, ake suze to use the hook toa safe height without causing ierference with raffic 2) Precautions before operation: 1. Chek the ste exble for partially broken co 2. Chek the limit siteh and take device for excellent performance, 3. Cheek the tacks for good working conditions. 44 Make careful evew of hoisting performance of unsteady articles before operation. 5. Make sue there & no service personnel or una 6, Make sue of sae and clear moving lines 3) Conduct inspection ona regular and imeguar bass, especially aera storm or earthquake, and check for any irezularity. 1. Routine checks: Check for any crack oF deformation in machine strscture, erack in welded joints Toosened screws oF nuts, and inspect steel cables, windlass, pulley, boist hook and bearings 2. Monthly inspection: (1 Inspection of steel cable, hoisting hook, safety device, wiring, isolator, power Aistibution panel switees, control switches ete (2) Measurement of diameter of steel eable (Inspection af gears inside gearbox. (4) Inspection of wear on brake dise and brake lining (5) Check for wear of bearing (6) Measurement of resistance of insulation of motor (9) Sade pat inspection of ron plat an Fixing of serews. hnried personnel staying on the host.3, Annual inspection (1) lspeetion of tras bearing in hoisting hook (2) Measuring snd inspection of traveling sel tracks {G) Inspection of coating and rust (4) Inspection of safety signs 4, Performance inspection: Make records of the routine inspection, monthly inspection and annual inspection in sequential order © confirm repr and replacement of pats. B, Machine inspection and method |. Machine: Funeions of mechanical parts and preparation of spare pars fo achieve maximum working fficieney 2. Inspection of surroundings: Cleat of dst, inspection of sews and ol eed, noise in rotating paris and heating of beaings, to make sure of their normal funetions. 5. Inside gearbox: Replacement of grease (engine ol). Inspection of bearings: Proper lubvication and oiling performance. Inspection of gea’s inside gearbox: Replace them with new when the wear on teeth his reached 30-40% of original measurements; and check ther noise, loosening keys, fixing keys 6, Inspection of brake device (0) tnspestion of brake dise (2) inspection and replavement of brake plate @) Adjustment of ce Inspection ofstel cable (1) Check for any breaking pulley grooves (@) inspection in high-heat operation (6) Inspection of steel cable diameter and replace with new when ts diameter has reduced by 7% or nore of tolerable diameter. Inspection of lengthwize and crosowise travel: Including the height of sel tracks, wear diameter of wheels, and wear on lange of wheel. Tolerance of wear as fllows: ‘Wear on diameter of wheel ~ Tess than S% of original measurement ‘Wear on flange of whee! = less than 50% of erginal measurement Difference in diameter between el an sight wheels (diving whee) 0.2% or tess = (diven wheel 0.5% ores 9. Check if the hoist is traveling in 2igza condition.C. Inspection of electrical pats [Make sute to check fall switches ae in normal condition before power is supplied 2. Make sure to exe all an controls before stopping operation 5. Make sure to switch eff main power Source after operation. 14 Check the interior condition and any damage inside power switches. 5, Check power cords nd crossvise cables, loosening or breaking steel cable in windlass; make sure to tighlen the sersws on two sides in ease they are loose, 6. Check for any wear o1 contact points of switches and mechanical pars; he tolerable wear shall sot be moze than 15% of original measurement 1. Check it init switchs in proper condi, an its wp-olingelestance shall he more than 0m. 8. Check insulation resinane of circuits: 02MQ) for 200V grade. 0.4MO for 440V grade 9, Brake slide ravel: When power is switched of, brake side travel shall be less than 2% up-ol distance in an: minute 10. Cheek for proper grounding of travel racks. 1D. Troubleshooting for electrical hoist Ten] Trouble ‘Cue Tree T [Nomovemest | Broker ea power sole 1 Replies se ‘easel [2 Daomctonin fuses wich ——_[O Tum fasts switch ON poston eis [Broker wie in sceroid fo Replace five [Bunt acai in solenoid Jo Repic with ow sor cenecion of kod contact print J Replace conc point Bumouiersseshase dezcor” | Replce 17. Taohiherto Tow wots in power YO Power wing to hin ee vluge anton sunoly pacity too lo. : lover yllge when stating tne unit and ak chica cove 7 [Dison [rcoresihase RST. [@ Bxchangs wo of power source wns cont 1 en ndicion TJs does oe | Poor otaon of in sch [OF nt sch Inorein 2. Peoronmosion of kc cont pint JO Replace conc pit jewerine [8 Brokeakan ie Je Connect sandy wie lesion, or [8 Broken wien solenoid JO Replce comection wire les na move hig lpr, or fT mh ie] oo Tre la of lasagne vc] dan cence inssewid Irate] 3 Falco [C-Burt at oa soled JO Repacsaal ford bake [To ge clearance in solecid Jo Adiust cearnce 15, Lonsalsr o int Key [© Tnhten screw onset key ls. Too ch Macwaton of vltgein JO Chk he owe © [Fetes na] Osco apeaton (© Check at ine when [2 Falureot seraid bake \O Sane ss ems smying oad [3 Ove motor fo Check solerid bake operation }4Teolew ertoohighcurewvalage | Check rower |S. Nocilr low aise 1 TopupailTo mich woe] Noailor bw a Teve [@ Toppa jnscar (2 Exwomelydcevioratcdenpne oil JO Repice [Ween sea [o> Replace gar ad check ot |_| le, Ween bain JO) Replace ween pats Wot partes [I Damaged knob ich Jo Reloce when nab is 2. Fused onc poi insoles or ob JO Replace fe pressed —_| sich TRanging up oF [Fen tng operon | Rovew opcaion wtkod Jesteale 2 Hanging ook as it round and sel etl iso 10 faa fii Po eosin of Fite [o> Rese sigh [2 cot are conection dst ret TT festendod op [1 To lrgeclearana: in soled take [OD Ast cleance hers J. Bake pine ween tera ink FED Replane Pak oat = T? fovick wearon” | Owed operation 1S Chak ad jor [2 Nocior wo ove (© Tor woi Heng and sa 15 foo much wear eclnd Wisin operon [@ Review option etiod lnnging [2 Ineaecthanging device hock, Tngontese TH [ign on Paleo snc bake (@ SaneastenS luc pu E, Adjustment of brake clearance in electrical hoist ‘When load has topped and its slide disance is higher than Tale 1, and when the clearance of solenoid is too lage lease make adjustment according to Table 2 Tele ‘able? [ndidstde dance (7-13 mm Moaet [en ESF b= init distance Ome i [SE, 5S~30S, 3F-30P_|14~ 18 F. How to adjust Fist loosen the “xing wut in antilockwse direction, then tighten “adjust srew" clockwise as show in Table 2, then tighten(paodg 2]8uIg) weIFEIq FIMOITD 4STOH 914;99TqCpoadg [enq) weeLq FOI] 1SToy 91430019JBBEREER Baer ey 1 Tava] ea 1 fssoey er] 08 waa os i [= @ Hi oe dds OTA TouOT OOS 77) GTER ISTO O10 1gRy een] & | SS Te aasey Bands) oe [a ds |b dey fe | Bases TH 2H aE Te aes 20K we | ma 29 | we] wma fi] aay ed EN ae 8 il ae 4 *Sbd/05d650068 TERT TeyOUOA) wot TBUOTIONG FS] ON] IOION ISTH STOTTB]-|a|o|~] 0]! os o—# JS SS Sdduayiied (aan, Tea-STqHOg) WBTA TEUONONG Ao] [OI] IOOR ISTOH O1OTGLt a 8 | (SIIB F) (sited 2) BTA TeUDTIONS HOTS OOH) OOOH DOO “Wty Teubroeg aeeg uoTTonpey poeds TengeS 2) mH Max Power Electric Hoist Lih Yeh HoistCo., LTD.© AEH FLAMA atx rover blectric Hoist Special Features “AE: ERR ie » PLAT ROAENIE + aN ARIE © 2 AERA RMAC SH IRIE + RCE © ‘yf ARMM ERHMAE + SBMA «(AFTON AL FIG » NBA L) GD : IAAT RTT LAIR» Santa: MCE « BISTROT » MBER © Ovi REDIRERIERFOANITAL AL TAMESRSR » SUNG ARAGREIRIMEATEL = yA + OG MN» Pe RS RL» 8): MELASMA» RERBIOTS DLE » MBRaT SSO E RERUN LLORAS LRN © SENSE TEANEISS + AAMUERTSS « RAEN = 10-51 CNSIRD EIRENE BLS « BALI COP H 1. Motor: The motors special cesgn fr hoist and possess high starting que and low stating cunt, 2. Brake The brake device wth AC magnetic and high efficent nr Jw abrasion wo assure operating say, 3 Dru ts good construire fom weld steal having with big long. (Can a with up donAmi sutch ae rope gusto prover stool repo knot.) 4. Cont With top grade magnete stitch and tp it sch fa protr motor, °, Gear: Mala rom henson aly steel with eamntaton and high fequency treatment 6. Hook sheave: Sheave's mateo aro made of h-nearproof cast ron fr vey tough are durable. 7. Wite tops The steel rope is excuve of steel rope for cranes safely fecloris more than 5 ties. '5. Hook: Made of mide carbon tel safely factor is more than 5 times top of heok canbe rotated 360" and latachst wich safety device to prevent eroppine. 9. Main mactne is used vith compete dust-poottis convenient or maitoanoe and demountable 10. Our machines are designod and made according to CNS solely standas + Safe + Durable s+ Long life time +=© Max Power Electric Hoist F-M Type Siig 214m & XT Hh B Mono-Rail Single Speed With Motor Trolley et omy 0 i [ew [ sas [a aati 0 aay ww wIua WA) [we [87 [ ar] sa [3 | a isting Sed tie @ [oes passa sxAbictig esol —.6 [aT pat fee pas | mira cand] so 7 u [travers Speed | ¢olte 20 17 Rirmitbistin werd] oe [aM [ee | iW Gol ies Pediat Rincon FE fer Sco 32/0/5400 Ten sho so ae Sa] 2k wn] wERT MaRE WaER [aw we Cap} odet |Lite] BreXaot Approx. Disension (on) tom ath] Yedht © OOfenssiacel a Toe totale try a] wo | oo ira | 6 a [2a a0 ‘Pines | 2" [eas fase] 2 | 7 | | 8 | 9 | 798 150 oriewx | 6 |, | S88 | 20 . ou | on0 2 ane] [ree fae | | te] a [| se | ven | ras | eopanemul ss |. Lot) Tel w lawl aw lm 288 [3 [one [| 2°" [ers Fa es aan spade | 8 a0 | 6 ee) 5 ano | 120] 25 ) ox | 55 | ooo eran | 12 1065 | os 5 [Ta ve seo |, em as baw | a 60 fr srearz-n| 12 Fins ae is [ow rorea6-x] 8 i070 | 15 ied [oso » ou a vorzare-n[ 12] "Pros [oro| "| "88 | 100] 2 | 100 | Mee 0© Max Power Electric Hoist F-D Type 4 LH ik 41 29 HEH fb P Double-Rail Single Speed With Motor Trolley EP tm Oo] 7 [em] s [7s] wf | ae ine oo | 6c) aci2) acad od [ome | 67 [3d [5 [43 [ae [ae] ae Heistine Soeed [one] ¢ | 6.9 | 5 [se | 5.5 BEAAbistig wig! a1 [37 | ss [ts | | | pie) | oe " 2 Travers. Speod_| ke it 6 irmittoistg Wioeto| a7 [OT [ae [ome [1s | os | ae fe Control ‘eile M Pent Pusbtton Staion EA Power Source 3 P0/A80/I5/40/480" 30780 ee] et wal met WERE aa [Ra ee tap] sodet | Lite} Reta Approx. Dincnsion (aw Woight w Go fatisoia wo aT BTC [Ta] a] [a |saare| wir [oo wrimeD |e wa [30 | 00 5 2 Gree tar| © brootaesy eso] 120) 48 | 0] s60| 0 = fanfare a | [os also eT Tel en| am] 3 | te Lae arr2i2-0 | 12 75 [a [600 am | Be/t [355 5 Peremee LST yg FO LOL as a || | se | sw | sree | 12 rows 6 [150 88 Cd en j-srzte-o] 12 iB [1250 a | is [70 vorzané-D[ 8 |, ,,. | oo) 75 [io] sw | Ber [198 Foreme-o[-1e| _*°'S [rinse [ras 17 9 "| 98 | [toon 108-08 Tis 5 | a '8 [sraue-o| 12 raters aso} 7" | |S 1820) 7 | sy | ae [0 aorzne-o | 8 | vg, | 68] a [1150 an | fer [00 % Faoreaa-o [| _[reoofrtnaftao] “| %° | | | Ts‘Test Report Of Max Power Electric Hoist Taw Of Gvlewr [WL TENE ui. [ous or ee] ar i as wil vente [usw Sion cane vote |For soso | 300 Sos Wire Rope B*L 16" 3am Weight L 800 Ke Hoisting Teising Seek | SST ia [io oor | 700 Wo ed Groen [66.064 [ont owen Tanase Traversing Teen Sl Thani [Tewem mer [a Wo ed Green [rk [and owseat [at 125% Load Woisting Test : ox Dielectric Test: 1760 VA.C (For 1 Minute) att Insulating Resistance : 100 Nogohms (Iy SOOV Messer) Lih Yeh Hoist Co., Ltd.HORT RRA RAR ROMER (DUTY BRITS WIRE ROPE INDUSTRY CORP, EOS S228 .om we mt aR RB BREAKING TEST REPORT OF STEEL WIRE ROPE, am Ret. No 130868, ‘ AM Nessrs am Date 2013.05.20 S920 STEEL WIRE ROPE TYPE oe 8 ‘Construction (6370/0 Ow mew om & mm Rope Dis. 16mm. Grade of Stee Wire 165 gdmme Om ow * x Length aon Dia, OF Steel Wire 076mm om # Of eee ee Quantity Specified Breaking Losd 13,867 Kgs mBSER TEST RESULTS ye A (ey ke ® Actus) Bresking Loud 14214 KGS Broken Strands 3 Strands ww @ wee Inspector Authorized SignatureSafety features for clectric overhend_ travelling crane 4) Rubber sloppet for lang navel movement to sop long travel overt ‘Robber stopper for eos ave move -o stp eos vel movement <6) Uperlnit svt =o rots test 4) Te power conta vlags supply a ow as 48V- promoting safety while ‘operation ©) Overload device =f revet overload forthe istPMA St 237474 KERAJAAN MALAYSIA, AKTA KILANG DAN JENTERA, 1967 tun jeraturen Pemberits PruanKelyaan an Peneriksan) Kil an ener, 1970 Fetus 100) The Fore ot Machina Nofeaon Coe Fes ond Impetigo, 170 Raglan 102) Perak Kelaytkan MESIN ANGKAT (lain Mex Agha ga tree) ia rast ba enna 7 Faensiona, ao soca HASICTHNA | Eee nt Ao ‘Dag psa Tava garam chan | oapaone Eas 005 Sao SN PNM ay — [se Pendtean SL PMA 46775, | Nana Po | 35 -HsTenkinO No Penta eaerae inane — ‘ecg MR Ts (PU aan Waa) Take a | SRR skorts Ser Aap, L “FERAUAN NT sh hg lh vn wcnan ach mg, lon a gn ln ln San ot dn taepnse-pwan Ant i eg a a ple Pn hon Atte ds entra een eg es Ange ds Hk ns Mee ‘Mobd. Nor in Setam Teas [avers - enc img Dan at Pon in karan Kasam doen pr aka ean) ian vty ead nan on rach aan seaple angdnaian en jvm kan ‘orga BPR HRENDALNAT BOT THD SHEESTS SEP aeGIRDER DESIGN CALCULATION “pe of aser= Sige gee Satewonurgices Ps 1060 Wagternast = G) caen ‘Witt ofendcariages, osm Span C 8m Fokeppreee, ee oben pt Tote : 5 ‘GROER SECTION Toppa war stem MSS erva Topple ten Bt = eaasen ‘ata wth Sten M2 as ene Baton pia 2m 2 = aban Wen pie re fem 3 mena wes peo dem = 03> abe AsatAtens = 20 ewe Disiarce real axstomtotom, 08 = 27-148:6 em DTOI-Oe = 8TaTeFeIB cm t= TOS ents ot=o4 b2 = 25aseiaie2 em 248 17708 ome Bo1=09-be > Samnereie2 om 21600 et ‘istance btuoen we te = them jos 2A ant Zn = S00095 end gn = taragtenra Be = ars2is ems Vloototgraecw = 2.2898879 00 Nox vensng more oan, tat 8135 enim ax, bang mort by sta, Ma = aastre nm ‘otlvetealbencng men MY = 42.9509 ton “atalhazr enng momen, 388125 ron Combines fr tain, 1 = 090 tonen2 ‘Cambie sees or ampesin, Sp = 1.25 ene ‘Nawab avess= tes teen's Dalecien = (PrOMSSIASED) wha =2. 910% Role? f 103 em tawanedetecten = 750 183 em