Maintenance Manual

MANUAL: EH
Electric Wire Rope Hoist
Model: Trolley Type D HF/HR
TABLE OF CONTENTS

Chapter Description Page

1 General 2-3
2 Safety 4
2.1 General Notes 4
2.2 Safety Instructions for the User 4-7
3 Description 8
3.1 Components 8
3.2 Electrical Equipment 9-11
3.3 Technical Data 11-12
4 Assembly 13
4.1 Preparations for Assembly 13
4.2 Assembly Instructions 13
5 Commissioning 13
5.1 Electrical Systems 14
5.2 Checking the Direction of Rotation of Motors 14
5.3 Inspection and Testing 14-16
6 Operation 16
6.1 Before Starting Work 16
6.2 Normal Operation 17
7 Maintenance 18
7.1 Records of Service 18
7.2 Maintenance Schedule 19
7.3 Wire Rope and Rope Guide 20
7.33 Spare Parts List 21-28
7.4 Hoisting Gear Brake 29-32
7.5 Trolley Brakes 33-34
7.6 Changing Lubricants 35
7.7 Problems, Causes, Remedies 35-36
8 Disposal, Decommissioning 37
9 Not Applicable to this Manual 38
10 Hoist Limit Switch GF4C 39
10.1 Adjustment Instructions Hoist Limit Switch 40-41
11.0 Lubrication Table 42
1. General
1.1 General Notes on Hazards
Except for products designed solely for operation by human agency, the product is designed for operation on
industrial power systems. When the product is in operation, there will be hazardous exposed live
components and hazardous rotating or moving components inside the product.
Contact with concentrated acids or caustic solutions may result in damage to plastic components or the
corrosion of metal parts; any parts affected by such damage or corrosion must be replaced in good time.
Severe personal injury or damage to property may occur as a result of:
 the forbidden removal of covers
 improper use
 incorrect operation
 inadequate repair and maintenance
Failure to comply with the safety instructions given in this Manual may lead to injury or even to fatal
accidents.
The product may present hazards to life and limb if it is operated other than for the intended purpose or by
non-trained or inadequately trained personnel.
The operator of the product must ensure that operation and maintenance personnel are instructed in good
time before starting work with or on the product.
Because of the risk of injury due to clothes or parts of the body catching on or being drawn into the
equipment, personnel working with the product must not wear any loose clothing, unprotected long hair or
jewelry. Rings (!) must not be worn when working on the product!
Persons under the influence of alcohol, drugs, or medicines impairing their reactions must not perform any
work on or with the product.
The product must not be operated in hazardous atmospheres except where the product has been specifically
designed for such use.
During operation: Compliance with all the precautions required by this Manual before, during, and after
commissioning and all the general safety requirements, especially those concerning operational safety and
accident prevention, are essential. Failure to comply with these precautions and requirements may lead to
personal injury or even fatal accidents.
The use of non-approved or unsuitable tools or auxiliary equipment may result in injury.
In connection with the movement of components, squeeze and shear points may occur on the equipment and
between the equipment and its surroundings. You must therefore always keep a sufficient safe distance from
moving or rotating components to prevent parts of the body, clothing, or your hair from being caught in the
equipment.
Extreme heat, sparking (e.g., during welding), or the use of detergents or open flames in the vicinity of
components which are combustible or may be deformed by heat (e.g., wood, plastics, oil, grease, electrical
systems or wiring) must be avoided. Otherwise, there may be a risk of fire resulting in the development of
toxic fumes or damage to insulation or parts of the equipment.

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1.2 Use for the Intended Purpose
The system described in this document is fit for the carrying and lifting of loads subject to the maximum
load capacity and the FEM/HMI or load group for which it has been designed. Load capacity, FEM/HMI
group, and load group are indicated in the data sheet or test book of each product.
Among other things, equipment is not considered to have been used for the intended purpose if:
 the maximum admissible load capacity is exceeded
 loads are pulled diagonally
 loads are torn away, dragged or pulled
 it is used to catch falling loads
 it is used to lift persons with or without loads
 inching operation
 reversing operation (operation of opposite direction when system is in motion)
 intentional operation against emergency end stops
(See also Section 2.2 “Safety Instructions for Users”).
1.3 Warranty
EMH will assume no liability for any damage to the crane or hoist resulting from abnormal operation or
work performed improperly or by unauthorized personnel or for claims by third parties.
Caution! If you modify any components under your own responsibility, assemble components other than in
accordance with the installation instructions and/or plans or use any components other that genuine EMH
components, EMH will be released from any warranty obligations for the entire equipment.
For the safe and reliable operation of the product and for the retention of warranty rights, it is essential to use
genuine EMH parts when you need spare parts. Safe operation is only possible within the service life stated
if the crane/hoist is operated within its rating and the installation, operation, and maintenance instructions are
followed.
You will find the hoist class and load group of your crane/hoist on the data sheet or in the manual for the
product concerned.
EMH products must be maintained and repaired only by trained, authorized, personnel.
1.4 Other Notes
The product will only continue to perform reliably to your satisfaction in the long term if it is operated,
maintained, and repaired by persons assigned to these tasks by the operating establishment. Such persons
must be familiar with the installation, operation, and maintenance instructions and the applicable safety
regulations and accident prevention regulations.
The operating instructions must be available to the personnel responsible for repair and maintenance work at
all times.
EMH products are largely maintenance-free.
The little maintenance work that is required, must be performed in accordance with the operating instructions
and the maintenance schedule

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2. Safety
2.1 General Notes
The installation, operation and maintenance instructions must always be stored near the EMH traveling
crane and must be available to operating personnel at all times.
Operating, maintenance and repair personnel must have read and understood the operating instructions
before starting work.
The organization operating an EMH crane is responsible for supervising operating personnel to ensure that
traveling cranes are properly operated.
2.1.1 Requirements
EMH products are manufactured and tested and must be operated in accordance with the requirements of
United States codes, standards and regulations.
The following codes, standards and regulations are applicable and must be observed by the operator. The
following list should not be considered all inclusive and does not reflect state or local regulations that may
apply:
B30.2- Overhead and Gantry Cranes
B30.10- Hooks
B30.11- Monorails and Under hung Cranes
B30.17- Overhead and Gantry Cranes
CMAA Specification 70- Electrical Overhead Traveling Cranes
CMAA Specification 74- Specifications for Top Running and Under hung Single Girder Electric Overhead
Traveling Cranes
CMAA Specification 78- Standards and Guidelines for Professional Services Performed Overhead and
Traveling Cranes and Associated Hoisting Equipment.
CMAA Crane Operators Manual
CMAA Consensus of National Electric Code
ANSI-MH 27.1-1981 Specifications for Under hung Cranes and Monorail Systems
NEC- National Electric Code
1910.179- OSHA Regulations for Overhead and Gantry Cranes
2.2 Safety Instructions for the User
Caution! For safe working, it is absolutely essential for operation and maintenance personnel to receive
thorough instruction in the requirements of this Installation, Operation and Maintenance Manual.
Release all locking devices before starting crane.
Switch off the main line disconnect switch in hazardous situations.
At the end of the work day, put the load suspension devices such as grab or magnet on the ground, pull up
the empty hook, and home the crane. Any locks, which are available, must be operated and the main line
disconnect switch must be switched off.
All accident prevention regulations and regulations issued by local authorities, especially the operating
instructions for cranes indicated on the respective plate have to be adhered to when operating or attending to
the crane. The instruction plate has to be affixed in a position where it is clearly visible to the crane operator
at any time per ANSI B30.2

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These notes mainly consist of excerpts from the, “Crane Operators Manual” prepared and published by the
Crane Manufacturer’s Association of America. The term “crane” which will be used in the text below, also
stands for trolleys running on rails. “Crane Operator” is the person operating the crane whereas “crane
attendant” means the person responsible for the maintenance of the crane or the trolley
If the operator or operating establishment of the cranes has to abide to existing local regulations, the
following notes shall remain valid insofar as they do not expressly conflict with these local regulations. It is
not intended that the following take precedence over existing plant safety rules and regulations, OSHA
regulations, or instructions issued by the Crane Manufacturer.
1. Before the initial start-up of a crane or before re-operation after major modification have been affected,
cranes must be inspected by an expert commissioned by the operating establishment.
2. Cranes must be inspected by an expert commissioned by the operating establishment at least once a year
and if need be, more frequently, depending on their operating conditions and the conditions within the
factory. (See Section 5.3.3”Scheduled Inspections”)
3. Results of such inspections must be put down in writing and kept on file.
4. The following groups of persons may be employed as crane operators or crane attendants:
 Persons who have completed their 18th year of age.
 Persons who are physically and mentally suited to those activities.
 Persons who have been instructed in the operation and maintenance of a crane and who were able
to furnish proof of their qualifications to the company.
 Persons who can be expected to reliably fulfill the tasks assigned to them. These persons are
required to have been appointed crane operators or attendants by the establishment.
5. Before starting daily work, the crane operator must check on the performance of the brakes and
emergency stop devices and see whether he can detect any defect on the crane. The crane operator must
proceed with great care regardless of the existence of safety devices. These devices are to provide the
necessary safety in the event of an operator mistake.
6. The crane operator must stop crane operation as soon as any defect jeopardizing operational safety
becomes apparent.
7. The crane operator must notify the responsible supervisor at the time of detection and also at the end of
his shift, the relief operator - of any defect detected on the crane.
8. Controlling equipment must only be operated from operating stands or locations.
9. The crane operator has to make sure that:
 Before releasing the power supply to the drive units, all control units are in switch-off or neutral
position
 Before leaving the operating stand all controlling units have been put back to switch-off or neutral
position and the power supply has been shut off.
10. In the event of a storm or when finishing work, the crane operator must make sure that cranes exposed to
wind are properly secured by means of locking devices.

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11. If the crane operator cannot observe the load in all crane movements or if in the case of no-load operation
he cannot keep an eye on the load suspension device, he may only operate the crane by following the
instructions of a second person. This does not apply to program-controlled cranes.
12. If need be, the crane operator must give warning signals.
13. The load must not be lifted over passenger areas unless, detachment or falling of the load or parts of the
load from the load suspension device are excluded.
14. To move a manually slung load the crane operator must wait until the corresponding signal has been
given by the signalman, a guard posted on or near the crane. This must be a competent person who has
been appointed by the operating establishment. Insofar as the communication with the crane operator
requires the use of signals, the signals must have been previously agreed upon between the crane
operator and such competent person.
15. As long as the load is suspended from the hook, the crane operator must keep the controlling unit
(pendent or radio control) within easy reach.
16. Regular crane operations approaching the final position, which is limited by an emergency stop device,
are only admissible if an additional stopping device is series connected. With program-controlled cranes,
all working and traffic areas must be safeguarded in such a way that the crane in motion or any falling
objects will not cause damage to persons or property.
17. Crane loads may not exceed the admissible maximum weight capacity of the crane or hoist.
18. The operator has to make sure that when placing objects to be lifted near the crane there is a safe distance
of at least 1.5 feet between the external movable parts of the crane and these objects.
19. (1) In the event of an overlap of the working ranges of several cranes, the operating establishment or
their agent must previously set up a work schedule and create all the conditions for a trouble-free
communication between the crane operators.
(2) If one load has to be jointly lifted by several cranes, the operating establishment or their agent must
previously set up the corresponding work schedule and the procedure is to be carried out under the
supervision of a person appointed by the operating establishment.
20. Maintenance work must only be carried out after the crane has been switched off. Any maintenance work
that cannot be carried out from the ground must be affected from working stands or platforms. When
carrying out maintenance or repair work at the crane, the crane must be unloaded and the main line
disconnect or isolating switch must be switched off and protected from unauthorized switching (locked
out). Each of these switches can be provided with several padlocks. This enables each person working on
the crane to lock and secure the crane against unauthorized switching-on by means of his own padlock.
(See OSHA Regulation 1910.147 Lockout Tag out)
21. (1) For repair and maintenance work on cranes and in the crane traveling area, the operating
establishment or his agent must see to and supervise the following safety measures:
 The crane must be switched off and safeguarded against erroneous or unauthorized re-energizing.
 If there is any risk of objects falling down, the risk area underneath the crane must be closed off
or by posting guards to the site.
 The crane must be safeguarded against collision with other cranes by means of rail stops limit
switches or by stationing guards to closely observe the crane in motion.
 The crane operators of adjoining cranes must be informed of the activity and location of
operations. This applies as well to the relief operator in the case of shift change.

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 (2) If the aforementioned safety measures have not been taken properly or were not arranged for on
operational grounds or turn out to be insufficient, the operating establishment or their agent must arrange
for different or supplementary measures to be taken and supervise the execution thereof.
22. (1) Unauthorized persons are not allowed to walk onto a crane.
(2) Cranes that are being operated by a crane operator shall only be entered or left with the consent
of the crane operator or when the crane has come to a standstill.
23. It is strictly prohibited to carry passengers together with the load or by means of the load suspension
devices.
24. The load may not be directly slung by means of the hoisting rope or chain; hoisting ropes or chains or
such shall not be bent or pulled over sharp edges.
25. It is prohibited to drag or to pull the load sideways or to move vehicles with the load or the load
suspension device.

Caution! The crane must not be used for breaking loose loads, pulling, dragging, or transversely
pulling loads since this could result in overloading. Loads that have gotten stuck must only be pulled off by
cranes equipped with overload protection.
26. After repair or maintenance work or after any work carried out in the crane traveling area (runway),
crane operation shall only be started if the operating establishment or their agent have consented to do
so. Before releasing a crane for operation, the operating establishment or their agent must make sure that:
 The aforementioned jobs have been completed.
 Conditions for a safe operation of the whole crane have been restored.
 All persons having participated in such work have left the crane and traveling area.
27. When operating additional crane/hoisting equipment, the corresponding special instructions may
have to be followed. If additional equipment is subsequently installed on the crane, it is the
responsibility of the operating establishment operating the crane to check whether such additional
equipment is admissible and suited for the crane installation.
28. Make sure the control devices operate correctly when starting the crane after work has been done at
the main current supply cables; incorrectly connected wires will disturb operation and create the
danger of an accident.
29. The operator must ensure that the workplace is adequately lit.

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3. Description
3.1 Components
3.1.1 Trolley Frame
EMH Series EH electric wire rope hoists are equipped with a trolley frame made from welded steel sheets
and end trucks with twin drive motors.
3.1.2 Hoist Motor with Brake
The hoisting gear is driven by a single speed squirrel cage motor with integral D.C. rectified magnetic disc
brake. Insulation class F, protection type IP 54. Speed control is by closed loop frequency invertor. The
asbestos-free brake lining achieves a service life of approx. 1x106 stops.
3.1.3 Hoisting Gear
The transmission of the motor speed to the rope drum is through the helical gear in a light alloy casing. The
helical gear wheels are hardened and polished or shaved and run in a closed oil bath with lifetime lubrication.
3.1.4 Rope Drive
The rope drive corresponds to the CMAA calculation rules for series hoists. None of the bearing points
require maintenance. The rope guide is made of wear resisting material and provides trouble-free rope reel-
off and careful treatment of the rope and the rope drum. The high-tensile hoisting rope is a special design
that has considerably higher breaking resistance and life than a rope of conventional design and structure.
That is why only original wire ropes from EMH should be used as replacement parts.
3.1.5 Limit of Lift
The lift is limited in the highest and lowest hook position by means of a rotary-geared limit switch directly
coupled to the rope drum. The standard hoist limit switch (S31) comes with 3 switching contacts which have
the following functions:
1. Emergency limit safety switch – lifting (S31.3)
2. Upper limit safety switch – lifting (S31.2)
3. Lower limit safety switch – lowering (S31.1)
The emergency limit switch (S31.3) interrupts power to the mainline contactor (K1). This switch point is set
by the manufacturer, and must only be reset by authorized personnel. If for any reason the upper limit switch
(S31.2), fails to limit the travel of the block in the up direction, the power from K1to the crane is shut down
by the emergency limit safety switch (S31.3). Subsequent operation of the hoist should only be attempted by
a trained service technician. If the hoist is run to the highest hook position (S31.2) the lift travel will stop and
only the lowering circuit will operate until the hook has traveled sufficiently to reset the S31.2. The lowering
limit switch (S31.1) will stop the lowering motion of the hook when the lowest set point is reached and only
the lift motion will function until the hook has traveled sufficiently to reset S31.1. The upper limit (S31.2)
and the lower limit (S31.1) should be checked prior to the start of each shift. For adjustment of the hoist limit
switch see Section 10 of this manual.

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3.1.6 Overload Limit Switch (Optional)
This device is installed to prevent exceeding the load capacity of the electric wire rope hoist. This switch is
checked during the load test after the initial installation. Adjustments to this switch can be made in the field.
The switch should never be set to allow more than 10% over the rated capacity of the hoist to be lifted. The
switch is a micro-switch located on the fixed point cross head for the rope dead end socket.
3.1.7 Trolley Traveling Gear
Maintenance-free, shaft driven flanged wheels made by drop-forging or of spheroid graphite iron and
positioned in roller bearings assure a good, smooth running trolley. The trolley drive wheels are driven via
spline shafts by 2, TEFC single speed squirrel cage motors. D.C. rectified disc brakes are included as
standard. Speed control by frequency invertor.
3.2 Electrical Equipment
Work on electrical systems must be performed only by qualified personnel. The power supply must be
disconnected before starting work. Details of the electrical wiring are given in the circuit diagram.
3.2.1 Wire Rope Hoist
3.2.1.1 Hoist Panel
The hoist panel is installed on the wire rope hoist and has NEMA 12 protection.
All wire rope hoists are equipped with variable speed control flux vector encoder equipped motor control.
(See variable frequency drive documentation for details on operation.)
3.2.2 Hoist Only (When not purchased with bridge or jib crane)
3.2.2.1 Mains Connection Line
Conductor cross sections for power supply circuits from the distribution assembly via the mains switch to the
contact conductor input terminals must be determined by the end user. The cross section of the power supply
circuit must be sufficient to ensure that the voltage at the input terminals of the contact conductor system
does not fall below the specified minimum value.
3.2.2.2 Mains Switch
In accordance with CMAA Specification #74, 5.6, 5.6.1: it must be possible to disconnect a crane or hoist
and to lock out the power supply using a mains switch. A crane disconnect means, either a current-rated
circuit breaker or motor rated switch, lockable in the open position, shall be provided in the leads from the
runway contact conductors (bus bar) or other power supply. The mains switch is not included in hoist only
system unless specified by the customer (see circuit diagram). Mains switches may be obtained from EMH.
3.2.2.3 Crane Switch
The crane switch is installed in the Bridge panel (or the Trolley panel if requested by customer) directly
behind the mains connector. The crane switch is a contactor coded “K1”. The function of the crane switch is
to turn on and off the main power supply to the system via a contactor that can be easily energized and de-
energized with the emergency stop button. (See circuit diagram).

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3.2.2.4 Bus Bar Conductor
The bus bar conductor system is used for all EMH solo trolleys and crane systems. Four bus bars (Four
phase conductors) with contact protection are installed in a plastic housing. The bus bar conductor is
installed on mounting brackets parallel to the crane or trolley track. The bracket spacing is normally 5 feet on
center. The type and size of the bus bar depends on operating conditions, the maximum admissible thermal
load and the maximum admissible voltage drop. Start-up current must be carefully evaluated, taking the high
start-up current of the motors with direct starting systems into account.
3.2.2.5 Trolley and Bridge Panel
In a standard configuration, the trolley panel is installed on the wire rope hoist, the bridge panel is installed
on the bridge girder or bridge end truck and both have NEMA 12 protection. In the case of wire rope hoists
installed on solo trolleys, the trolley panel houses standard fuses as the main fusing (F1), the main contactor
(K1) and a control transformer with fine fuses on the primary and secondary sides in accordance with the
transformer rating. When a bridge panel is provided the above components will be located in it. All wire
rope hoists are equipped with manual motor starters for motor protection that are set at the factory in
accordance with the rated motor current and sealed.
3.2.2.6 Bridge and Trolley Travel Limit Switches (Optional)
Advance slow-down switches to slow the bridge or trolley to low speed before the end of the runway or track
is reached are normal practice. This configuration prevents the bridge or trolley from being ran against the
end stops at high speed, which could cause severe load swing, putting the attendant at risk of injury or
damage to equipment. A limit switch recognizes the speed limit in both directions. The bridge or trolley can
be accelerated out of the low-speed zone at full speed in the other direction. Where there is a high risk or
special safety circuitry is required, an “end shutdown” system can be used to bring the system to a halt.
3.2.2.7 Pendant Control
a) Operation
Motors are operated using two-stage spring-loaded switches. It is recommended to use the first stage for
load positioning work. Frequent inching may damage the motors and switch gear. A mechanical
interlock is provided to prevent simultaneous operation of the controls for both directions of travel.
b) Emergency stopping
The emergency stopping function required by OSHA 1910.179 (a) (59) is provided by a red mushroom
switch operated from ground level on the pendent or radio transmitter or from the point of operation.
Caution! An emergency stop is not the same as an emergency shutdown. Only the power supply to the
travel drives is cut off and the brakes are set during an emergency stop. The main line system is not
disconnected from the main power source (K-1). An emergency stop is initiated by pushing the
mushroom switch. The system can be restarted by turning the switch to the left.
An emergency stop must be initiated under the following conditions:
 If the crane travel motors fail to obey normal control commands and a hazardous situation may
occur.
 If the crane operator leaves the control position.

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3.2.2.8 Replacing Fuses (Insure main line power is disconnected prior to work)
The main fuse (F1) is a standard fuse link, (after disconnecting power) remove the old fuse or fuses and
replace by pushing in a new fuse or fuses of the same size and rating.
The control circuit is protected by a fuse (F3) on the secondary side of the control transformer and 2 fuses
(F2) on the primary side and earthed on one side. The fuses are installed in the connection terminal strip
normally on the transformer. To replace the fuses, pull the fuse out of its mount, place the new fuse in the
fuse holder using a new fuse of the same size and rating. Again, insure that the main power is disconnected
prior to working on the system (follow all lock-out, tag-out procedures). Placing the E-Stop in the off
position will not shut the power off to the control transformer.
3.3 Technical Data
3.3.1 Sound Emissions
As the distance between the noise source and the workplace is normally not fixed in the case of hoists, the
sound power level is quoted in addition to the required sound pressure level figure (given for a distance of
4m (14 feet) in this case). The sound power level may be used to calculate the sound pressure level at any
distance (under free field conditions + 2dB (A)). Contact EMH for the appropriate sound power level.

3.3.2 Lubricants
All roller bearings are provided with lifetime lubrication. The hoist gears are oil-lubricated. The gears of the
trolley drives are provided with fluidized-grease lubrication. The wire rope and the rope drum must be
lubricated in compliance with the indications of the maintenance schedule.
The locating pins at the hoisting gear, the external splines at the rope drum and at the travel drives have to be
lubricated when the drive is replaced or in the course of a general overhaul. Details of lubricants are given in
Section 11 “Lubrication Tables”
Alternative Lubricants:
For a table of alternative lubricants, see Section 11 of this manual
Caution! Synthetic oils must not be mixed with mineral-based oils.

3.3.3 Weights and Dimensions

Weights and Dimensions for any EMH hoist and trolley, contact your EMH dealer.

3.3.4 Electrical Motor Data

Electrical motor data can be obtained from your EMH dealer.

3.3.5 Tightening Torques

Contact your EMH dealer for hardware torque information.

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3.3.6 Typical Layout of EH-HR/HF type hoist 4.0 Assembly and Installation

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4.1 Storage and Interruption of Operation
If the crane system cannot be installed directly after being delivered, or if the crane system will not be used
for a long period after being installed, or if there are longer periods of intermission, the crane system has to
be stored in a clean, dry area. The crane system and its components have to be protected against damage,
dirt, and corrosion. If necessary, ask the manufacturer for appropriate measures.
4.2 Assembly Instructions
The hoist must be assembled only by authorized personnel. The EMH hoist is normally shipped assembled
with only minor adjustments to be made at the site.
4.2.1 Mechanical Installation
The installation of EMH electric wire rope hoists must only be carried out by authorized persons. EMH
electric wire rope hoists are supplied correctly reeved with hook block installed and upper limit switches
adjusted for the application. Minor adjustments of the upper limit switches may be required in the field after
initial start-up.
4.2.2 Electrical Installation
Switch off power supply before starting work on any electrical installation. Have work carried out by trained
personnel only. Connect the cables in the bridge and/or trolley control panel as shown in the circuit diagram.
A copy of this diagram is placed in the trolley panel and bridge panel.
Caution! The rope hoist must be wired to a three phase fused disconnect or circuit breaker (per NEC)
properly sized and grounded. The maximum voltage deviations are -5% from the lower and +5% from the
upper voltage limit.
4.2.2.1 Connection to the Mains
The operating establishment must connect the system to the mains power supply.
4.2.2.2 Main Line Disconnect
The mainline disconnect switch must be wired so that it will switch off all poles of the incoming power. The
mainline switch has to be installed at an easily accessible location and must be secured against erroneous or
unauthorized entry.
5.0 Commissioning
Before starting to operate the new installation, check the following points:
 Have all fastening devices been properly tightened and locked?
 Check the oil-level in the hoisting gear!
 Has transport caused damage to the wire rope?
 Make sure the wire ropes fit tight at the rope clamps on the rope drum.
 Are the track ends equipped with operative end stops?
 Does the moving direction of the hook correspond to the symbol at the pendant control? In case
of a wrong directional move, 2 phases of the feed line must be exchanged; only then can the
operation of the emergency hoist-limit switch be guaranteed.
 Figure
Does the hoist limit switch cut off at the highest hook position? (Lowest hook position Figure
must3be set
during hoist installation.) For adjustment of the hoist limit switch see Section 10 of this manual.

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Caution! Before starting any work on the electrical system, the crane must be disconnected from the power
supply. The main switch or isolator switch must be off and secured against unauthorized operation (follow
proper lock-out / tag-out procedures). Each of the switches are so designed that padlocks can be used. Each
person working on the crane can therefore use his own padlock to secure the switch against unauthorized
operation. Wiring diagrams with details of power supplied to the crane are placed in the cranes bridge and or
trolley panel.
5.1 Electrical Systems
The service life of electrical switch gear depends on the way in which it is operated. The crane operator must
be informed that inching is not the best way of reaching a precise position. Since the crane has variable
speeds, inching operation can easily be avoided.
5.2 Checking the Direction of Rotation of Motors (Hoist Motor)
When the motors are first switched on, the direction of rotation must be compared with the rotation direction
required by the control system. The direction of rotation depends on the phase sequence of the mains
connection. After unlocking the red mushroom switch, the precision LIFTING button must be pressed
first. Never press the lowering button first. If the hook is raised or no movement is produced because the
upper limit switch has already been tripped, the phase sequence is correct. Press the precision lowering
button as a countercheck. This check shall be done in low speed only until correct direction is
established. If the equipment does not move in the direction indicated on the controls, the connections of
two phase conductors of the power supply cable must be interchanged. If you do not ensure that the hoist
motor rotates in the correct direction, damage may occur.
5.3 Inspection and Testing
Caution! If tests and inspections are not conducted by specialist personnel of the crane manufacturer and
third parties are commissioned for such work, the organization operating the crane is responsible for
selecting suitably qualified personnel to commission the crane and conduct the tests. Requirements to be
met by inspectors:
 Comprehensive knowledge of the mechanical and electrical systems of overhead cranes.
 Sufficient experience in the assembly and repair of cranes.
 Comprehensive knowledge of the state of the art of crane testing and of the applicable codes and
standards that apply and of safety regulations e.g. accident prevention regulations
The requirements of all applicable national, state and local regulations must also be taken into consideration
during the test and inspection.

14
5.3.1 Inspection before Initial Commissioning
The acceptance test before initial commissioning must be performed by the inspector on a crane ready for
operation under normal operating conditions. During the inspection, no-one must be exposed to avoidable
risks. Personnel required for operation during the inspection including crane operators and load handlers
must be provided by the organization operating the crane and must be suitably qualified for the work which
is involved.
All persons involved in the inspection must be able to communicate effectively with each other during the
inspection. If direct communication between control points and load handling points are not possible, the
organization operating the crane must provide suitable communication systems.
The inspection must include at a minimum the following items:
 Inspection of compliance between the completed system and the technical data
 Inspection of compliance with all applicable safety rules, for example: accident prevention
regulations.
 Testing of all safety systems and all brakes for proper operation and effectiveness.
 Inspection of any required safe distances.
 Dynamic load test at not less than 1.0 times the rated load capacity of the crane.
The following test must be conducted in accordance with OSHA Regulation 1910.179 and ANSI B30.2
Rated Load Test
 Dynamic load test at a minimum of 100 % of the rated load capacity of the hoist/crane and not to
exceed 125 % of the rated load capacity.
 In the case of slewing jib cranes, the most unfavorable position is the position with the jib fully
extended.
 In the case of all other cranes, such as bridge cranes, ceiling-mounted traveling cranes and suspended
monorail systems see B30.20.2 Par. 2.2.2 Rated Load Test.
 If the crane control system allows several simultaneous movements (such as lifting and crane travel),
these movements should be performed simultaneously during the test. It is not admissible to use a
spring balance or a similar device between the crane and a ground anchor as a substitute for a test
load.
Caution! The acceptance test in accordance with this Section is not intended as a substitute for any other
tests which may be required by applicable national, state or local regulations. Such tests must be conducted
in addition to the acceptance test. Where national, state or local testing regulations require higher test loads
than those specified in this Section for dynamic or static testing this point must be clarified with the crane
manufacturer before testing is started.
5. 3. 2 Inspections Following Major Modifications
Following any major modifications to a crane system, the system must be inspected by a qualified inspector
before it is re-commissioned. Examples of major modifications are (but not limited to):
 Changes in the type of power supply
 Replacement of trolleys
 Conversion or modification of motors
 Increases in the load capacity of a crane

 Extension of a crane runway

15
  Movement of cranes to other crane tracks in the case of stationary crane systems
 Welding work on load-carrying structural components
 Design changes to supporting structures
 Modifications to components of supporting structures including but not limited to, crane runway
girders, crane runway supports, crane girders, trolley track girders, trolley frames, etc.
 Changes in operating conditions including the duty cycle and the load range of the crane
5.3.3 Scheduled Inspections
The crane must be inspected as required, in view of service conditions (utilization of maximum load
capacity, frequency of operation, and ambient conditions). At any rate, the crane must be inspected at a
minimum of once per year. This inspection must be completed by EMH or an authorized crane inspector.
For example, cranes with high operating hours, which are often operated at full load capacity will need to be
inspected more frequently than cranes which are used only occasionally for assembly work. In the case of
occasional use, one inspection per year may be adequate. It may also be necessary to reduce the inspection
time interval in the case of dusty or corrosive atmospheres. Organizations operating cranes must therefore
determine more frequent inspection intervals than one year taking operating conditions into account. In case
of doubt, the organization operating the crane must agree on inspection intervals with the crane
manufacturer. Also see CMAA Specification #78
6.0 Operation
6.1 Before Starting Work
In general, the following points must be checked by the crane operator not only before the hoist is started up
each day but also at the beginning of each shift and when a new crane operator starts work during a shift:
 Testing the traveling brakes
 Testing the hoist brake
 Limit switches both upper and lower
 Does the lift limit switch cut off the lifting motion in the top hook position in good time? This has to
be checked by carefully approaching the top position.
 Inspect both the wire rope and hook for any damage.
 Does the bridge and trolley travel limit switches (if installed) limit the bridge and trolley travel
according to their pre-set functions? Test them by means of a careful start-up.
Wire Ropes
 Are the wire ropes in good condition?
 Never lift loads exceeding the weight indicated on the load plate!
 Use only the load hook and not the wire rope to attach to the load.
Control Switch
The crane operator sends out his control commands through the control switch (pendent station) which is a
vital unit and should therefore be handled with due care and attention; do not let the pendant control swing
uncontrollably after use but only release it when it hangs down vertically.

Bumpers

16
The crane is equipped with elastic bumpers to absorb the impact when the crane runs up against the crane
runway end stops or collides with a neighboring crane. Bumper impacts are special load cases which should
be avoided when possible. Do not run the crane against the end stops or other cranes intentionally as part of
normal operation. The bumpers themselves must be inspected regularly (at least during the regular inspection
of the crane; see Section 7.2) to ensure that they are serviceable. Bumpers with cracks or permanent
deformations are not serviceable.
How to deal with disturbances
All irregularities, such as noises or unusual responses appearing during crane operation should be
immediately communicated to the responsible person in order to exclude the occurrence of more serious
faults. If dealt with early enough, causes of faults can be eliminated by simple means and at low cost. To
avoid any risk in case of power failure, all crane motions are reliably stopped by spring-loaded brakes
engaging automatically. The crane operator, however, has to set all switches to the off-position. In hazardous
situations the red Emergency Off-Button can be actuated to stop all crane driving movements immediately.
6.2 Normal Operation
Standard EMH traveling cranes are designed for operation in enclosed buildings with normal atmospheres
and normal temperatures between 20F and 104F (-5C and +40C). Temperatures may reach 149F (+65C) on a
short-term basis.
If a crane is required for other operating conditions, this must be stated so that the crane can be checked for
operation under such conditions and appropriate action can be taken.
6.2.1 Other Operating Conditions
1. If the crane is to be operated outside the temperature range stated above a grease or oil grade appropriate
for the actual operating conditions must be used in the gearboxes or any motors.
2. Cranes that are to be operated wholly or partly in the open air require canopies over the motors, hoists,
and electrical panels.
3. If the admissible loads on the hoist could be exceeded as a result of wind, care must be taken to ensure
that the hoist is not exposed to such loads in operation. In this case, the hoist may be fixed in position by
suitable devices (such as wind locks).
4. EMH electric rope hoists are NOT suitable for conditions where they may be exposed to explosive or
corrosive substances. See manufacturer for any other environmental operating restrictions.

7.0 Maintenance

17
The hoist must be inspected by an EMH or approved inspector at regular intervals determined in accordance
with the operating and service conditions of the crane. Such inspections must be carried out at least once per
year. The results of all inspections must be recorded and kept on file. It is recommended that the crane
should be maintained at least as frequently as it is inspected.
Operation in shifts affects both inspection and maintenance intervals.
Crane trolley wheel bearings and crane motor gearboxes have permanent lubrication and do not require any
maintenance. Gearbox fluid levels should be checked periodically.
Hoists must be maintained in accordance with the appropriate hoist maintenance instructions.
During maintenance, any excessively worn or faulty parts must be replaced.
For safe and reliable operation, it is essential to use only genuine EMH parts when replacing any
components.
It is expressly stated that EMH will only accept warranty claims when genuine EMH parts have been used.
The following maintenance schedule applies to the entire crane. The maintenance intervals stated are based
on single shift operation. Multiple shift operation will require more frequent maintenance and inspections.
EMH specialists will be pleased to assume the responsibility of this maintenance work for you. Our experts
are experienced in maintaining the EMH hoists and cranes. All wear parts are available either immediately
or within a very short time.
7.1 Records of Service
The organization operating the standard hoist is responsible for recording the actual type of service of the
hoist and documenting it at least once per year and keeping it on file.
If the actual operating conditions are not verified or such verification is not possible or operating conditions
are only estimated, a complete overhaul must be carried out 10 years after the delivery of the standard hoist
or earlier.

18
7.2 Maintenance Schedule

Work to be performed daily at scheduled every 10

inspections years
Inspection
Check functioning of brakes X
Check functioning of limit switches X
Check rope for damage and wire breakage X
Chive covers on bottom block for damage and security and not faulty X
Check overload protection device In the case of electromechanical overload X
protection devices, grease the disc spring packages as required
Maintenance
Check oil level in hoist gearbox X
Change oil in hoist gear unit X
Lifting brake, check clearance and adjust as appropriate X
Lubricate gears of hoist drive and rope drum X
Trolley travel brakes, check clearance and adjust as appropriate X
Lubricate gears of trolley drives and bearing X
Lubricate wire rope and rope drum X
Check rope mounts and guides X
Check bottom block and load hook suspension X
Check hooks for cracks and permanent deformation X
Check the condition of all buffers X
Check all bolted joints and welds. Check the tightness of bolted joints, especially X
the tightening torques of the long bolts connecting the motor housing and the
gearbox on hoist lifting and trolley travel motors
Check power supply systems, especially current collectors X
(check rollers and sliding contacts for wear)
Check wheels of trolleys X
(especially conditions of wheel flanges; no plastic deformation)
Check electrical switchgear and wiring X
Check paintwork; repair if necessary X
Check any wind locks and lubricate joints (if installed) X
Rope wedge protrusion (section 7.3.1) X

19
7.3 Wire Rope and Rope Guide
Wire rope and rope guides are parts that are subject to wear whose life can be increased by regular
lubrication according to the maintenance schedule. Clean drum and rope guide before lubrication.

7.3.1 Rope Wedge Protrusion (Not provided with double reeved hoists)

rope socket

rope clamp
ing wedge

rope

a,zul
Bild Seilkeil

d Figure12
Figure 4

The spacing must be checked during annual inspections. If the maximum dimension is exceeded, the rope
socket and wedge must be replaced.
7.3.2 Replacement State of Wear
Wire ropes must be immediately replaced in the following cases: breakage of the strands, opening of the
rope structure, crushing, buckling, extreme wear, serious damage or considerable rust deposits.

Spare parts list

20
Hoist and Trolley Options
LUFKIN

21
 Summary

1. Anti crossing wire rope Page 23

2. Limit switch Page 26
2.1 For One rope Page 26
2.2 For Two ropes Page 27
2.3 With lever Page 27
3. Revision sheet Page 28

22
 Articulation RearArm
Size I, Dwg nbr : ACRW-1110 2 1 1 Anti crossing wire rope support ACRW-1001
Size II, Dwg nbr : ACRW-1111 3 8 1 Socket head cap screw HM8x40/22 8.8 DIN912
12 Black
8 13 11 9 1 Bearing Shaft Size I_II ACRW-1140
10 1 Anti crossing wire rope spring ACRW-1007
14 1
11 1 Anti crossing wire rope D17 Shaft ACRW-1008
19
12 2 Anti crossing wire rope D17 Washer ACRW-1009
12
13 2 Split pin V3x30 DIN94 Zn platted Goupille_V3_30
10 13 14 4 Socket head cap screw Chc M10x50/32 8.8 DIN912
black
15 4 Nut MP10/110 M10 NYLSTOPDIN985
16 1 Balls bearing 6003 2Z 17x35x10
17 1 Roll Hub Size I_II ACRW-1150
18 2 Nut MP10/108 M8 NYLSTOPDIN985
18 19 1 Socket head cap Screw CHc M8 45/22 8.8 DIN912
20 2 Spring pin Ø4.5x40 DIN1481
18 Item Qty Name Dwg nbr
1. Anti crossing wire rope

Articulation Top Arm

4 Size I, Dwg nbr : ACRW-1120

23
5 Size II, Dwg nbr : ACRW-1121

15
20
9 Threaded rod M10
16

20
Articulation Front Arm 17
6 Size I, Dwg nbr : ACRW-1130
7 Size II, Dwg nbr : ACRW-1131

Pipe D48
 Articulation Support
Dwg nbr : ACRW-1001
6 6 L=
6 6
5 5 8
194

L=
1

L=
4 8 5

188
2

L=
156
8

123
8 3 2
2
Articulation Rear ArmSize I
Dwg nbr : ACRW-1110
1
1
2
1 1
Articulation Rear ArmSize II
Dwg nbr : ACRW-1111
Drum O 171
5T Drum O 219 Drum O 244 3
EMHJOB#112628 : LUFKIN# M-S:T-05-2 15T 20T 10T Drum O 271
LUFKIN# M-S:T-05-3 EMHJOB#112629 : LUFKIN# M-R:S-15-1 EMHJOB#112621: LUFKIN# M-R:S-20-2 EMHJOB #112623 : LUFKIN# M-11:13.3-10-1
EMHJOB#112631: LUFKIN# M-T:U-05-1 EMHJOB#112622 : LUFKIN# M-S:T-20-1 EMHJOB #112624 : LUFKIN# M-13.3:15.6-10-2
EMHJOB#112632 : LUFKIN# M-15.6:18-05-2 EMHJOB #112626 : LUFKIN# M-P:Q-10-1 Articulation Top ArmSize I
EMHJOB #112630 : LUFKIN# M-R:S-10-3 Dwg nbr : ACRW-1120
LUFKIN# M-R:S-10-4 4
EMHJOB #112633 : LUFKIN# M-11:13.3-10-2
EMHJOB #112634 : LUFKIN# M-15.6:18-10-1 Articulation Top ArmSize II
Dwg nbr : ACRW-1121

24
6 5
6 7
L=

L= 5
17

5 8
2

5 155
2
2 Articulation Front ArmSize I

L=
3 Dwg nbr : ACRW-1130
8

174
8
6

Articulation Front ArmSize II

1 Dwg nbr : ACRW-1131
1 1
7

Anti crossing wire rope

spring Size I
30T Drum O 295 Drum O 325 Dwg nbr : ACRW-1007
EMHJOB#112625 : LUFKIN# M-Q:R-30-3-S 20T
Drum O 355
EMHJOB#112636 : LUFKIN# M-Q:R-30-2-S EMHJOB #112627 : LUFKIN# M-A:B-20-1-CM 40T L
EMHJOB#112637 : LUFKIN# M-Q:R-30-1 EMHJOB #112635 : LUFKIN# M-13.3:15.6-20-1 EMHJOB#112570 : LUFKIN# P-2:3-40-1
LUFKIN# P-3:4-40-1 8
 6 Articulation Front ArmSize I, Dwg nbr : ACRW-1130 4 Articulation Top ArmSize I, Dwg nbr : ACRW-1120 2 Articulation Rear ArmSize I, Dwg nbr : ACRW-1110
7 Articulation Front ArmSize II, Dwg nbr : ACRW-1131 5 Articulation Top ArmSize II, Dwg nbr : ACRW-1121 3 Articulation Rear ArmSize II, Dwg nbr : ACRW-1111

4 5
DRUM 2 3
6 7

D A B
C
D171
D C B A

C D A B
D219 A
D C B

C D A B
D244 A

25
D C B
D A B
C
D271
D C B A

D A B
C
D295 A
D C B
D A B
D325
C B A

C D A B

D355 D A
C B
 2. Weight Operated Limit Switch

17

16 1 1 MOUNTINGPLATE UCC83473-4
14 2 1 Compression spring OD12.5-Wire d1.4-14wraps-Free
Lght = 50
3 2 Spring lock washer W4 DIN127 BZinc platted
4 2 Socket head cap Screw CHc M4 25x14 8.8 DIN912
12 1 5 1 Actuated plate 25x8x70 UCC83473-2
6 1 Bent Eye bolts D8x120x12 BN1006 not threaded QU12022
9 11 7 1 BUMPERD10 BUM10
8 2 Ecrou HM4 6 DIN934 Zinc platted
8 3 9 2 Spring pin Ø4.5x25 DIN1481
5 10 1 Limit switche XCM+ Metal end plunger with
elastomer boot
11 2 Hex cap screw HM8 25x25 8.8 DIN933
2 4 12 1 MOUNTINGPLATETHREADED UCC83473-5
10 13 1 Rope D6.4 lght : 600
18 7 9 14 1 COVER UCC83473-3
15 1 Wire Rope clips Ø8 DIN1142
16 1 Spring lock washer W5 DIN127 BZinc platted
15 6 17 1 Hex cap screw HM5x08/08 6.8 DIN933 Zn platted
18 1 Flat Washer M8UDIN125AZn platted

13 Item Qty Name Dwg nbr

2.1 For One RopeWire rope 1 2 Nut MP10/106 M6 NYLSTOPDIN985

2 1 Hex Nut HM6 8 DIN934 Zinc platted
3 2 Hex cap screw HM6 90x18, 6.8, DIN933
4
4 1 Bent Eye bolts M6x60x8
3 5 1 Wire Rope clips Ø8 DIN1142
2 6 1 Rope D6.4 lght : 600
Item Qty Name Dwg nbr
5

Complete Weight
Dwg nbr : UCC83473-1 1

26
2.2 For Two Ropes

1 1 WEIGHT 8/2 UCC83673-1

Wire rope
2 1 Rope D6.4 lght : 600
3 1 Wire Rope clips Ø8 DIN1142
Item Qty Name Dwg nbr

2.3 With Lever

1 1 Screw HM12x80/30
2 1 Nut MP10/112 M12 NYLSTOPDIN985
3 1 Straight Lever Hoist lever operated limit switch UCC83872
4 1 Adjustable Lever support Hoist lever operated limit switch UCC83883 8 7
5 1 Rope D6.4 lght : 386 5 4
6 1 Wire Rope clips Ø8 DIN1142
7 4 Spring lock washer W8 DIN127 BZinc platted 6 9
8 4 Hex Nut HM8 8 DIN934 Black
9 4 Hex cap screw HM8x40/40 8.8 DIN933 Zinc platted
Item Qty Name Dwg nbr

3
2

27
3. Revision Sheet

Rev. Date Comments Name

- 21/02/12 Original version CT

28
Repairs-- Caution! All repairs must be carried out only by specialist personnel!
EMH cranes, electric wire rope hoists and electric chain hoists must be repaired and maintained only by
qualified, authorized personnel. EMH will not assume any liability whatsoever for loss or damage due to or
in connection with repairs to cranes or hoists not properly performed or performed other than by authorized
personnel.
We must point out that you will retain your warranty rights only if genuine EMH spare parts are used.
7.4 Hoisting Gear Brake

Figure 10

The hoisting gear brake is a magneto-electric disk brake. In order to guarantee safe release, the brake is
equipped with an air-gap limiter. The air-gap of the brake must be checked regularly and adjusted to its
optimum value of 0.015 in (0.4 + 0.05 mm). This ensures optimum brake performance and minimum wear.
In order to prevent the brake lining thickness from falling below the minimum value, the screw-in depth of
the socket screws (4 Fig.10) in the magnet assembly (9 Fig.10) is limited.

29
7.4.1 Adjustment of the Air-Gap (See Figure 10 Page 25)
1. Remove the ventilator cowl (1) with the motor being switched off.
2. Remove locking ring (11)
3. Pull off fan (14)
4. Press out O-ring (7)
5. Loosen 3 fastening screws (2) by half a turn
6. Screw 3 socket screws (4) about one turn into magnet assembly (9) (screws-in depth limited)
7. Place distance plates (feeler gage) (3) 0.015 in (thickness: 0.4 + 0.05 mm) between anchor plate (6) and
magnetic body (9) each next to the 3 socket screws (4); tighten the fastening screws (2) so that the
distance plates (3) can still be removed.
8. Unscrew the 3 socket screws (4) from the magnet assembly (9) until they make firm contact with the
motor bearing shield.
9. Tighten the fastening screws (2) at a torque of 25 Nm. Then check the evenness of the air gap (at
approx. 6 places and readjust, if required).
10. Press in O-ring (7)
11. Place the fan (14) on the motor shaft (13) and lock with locking ring (11)
12. Install the ventilator cowl (1)
13. Do a trial run to check the brake
7.4.2 Removing the Brake (See Figure 10 Page 25)
1. Lower the bottom block and place it on the working platform, the ground, etc.
2. Remove ventilator cowl (1) with the motor being switched off
3. Remove locking ring (11)
4. Pull off fan (14)
5. Remove feather key (12)
6. Press out O-ring (7)
7. Open the plug-in connection for the power feed to the brake
8. Unscrew the fastening screws (2)
9. Remove magnet assembly (9) complete with anchor disk (6) and socket screws (4)
10. Remove brake rotor (5)
11. Remove locking ring (10)
12. Pull off catch hub (8) by means of the pull-off device

30
7.4.3 Installation of the Brake (See Figure 10 Page 25)
1. Slightly grease the motor shaft (13), install catch hub (8) and secure with locking ring (10)
2. Push brake rotor (5) on the catch hub (8) and check whether it can be slightly axially displaced
3. Mount the magnetic body (9) complete with anchor disk (6) and socket screws (4) and slightly tighten
by means of the 3 fastening screws (2).
4. Screw 3 socket screws (4) into the magnet assembly (9)
5. Place distance plates (3) 0.015 in.(thickness: 0.4 + 0.05 mm) between the anchor plate (6) and the
magnetic body (9) each next to the 3 socket screws (4); tighten the fastening screws (2) so that the
distance plates (3) can still be removed.
6. Unscrew the 3 socket screws (4) from the magnet assembly (9) until they make firm contact with the
motor bearing shield.
7. Tighten the fastening screws (2) at 25 Nm. Then check the evenness of the air gap (at approx. 6 points)
and readjust, if necessary.
8. Press in the O-ring (7)
9. Push on the ventilator (14) and secure with locking ring (11)
10. Install the ventilator cowl (1)
11. Do a trial run to check the brake
7.4.4 Replacement of Brake Rotor and Anchor Disk

Figure 11

31
If the brake lining is worn below minimum (see table) and it is no longer possible to adjust the clearance, the
brake rotor (figure 10, Item 5) and the anchor disk (Figure 10, Item 6) must both be replaced.
For the replacement of the brake rotor and anchor disk, the following work is necessary:
Dismantling of the brake in accordance with sub-section 7.4.2
Dismantling of the anchor disk in accordance with the following instructions:
1. Screw the socket screws (Figure 10, Item 4) on the dismantled brake into the magnet assembly up to
the stop.
2. Remove and destroy the lifting travel limiting screws (Figure 10, Item 2) (The emergency lowering
bar (Figure 10, Item 1) will then be released.)
3. Remove and destroy the socket screws (Figure 10, Item 4) (This releases the load on the springs
between the anchor disk (Figure 10, item 6) and the magnet assembly (Figure 10, Item 9)
4. Remove anchor disk.
To install the new anchor disk, proceed in reverse order. The socket screws (Figure 10, Item 4) and the
lifting travel limiting screws (Figure 11, Item 2) must be replaced. The clearance between the anchor disk
and the magnet assembly (Figure 10, item 9) must be set to 0.046 in.(1.1 mm) with the brake dismantled
using the lifting travel limiting screws (Figure 11, Item 2)
Assemble the brake in accordance with sub-section 7.4.3
Wear table for brake lining (lifting motor). Consult brake adjustment documentation provided with each
hoist.

7. 4. 5 Emergency Lowering of Load

Caution! The hoist must be disconnected from the power supply before the following steps are taken!
Figure 10/11
If it is necessary to lower the load in an emergency following a power failure or problems with the hoist
motor or brake coil, the following steps must be taken:
1. Remove fan cover (Figure 10, Item 1)
2. Screw stud bolt into emergency lowering bar (Figure 11, Item 1)
3. Release the brake by carefully moving the lowering bar and lower the load slowly,

32
7.5 Trolley Brakes
Brake Operation:
The trolley brakes are spring set. When the power is removed from the brake, the brake will automatically
set to hold the load. These brakes are DC voltage brakes and are supplied with a motor mounted brake
rectifier.
When the brake is de-energized (power off), the braking springs exert a force against the anchor plate which
prevents the brake rotor from rotating. When the brake coil is energized (power on), a magnetic field builds
and pulls the anchor plate across the air gap to the brake casing which frees the brake rotor and allows the
motor shaft to turn.

7.5.1 Brake Adjustment Figure 12

To maintain the maximum life of the brake the air gap must be set properly. As the brake wears and
decreases in thickness, the air gap will increase. If the air gap is too great, the brake coil may not have
enough magnetic force to pull the anchor plate across the gap and the brake will drag.

The following procedure must be done with the power off.

While checking the air gap, measure the gap around the socket head cap screw as shown in Figure 12
perform this check at all 3 cap screw locations.
A. Loosen the socket head cap screw that attaches the brake to the motor end bell. See Fig.12
B. Depending if the air gap needs to be increased or decreased, turn the adjusting nut accordingly. A quarter
to a half turn is usually sufficient for adjusting purposes.
C. After adjusting the nut, tighten the cap screw back onto the brake.
D. Measure the air gap for spacing-Repeat the process A thru C above to achieve recommended setting.

33
34
7.6 Changing Lubricants
All motors have permanent lubrication suitable for normal operating conditions (see Section 6.2 “Normal
Operation”). It is only necessary to change the lubricant if the crane system is overhauled. Under abnormal
operating conditions, it may be necessary to change the lubricant at appropriate intervals. To change the
lubricant on crane travel motors, the gearbox must first be removed and the gearbox components and
housing be cleaned using suitable proprietary cleaning compounds. The gearbox must then be filled with the
new lubricant and closed. Lubricant quantities are given in Section 3.3.2.1. Used lubricants must be disposed
of properly.

7.7 Problems, Causes, and Remedies

All the malfunctions described below must be remedied by a specialist

Problem Possible cause Remedy Remarks

Crane does not run Mains power not available Check current collector(s)
Check emergency OFF–button
and contactor K1

Emergency limit switch of Check phase sequence

hoist has tripped
Check functioning of
emergency limit switch
check setting of limit switch

No control voltage Check control voltage fuse on

control transformer

Motor does not turn in any Mains power not available Check voltage
direction and does not hum
Mains connection not Connect all three phase
when the pendant control is
properly made conductors correctly
operated

Faulty fuses Replace fuses Follow wiring diagram

Plug–in connectors for Plug– Insert connectors firmly and
in connectors for control not lock using bracket
properly inserted or not
locked

Loose contacts in pendant
control, broken wires in
power supply line or in
pendant control or, possibly,
on travel drive
Check wires for breakage; if Caution! All work
must be performed
necessary replace control cable with all equipment
disconnect from the
power supply

35
 Motor does not turn in Faulty mains connection or Check mains connection
any direction but
hums when the pen mains fuse
dant control is oper
ated
WARNING
Motorwindings may
burn out

Faulty contactor Replace contactor Caution! All work

must be performed
with all equipment
disconnect from the
power supply

Motor starts slowly Break does not release, motor See brake problems
runs against closed brake

Crane span deviates from Check play on wheel flanges

specification

Crane movement only possible Faulty switch element in Check and if necessary replace
on one direction pendant control switch element

Broken wires Check control cable

Faulty contactor Replace contactor

Gradiant an crane track too Re–align crane track

steep

Travel limit switch (if Check limit switch

installed) was operated

Brake does not release No power on brake coil, no Check and repair connections Caution! Pull mains
connector out before
AC voltage at rectifier input starting work!
Check motor

Rectifire faulty or Check DC voltage at brake Follow wiring diagram

incorrectly connected coil; connect rectifier correctly
or replace rectifier

Brake coil has no electrical Replace brake coil Follow operating instructions
continuity and is fault

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8.0 Disposal, Decommissioning
When EMH products are no longer needed, they may be disposed of in an environmentally compatible way.
EMH produces cranes, hoists, and crane system components characterized by high quality, long service life
and low maintenance requirements. Details of the disposal and re-use of components are given in the
following table:

Product Materials Disposal

Crane bridges
Track girders Separation of materials
Trolley frames Metals
Motors Recycle by remelting
Gearboxes
Drive component

Brake linings Multi–purpose On special landfills in according with

components applicable local regulations

Protection hoods Recycle by remelting

Cellulose buffers Plastics incineration
Housings or to special landfills

Lubricants Öils and greases Treatment or disposal in according

with regulations, e.g. incineration

Cables, Housings Rubber, PVC, Separation of materials

Connectors Silicone
Pendant controls PCP Recycle by remelting

Electronic– Plastics, Metals On special landfills in according with

components Elektrolytes applicable local regulations

Painted products must either be recycled or disposed of on special landfills in accordance with the applicable
local regulations.

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 9.0 Not Applicable to this Manual

10.0 Adjustment Instructions for Hoist Limit Switch

10.1 Hoist Limit Switch GF4C with 3 Switch Points
10.1.1 Adjustment Instructions
The EMH hoist limit switch GF protects the electric wire rope hoist as an independently working
emergency-stop-device to limit the up and down movements at the highest and lowest hook position.
As a further improvement of safety the standard system is always equipped with the “Emergency lift limit
switch” a second switch set just above the normal operating highest hook position.
Switching points 2 and 3 of the EMH hoists are normally set at the factory and should only be adjusted in
the field by a trained technician. The switching points are set in accordance with the table ”Setting of lifting
limit switches” on the basis of the reeving, electrical frequency range, mode of operation and flange width.
Switch points must be adjusted by specialist personnel according to respective table “Setting of lifting limit
switches” before the first operation as well as after maintenance work at the rope drive (e.g. rope
replacement). Limit Switch point 3 (Emergency Lift Limit Switch) should only be adjusted after work on the
rope drum has been preformed. During normal installation and start-up it should not be necessary to make
any adjustments to this switch. If adjustments are to be made at any time, the work should be done by a
qualified and trained technician.
Depending on your choice of the reference edge, values of column C1, A1, C2 or A2 can be used (see Figure
30). Adjust the switch points at the adjusting screws 1 - 3 with a screw driver of 6 mm. 3.25 turns at the
adjusting screw corresponds with 360 deg. at the cam disk. The table “Setting of lifting limit switches”
indicates what hook path corresponds with one turn at the adjusting nut. Turning the adjusting nut to the
right (Clockwise) = adjust switch points to a lower position. Turning the adjusting nut to the left (Counter
Clockwise) = adjust switch points to a higher position.

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Figure 13

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Default settings of lifting limit switches
The limit switches of hoists must be preset for dimensions C1 and C2 at the factory in accordance with the
above table on the basis of reeving, frequency range and mode of operation.
Caution! After the settings have been completed, it is essential to carry out a test of functions at maximum
speed to check whether the settings are correct and the hoist does not run up to the emergency limit switch.
It may be necessary to correct the settings. This test must be done by trained personnel.
10.1.2 Adjust Switch Points
Switch Point 1 “Emergency Limit Switch Lifting”
The switch point is adjusted and sealed by the manufacturer to dimension C1. Changes are only allowed in
case of maintenance work and must be carried out by specialist personnel.
The dimension C1 should not fall below this minimum for safety reasons!
Adjustment: Lift the load hook up to 5 mm (with reeving 8/2) or 10 mm (with reeving 4/2) of the highest
hook position (dimension C1 + 5 (10) mm). If necessary, previously turn adjusting nut 1turn to the left.
Turn adjusting nut 1 to the right until switch contact audibly switches (this will be a faint click sound)
Check switch point by running two starts first at slow speed to ensure proper operation and the second at
maximum speed to the highest hook position and if necessary correct the adjustment. A test run to reach
switch point 1 is only possible by manual bridging of the “emergency limit switch lifting.” Switch #2 see
figure 13.
Switch point .2 “Limit Switch Lifting”
Switching point 2 is set to dimension C2 at the factory and sealed with a lead seal. If necessary (especially
for low lifting speeds), this point may be set nearer to switching point C1. The minimum clearance between
the switching point and the emergency limit switch must be set so that the hoist does not reach the
emergency limit switch.
Adjustment: Lift the load hook up to 5 mm (for 4/1) or 10 mm (for 2/1) of the desired hook position (min.
dimension C2 + 5 (10) mm). If necessary, previously turn adjusting nut 2 to the left. Turn adjusting nut 2 to
the right until switch contact audibly switches.

40
Check the switch point by running two starts, first at slow speed to ensure proper operation and the second at
maximum speed to the desired hook position, if necessary correct the adjustment in this case. The switch
“safety limit switch lifting” must not switch in this case.
Switch point .3 “limit switch lowering”
The switch point is only pre-adjusted by the manufacturer. The lowest hook position must be suited to
operating conditions so that the unloaded hook never touches the floor. (Formation of slack rope!)
CAUTION:
When the hook is at its desired lowest limit there SHALL be a minimum of 3 full rapes of the wire rope
remaining on the drum. If there is less than three full rapes remaining the lowest hook height must be raised
Adjustment: Lowering of load hook to 2.0 in. (50 mm) above the lowest hook position required. If necessary,
turn adjusting nut 3 previously to the right.
Turn adjusting nut 3 to the left until switch contact 3 audibly switches. Check switch point by running two
tests (max. speed) to the lowest hook position and if necessary correct the adjustment.

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