Address Contact Phone Foxt YOB COMPONENTS GENERAL INFORMATION Customer _ Caterpillar Mexico SA DE CV ‘elo Omar Santos Inc. {8503 San Gabriel Dive Laredo, Tx. 76045 Hople Vela Jo FO-535 Pot ‘CRANE INFORMATION BUnderng Capacity 2 Tons Top Running Tre Gy 1 O canty 460 _V Power 60 Hz Suppiy 3 Ph New DD Glovelend Framed Cleveland Tramrall Parts fevoland Tramra Endtruck (Surplus shaw Box Mode _toF5(09 O eéstin Ol Glovela vives 2 ira Girt Beacon a Heads 4: = HOIST INFORMATION ~ Hoist#Het0024 | Hoist # HE10026 Undernung New — Serial# — _o7Koz680 (03K0288% ‘Type: Top Running Dl Surplus Modei# —eotazoaosia | eotozavosta O existing Lik 20: 2 O. cm Lit’ Speed 1415 fom T8 fom TR Shawboxs itech Holst # HE10030 | Hoist # HE10028 Make O pen (07K02662 ‘03K02883 Ol Yale woLoao20st4 | sotoz020st4 o 20.0" other ae —Fioietw Hes0027” | ~Hoiet# HE100z2 ‘ ‘O1K02685 01k02886 BoL.02020514 D Cleveland Tramrat Trolley El w/ Hoist toad Bar OD other: Drives Idler HeadsELECTRIFICATION Runway 2 Conductor Bar @ safpowrbar Y Cl_Festoon CO insu-8 duct-0-Wwire O other: Bridge 2) Conductor Bar 8 safpowrbar 8° Tl Festoon insure @ *c" Track C1 duct-0-wire 1 Tagine OF other: CONTROLS Bridge Trolley Hoist Cl G+ Impulse Series 2 1 G+ impulse Series2 1 G+ Impulse Saris 2 OC Quantum impulse 1 Quantum impulse (1 Quantum impuise Cl vee+ impulse O veG+ impulse Ol VFG+ impulse other: P3 ® other P3 O other: @ weco ® weco 1 weco Panel (1) With Hoist ‘with Hoist [lwith Hoist OF otter O other 1 otter Pendant [1 On Heist BQ electromotive Part! _ELSBP2-e.WHS @_Festooned OC whboist "C" Track O other: O TagineOPERATING SUGGESTIONS RANE operators play an important part in the safety of the plant. And, also they are responsible in a large measure for the kind of service you obtain from your Crane and the cost of operating and maintaining it, The measuring stick of a good operator is the smoothness of crane operation. Jumpy and jerky crane move- ments. flying starts, quick reversals and sudden stops are the “trade marks” of the careless operator. The suggestions below may be helpful to the operator of this Crane. CRANE OPERATORS SHOULD AND SHOULD NEVER DO SHOULD ALWAYS DO 1 — fig ll mafene deer, and meee coe, troller handle step by step until fastest speed is obtained, 2.— Make all stope slowly by bringing con- seller hon oof peton dp by 3—Leam to judge “dit” of each motion cir power shot oft Tha aliinaiog sling he badge brakes 4 — Uae ladders or stain to get on or of the Wl $—Always sound waming signal when carrying leads. 8—Always leave all controllers in “olf” position, 7 — Report any adjustments that should be to foreman os soon as need is ‘Never move any load except on signal from ONE floermen. 2—Never drag slings, chains, heoks, or loads along the floor with the crane, 3—Nover allow anyone to go up on the crane to make adjustments or repairs betere.he opens the main line switch. 4—Never operute the crane when adjust- ments should be made to it. S—Never hold a circuit breaker closed, if it opens, or place wire ar copper bars in the fuse blocks if fuses blow out, FLOORMEN’S STANDARD HAND SIGNALSMANNING, MAXWELL @ WooRE OF CANADA, LTD, ERECTION SUGGESTIONS © THAT this Crane may be reassembled in the shortest possible time, the following precautions were taken in our shops: (1) the Crane was completely assembled and operated under its own Power: (2) wherever units were dismantled for shipping purposes, they were ‘match-marked’ to indicate how they should be reas- sembled; and, (3) wherever it became necessary to break wiring connections, matching metal tags have been fastened on the wires. ‘The following information is to assist you in arranging for the erection of the Crane on. ‘Your runway and insure that it will be properly erected in the minimum of time: J Erprten wit be expedited and expense minimized if ripping ls In place plo to extra ol Creme ‘and the erectlon superintendent, D iting tackle should be provided to handle the heaviest single unit of the Grune, Por your Tuldance, the fllowing are the walghts of the heaviest unite [dle Girder. End Trucks (ec.) Hoisting Trolley important that the helsting trolley be placed on the bridge salle correctly, amd net ‘around side for aide. Normally. the helat macklaery aide of the trolley la on the dle girder ‘ef the Crane. K positive check is to match the tags on the wires coming from the meters om, trolley with those coming from the controllers to the cross wires on the bridge. Contrellers Sdeatied “H for Hoist: “T" for Trolley: and “B" lor Beidge, These markings are on ince ccouteller cover, His of simost importance, to innure that girder are aquare with the ond trucks that the “EF ‘bolts furnished be used for these connections. lao, riggers should not be permitted to “él” ‘hese holes to permit entry of these bolts, 5 Te fasare that siicent sisctic current ie available ot the Crane, check fuses of setting of circuit breakers through which current ix supplied to Crane runway wires lor auficent capacity. FRRF ER set a a BEFORE YOU START THE CRANE Alter the Crane has been erected and before it is started up, a final “check-up” as sug- gested below is recommended. Experience shows that such @ check-up has. in many cases prevented costly accidents, and damage to a new expensive machine. 1 cece Att bette tor tightnees nd be sure lock uikers have been aed. D, Ghack for ead remove any loose parts such ox Bolt, aut, bors hammer. wrenches, oe. that may have been left on top of tha gicders or rolley. or on the platiorn. check fr cay ai eplloge thot macy have occured dusiag erecten end il say wipe oil «pot der. 4, Thstouchly grease EVERY bearing on the Craze: check all geer housings for sil: and grease heisting rope. Proper lubricants to use are lined ia this book, mahCrane Operator's Manual Prepared and Published by ¢ mM A A’ CRANE MANUFACTURERS ASSOCIATION OF AMERICA, INC. 8720 Red Oak Bivd., Suite 201 Charlotte, NC_ 28217-3992a a eo oe oo odForeword This booklet has been prepared to provide information and suggestions for Crane Operators in their operation of cranes.. Overhead cranes generally handle materials over working areas where there are personnel. Therefore, itis important for the Crane Operator to be instructed in the use of the crane and to understand the severe consequences of careless operation. It is not intended that the suggestions in this booklet take precedence over existing plant safety rules and regulations, OSHA regulations, or instructions issued by the Crane Manufacturer, However. a thorough study of the following information should provide a better understanding of safe operation and afford a greater margin of safety for people and machinery on the plant floor. itm recognized that this is a booklet of suggestions for the Crane Gperatar's use. Itis the responsi ty of the owner to make personnel aware of all federal, state and local rules and codes and to make certain operators are properly trained. It should be clearly understood that under no circumstances does the Crane Manufacturers Association of America, Inc. (CMAA) assume any liability for the use of these suggestions. CMAA makes no warranty whatsoever in connection with these Suggestions. There are no implied warranties of merchantability or of fitness for any particular use. Further, CMAA shall not be liable in tort or otherwise—whether based on negligence, strict liability or any other theory of liability—for any action or failure to act in connection with these suggestions. It is the user's intent to absolve and protect CMAA from any and all liability, in tort or otherwise. The Material Handling Institute (MHI) Division of The Material Handling Alliance ‘The Crane Manufacturers Association of America, Inc. (CMAA) is an independent incorporated trade association affiliated with The Material Handling Institute (MHI) division of The Material Handling Alliance. MHI provides CMAA with certain services and, in connection with this booklet, arranges for its production and distribution. Neither MHI, its officers, directors or employees have any other Participation in the development and preparation of the information confained in this booklet. All inquiries concerning The Crane Operator's Manual should be directed in writing to the Crane Manufacturers Association of America, Inc., 8720 Red Oak Blvd., Suite 201, Charlotte, NC 28217- 3992,Introduction Qualifications Crane operation, to be safe and efficient, requires skill, the exercise of extreme care Judgement, alertness and concentration, and a rigid adherence tolproven safety rules and outlined in applicable and current ANSI and OSHA safety standards. In general practice, no person should be permitted to operate & crane: (a) Who cannot speak the appropriate language or read and (b) Who is not of legal age to operate this type of equipment (e) Unless the operator has carefully read and studied the opsration manual supplied Manufacturer; (® Unless the operator has been properly instructed; (g) Unless the operator has demonstrated his instructions (h) Unless the operator is familiar with hitching equipment Operation ‘Before operating the crane, the crane operator should carefully read and study the oj supplied with the crane by the Crane Manufacturer and note any special instructions not previously by the proper instructor or supervisor. With the mainline switch open (power off) the crane operat push button in both directions so as to get the “feel” of each devick and also determine that bind or stick in any position. If any of them do, before doing anything else, the operator s the condition to the proper supervisor. Learning the Controls Having observed the feel of the controllers, the crane operatat is now ready to try the power applied. After checking to be sure no one is on or near the crane, closd the crane disconnecting press the "ON" or "RESET" button so that the power is “on.” Try the hoisting motion first. The hook should be in an intermediate position. Move push button slowly in the "up" direction or press the "UP" button ih the pendant in the samé ‘The resultant movement should correspond with master switch or push button markings for Observe the speed increase in relation to the steps in the controller|| Try to feel the steps in type controller. Move the hook to a position near the upper hook gosition and slowly inch the upper limit stop position. The limit switch should cause the hojsting motion to stop at limit of travel. If any malfunction of either the hoist brake or the limit switch is suspected, condition should be reported to the supervisor before proceeding., The hoist limit switch sh used as an operating control for stopping the load. It is to be consitlered as an emergency liff Repeat this procedure with the wrolley controller. If the trolley|is not equipped with a b how it can be stopped by momentarily operating the control in the first point of the reverse This is known as “plugging,” Next uy the bridge motion, first making sure that the first mGOOD operators should always remember and follow four simpie cules: 1. Start all motions slowly, by moving the controller handle or push button step by step until the fastest safe speed is reached. . Stop slow! minimize by bringing the master switch or push button to the “oft” position step by step s0 as ic inging" of the load and unnecessary wear of the brakes. 3. Leam to judge the drift of each motion of the crane after power is removed. Proper use of this drift will facilitate spotting of the load and'minimize wear of crane components. 4. Handle the load in a safe manner with the area free of personnel and other obstructions. Handling the Bridge Travel Motion Before using the trolley or bridge of the crane, the operator should be sure the hook is high enough to clear any obstruction. Before a load is handled by the crane, the bridge should be brought in position so that it is directly over the load. Otherwise it will be impossible to "spot" the trolley and hoist hook over the load. In addition to other operating controls, the bridge has a brake, usually operated by a foot pedal in the cab or an electric brake where push button floor control is used. The purpose of this brake is to rmit stopping the bridge exactly where desired. After the operator has learned the distance that the ridge travels after power is removed, te operator should Be able to judge distances go that the aved to use the bridge brake will be greatly reduced. On floor-controlled cranes, the electric brake will set automatically when the push button is released. Start the bridge slowly and bring it up to speed gradually. Approaching the place where it is desired to stop the bridge, reduce the bridge speed. If the operator finds that the crane is going to "overrun" the point where the bridge is to be stopped, apply the bridge brake. If extra fine control or creeping speed is not provided, follow the practice of "inching," namely: Move the controller handle or button on and off the point that produces a minimum of motion. This practice should be followed only as necessary because it causes extra wear on the controller contacts and the electric brake, Skidding of wheels when stopping will result in flat spots on the wheels and rough bridge action, Handling the Trolley Travel Motion Before a load is handled, the hoist should be brought directly over the load that is to be handled. When the slack is taken out of the slings, if the hoist is not directly over the load, bring it directly over the load before hoisting is continued. Failure to center the hoist over the load may cause the load to swing upon lifting, If the trolley is equipped with a brake, follow the instruction given for controlling the bridge. If the trolley is not equipped with a brake, this motion may require more skillful handling than any other motion of the crane. As the operator becomes familiar with the crane, he can gauge the amount of “drift” and allow for it. This will eliminate the necessity of quickly reversing power to the trolley motor to bring the trolley to a stop. Always start the trolley motion slowly and reduce the trolley speed gradually. For very slight trolley movements, follow the practice of “inching” as described in "Handling the Bridge Travel Mation." Handling the Hoist Motion After the hook has been brought over the load, lower it until the load can be attached.to the hook. As the hook approaches this level, reduce the speed so that the lowering can be stopped smoothly and quickly. If load slings are used to handle the load, the slings should be fully seated in the saddle of the hook. With the hook latch closed (if equipped with hook latch), the hook should be started upward slowly until ail slack has been taken out of the slings. Then the load should be lifted slowly until it is clear and it has been determined that the load is properly balanced and the slings properly placed. The hoisting speed may then be increased and maintained until the load is clear of all obstructions or if a hitcher gives the signal to stop.When low: oo. ing loads, the lowering speeds should be gradually decreased until the lod is near the || place where it is to be stopped. If a hitcher is used it is very impbrtant that the operator pdy particular attention to the directions of the hitcher. When the operator is signaled to continue lowerifg, it should be done at the slowest possible speed. [fextra fine control is not|provided, final accomplished by following the practice of “inching” described in "Handling the Bridge Tihvel Motion."r | When it is necessary that ioads be raised or lowered extremely short distances, particiftar| u raising loads off the floor or out of machine tools or fixtures, the practice of “inching” maj if extra fine control is not provided. Note: A good operator should minimize the nurnber pf in operations. | ‘The operator should check the hoist brake by aang load a short distance and stogping. floor dad stop. Again check fof drift. ff lo drift is noticed in either step, lower the load to the floor and report the situation immedi: the load for drift. If no drift, lower the load halfway to supervisor. General Suggestions Know Your Crane Crane operators should be familiar with the principal parts ofa crane and have a thoro\ knowledge of crane control functions and movements. (See Figur? 1) Both the crane operator and the person hitching (or rigging) the load should be required fp kno location and proper operation of the main runway conductor discohnecting means for all. area. The crane operators should be thoroughly familiar with the dperating manual provi ‘Crane Manufacturer. Responsibility | Whenever there is any doubt as to SAFETY, the crane operator s! handle loads until: (1) safety has been assured or (2) the operator Each crane operator should be held directly responsible ca safe operation of the c Do not permit ANYONE to ride on the hook or a load, | Don't Argue Cab-controlled crane operators should never argue with personnel on the floor. The operator's job requires close cooperation with the hitcher. ‘j All disagreements conceming crane operation should be called to the attention of the suf Entering a Crane (Cab-Operated Cranes) ‘Crane operators should enter and leave cranes only at designated places using the platfotm, steps or ladder provided—unless otherwise authorized by the superviso1 Both hands should be used when ascending or descending acrane ladder, Keep hands handline should be used for lifting or lowering material, tools, lunch buckets, etc. Operators fasten handlines securely to the crane or building structure, not to themselves. juld stop the crane and jas been ordered to proc supervisor, who then assumes all responsibility for the S of the lift. ting Should ly be followedHOIST SPEED REDUCER DIRECTIONAL MOVEMENT £ HOIST BRAKE nr % 7 > > BRIOGE RAL, cap ASSEMBLY aueig ebpiig—t ainBia CONTROL ENCLOSURES aioe LIGHT RIDGE SPEED REDUCER ~ RESISTORS PUSHBUTTON ASSEMBLY HOOK LATCH = ee BRIDGE ORIVE WHEELHousekeeping Good housekeeping should be maintained at all times. Thé se cab and access clear and clean. Do not permit loose objects suc! ab or on the crane because they represent a safety hazard. Inspection Test all controls on the crane at the begi ropes, hooks and other protective devices are in good working 6 proper functioning of all controls, and check for loose or dama Whenever the operator finds anything wrong or apparently immediately to the proper supervisor. jing of each shift, Signals Standard crane signals (See Figure 2) should be accepted onl} except where it is apparent that to do so would result in an acide! Obey a STOP signal at all times, no matter who gives it. 4] Loads should not be moved unless the standard crane signals| Unusual signals are seldom required, but if used they should operator and authorized person giving the signal. i i] [Be sure the limit switche fer. Check crane for sucf things] lare clearly given, seen be thoroughly un rane operator should ket as tools, bolts, boards, ef. Parts, from ONE authorized It. , brakes trane rere wn Ss SF Fr Se ceStandard Hand Signals (Courtesy of ANSI) Operator Should Wear Proper Safety Clothing HOIST. With forearm | LOWER. With arm ex- | BRIDGE TRAVEL. vertical, and forefinger | tended downward, fore | Arm extended forward, pointing up, move hand | finger pointing down, | hand open and slightly jin small" horizontal rrised, “make pushing circle. herizantal circle. motion in direction of I é lr] TROLLEY TRAVEL. | sTOP. Arm extended, | EMERGENCY STOP. Paim up, fingers closed, | palm down, hold posi: | Arm extended, palm thumb pointing in dizee- | tion rigidly. down, move’ hand e tion of motion, jerk rapidly right and left. hand harizontally, s m 1K R2 1 MULTIPLE MOVE SLOWLY. Use | MAGNET IS TROLLEYS. Hold up | one hand to give any | DISCONNECTED, fone finger for block | motion signal and place | Crane operator spreads marked "I" and two | other hand motionless | both hands apart — fingers forblock marked | in front of hand giving | palms up. 2", Regular signals | the motion signal. fellaw. (Heist Slowly shown as example) ) Figure 2 Stay Alert : ‘The crane operator should keep hands on the handles of the controller or master switches which control the motions in operation so stops can be made quickly in case of an emergency. Stand up, when necessary to improve vision, when making a lift or when moving a load in any direction. Be especially alert for any unusual sounds or warnings. Danger may be preseat that tie crane operator cannot see.Operating Sugg One measure of a good crane operator is the smoothness operation, flying starts, quick reversals and sudden stops are g00d operator should know and follow these proven suggesti 1. Crane controls should be moved load. Slack must be removed frot Center the crane over the load started. Loads should not be s Crane hoisting ropes should be kept vertical. Cranes's} smoothly and gradu: m the sling and hois 2 before starting the hoi swung by the. crane to re estions f the crane operation. J the "trademarks" of a ns for safe, efficient ci ly to avoid abrupt, je ig ropes before the I to avoid swinging the 1 ich areas not under the lall not be used for side far Figure 3 - Center Crane Over Load Never lower the block below the point where less than hoisting drum. Should all the rope be unwound from the correct direction and seated and the hoist limit switch will not operate to stop the hoi w Sound the warning device (if provided) when raising, lo are working to make them aware that a load is being mo 6. 7. Do not operate the crane if limit switches are out of orde: Make certain that before fully seated in the saddle ‘When a duplex hook (double saddle hook) is used, a dou! moving the load, load slings, 1o of the hook with hook latch clo assufe that the load is equally divided over both saddles o| perly in the drum grooves Be sure everyone in the immediate area is clear of the ite and aware that a load Do not make lifts beyond the rated load capacity of the é1 Betore Litting 0 fall wraps of rope drum, be sure itis rew or otherwise the rope it in the high position. ering or moving loads ed. fane, sling chains, rope . or if ropes show det 4d chains, or other lifting devices dd (if equipped with hook latch! le sling or choker should}be used the hook. (10, On alt capacity or near capacity loads, the hoist brakes should be tested by returning the master switch or push button to the "OFE” position after raising the load a few inches off the floor. Check the load for drift. If no drift, lower the load halfway to the floor and stop. Again check for drift. If load drift is noticed in either step, lower the load to the floor and report the situation immediately to the supervior. LL, Check to be sure that the load and/or bottom block Is lifted high enough to clear all obstructions when moving bridge or trolley. 12, Atno time should a load be left suspended from the crane unless the operator is at the master switches or push button with the power on, and under this condition keep the load as close as. possible to the floor to minimize the possibility of an injury if the load should drop. When the crane is holding a load, the crane operator should remain at the master switch or push button, 13. When a hitcher is used, it should be the joint responsibility of the crane operator and the hitcher to see ss are secure and that all loose material has been removed from the load before starting a lift. 14, Do not lift loads with any sling hooks hanging loose. ({f all sling hooks are not needed, they should be properly stored, or use a different sling.) 15. All slings or cables should be removed from the crane hooks when not in use. (Dangling cables or hooks hung in sling rings can inadvertently snag other objects when the crane is moving.) 16. Crane operators should not use limit switches to stop the hoist under normal operating conditions. (These are emergency devices and shall not be used as operating controls.) 17. Do not block, adjust or disconnect limit switches in order to go higher or lower than the switch will allow. ‘18. Upper limit switches (and lower limit switches, when provided) should be tested in stopping the hoist at the beginning of each shift, or as frequently as otherwise directed. 19. Operators shall not carry loads and/or empty bottom blocks over personnel. Particular additional caution should be practiced when using magnet or vacuum devices, Loads, or parts of loads, held magnetically could drop. Failure of power to magnets or vacuum devices can result in dropping the load. Extra precaution should be exercised when handling molten metal in the proximity of personnel. 20. If the electric power goes off, place your controllers in the "OFE” position and keep them there until power is again available. 21. Before closing main or emergency switches, be sure that all controllers are in the "OFF" position so that the crane cannot start unexpectedly. 22. If plugging protection is not provided, always stop the controllers momentarily in the "OFF" position before reversing—except to avoid accidents. (The slight pause is necessary to give the braking mechanism time to operate.) 23, Whenever the operator leaves the crane this procedure should be followed: (a) Raise all hooks to an intermediate position. —_ (b) Spor the crane at an approved designated location, (©) Place all controls in the "OFE" position. (d) Open the main switch to the "OFF" position. (@) Make visual check before leaving the crane. Note: On yard cranes (cranes on outside runways), operators should set the brake and anchor securely so the crane will not be moved by the wind.24. When two or more cranes are used in making one lift, is very important that ‘operators take signals from only one designated person, 25. Never attempt to clase a switch that has an “OUT OF ORDER" or "DO NOT OPERA: on it. Even when a crane operator has placed the card |i is Necessary to make determine that no one else is working on.the crane, before removing the card, 26. In cage of emergency or during inspection, repairing, cleaning or lubricating, a signal should be displayed andthe main esieee sia locked in the "OFE” should be done whether the work is being done by the operated cranes when others are doing the work, the cab unless otherwise instructed by the supervisor. 29. Never bypass any electrical limit switches or: ‘warning | 30. Load limit or overload devices shall Rot be used to meas} emergency device, it shall not be used as a production o mm is ksHOIST INSTRUCTIONS & GENERAL INFORMATION We are sending you a complete parts catalog as far as our records show. Any alterations not done by Shepard Niles to this equipment are not covered in this catalog. CAUTION ——_—_—$—$—$—$—$— << << — PLEASE READ BEFORE OPERATING HOISTING EQUIPMENT. 1. Observe all plant safety rules as well as ANS! and OSHA regulations, when operating equipment. 2. All operators of hoisting equipment should be properly trained, physically and mentally ft 3. Be sure area and load is clear of personne! and obstructions when lifting, transporting or lowering. 4, Do not attempt to lif more than the rated capacity of the hoist, crane, lifting chains, sings or attachments, 5, Do not use overhead cranes or hoists to lift persons or objects over persons. All personnel should ‘be warned of approaching overhead crane and load. 6. Always maintain a minimum of two wraps of cable around the drum. 7. Do not distract a crane or hoist operator. 8. Be sure all hooks have hook latches, are in safe operating order, and load chains ft properly into hook. 9. All loads should be lifted in a straight vertical lie and always keep the cable in the drum grooves. 10. Be sure all loads are securely and properly attached to the hook and balanced before lifting. 11. Do not use lifing cable for a welding ground or damage the cable in any way. 12. Do not make any unauthorized changes or repairs to the hoist or crane. 18. Avoid direct contact between the cranes or hoists or any other objects. 14. Do not leave @ load suspended on the hoist, or a hoist with a load unattended. 15. Open all main line disconnects when leaving crane or hoist unattended. 16. Be certain all limit switches are operating and properly adjusted, before lifting a load, and do not use the limit switch as a normal operation stop. 17, Cranes should not be operated with personnel on the crane platform, runway areas or service platform. 18. Be sure equipment is in good working order before operating and report any malfunctions or necessary repairs to your supervisor or qualified repairperson. 19. Be sure hook travel is the same direction as indicated on pushbutton or master switch controls. 20. Crane cab should be in a proper position to the landing platform before leaving the crane, and be ‘sure all pushbutton stations and hooks are out of the way of pedestrians. 21, Be sure load to be lifted is free to move. 22, Cable slack should be taken up slowiy, and avoid swinging or jerking the load. 23. Do not operate hoisting equipment with twisted, kinked or damaged cable.nn Sse sae eee eeeThe majority of cranes and hoists placed in service become extremely impor- tant elements of the user's operations. Down-time and lost operation time can be extremely expensive. We suggest our customers avoid much of this aggravation by maintaining a moderate inventory of critical spares on hand. Service Lists #1 through #5 (shown on the back of this page ), giving arecom- mended spare parts inventory, are based upon expected service or duty cycle of the equipment. These are in accordance with the Crane Manufacturers Associa- tion of America (CMAA), and the Hoist Manufacturers Institute (HMI), and are described below: LIST #1. LIGHT SERVICE. CMAA Class 8, HMI Class H2. Appropriate for repair shops, light assembly operations, service buildings, light warehousing, etc., where loads and utilization are randomly distributed, with total running time of equipment not exceeding 10-15% of the work period. LIST #2. STANDARD, or MODERATE SERVICE. CMAA Class C, HM! Class H3. ‘Appropriate for machine shops, papermill machine rooms, fabricating shops, where loads and utilization are randomly distributed, with total running time of equipment not exceeding 15-25% of the work period LIST #3, HEAVY DUTY SERVICE, CMAA Class D, HMI Class H4 Appropriate for high volume handling in stee! warehousing, machine shops, fabricating plants, mills, and foundries. Manual or automatic cycling operations in heat treating and plating operations. Total running time of equipment normally approaches 25-50% of the work period. LIST #4. SEVERE DUTY SERVICE. CMAA Class E, HMI Class HS. Appropriate for handling the rated load continuously at high speeds, Bulk handling of material in combination with buckets, magnets, or heavy attachments. LIST #5. STEEL MILL AISE SPECIFICATION. CMAA Class F. Cranes in this class are covered by the current issue of the Association of Iron and Steel Engineers’ Standard, for Electric Overhead Traveling Cranes.RECOMMENDED SPARE PARTS ol >efo oe ef fff Contactor, Set Complete. Friction Linings, Electric Brake, Holder, Motor Brush, Limit Switch Assembly Load Block Shaft Extension, Motor TROLLE ‘Armature, Brake, Brake Cap AssembV, Brake Coil Brake Elements, Electical Brake Solenoid Assembly, Brushes, Motor Collector Shoes, or Wheels Contactor Coit Contact, Moveable & Stationary ol > Contactor, Set Complete Friction Linings, Electric Brake. Gear Case Assembly Holder, Motor Brush Motor Shaft Extension, Remature, Brake Brake Cap Assembly Brake Coil Brake Elements, Electrical Brake Solenoid Assembly Brushes, Motor Collector Shoes, or Wheat, Contactor Coit Contact, Moveable & Stationary, p<} >> > > Contactor, Set Complete Friction Linings, Electric Brake, Gear Case Assembly Holder, Motor Brush Motor ‘Shatt Extension, ‘Truck Wheel Assy. w/ Axle & Bearings, Page 2 ASS we ee ee ee ee es aLUBRICATION MOTORS Use a good grade of ball bearing grease at grease fittings at each end of the motor. Where no fittings are provided, the motors are equipped with sealed bear- ings or oil bath lubrication. ANTIFRICTION BEARINGS — SHAFTS, AXLES, SHEAVES, ETC. Use same as for above. GEAR BOXES Keep oll to top of ol levels provided. Use Kendall 80-90 W Special Limited Slip Axle Gear Lube, which has been used in your unit(s). OPEN GEARING OR GEARING PROTECTED BY SHEET METAL ENCLOSURES Use a good grade of adhesive gear compound appropriate for the service and ambient temperature in which it operates. Note: Due to possible contamination, open gearing is not lubricated at the factory. LUBRICATED TYPE ELECTRIC BRAKES Use a very light weight non-adhesive, non-detergent oil & SAE 10 weight is usually satisfactory. This lubricant is primarily a heat transfer medium. A #2 diesel fuel oil has worked well on dynamic. controlled units, where the control pro- vides very low torque for light hook lowering. HOISTING CABLES Use a lubricant that will penetrate to the innner core and adhesive enough to Prevent dripping. Hot or cold applications are required depending on lubricant chosen. Usually a lubricant that can be applied cold is more convenient but may have to be applied more often. LUBRICATION FRQUENCY GENERAL ‘The frequency of lubrication is @ function based on the activity of the equipment and the conditions under which it operates. In the last analysis, this must be deter- mined by your own application. Following installation of new equipment check all oil levels and grease fittings to be certain of adequate lubrication. Lubricate all open gearing with adhesive gear compound. Make sure gearing in sheet metal enclosures is covered with an adhesive gear compound. NOTE: Due to possible contamination in transit, open gearing is not lubricated at the factory. MOTORS Antifriction bearing motors require a minimum of lubricant. Relubricate spar- ingly motors provided with extemal means of lubrication after approximately 1500 hours operation. ANTIFRICTION BEARINGS — SHAFTS, AXLES, SHEAVES, ETC. Check monthly. GEAR BOXES Check after 50 hours operation to make sure no leaks develop and oll remains at the top of oil levels. After this, a check twice a year should be sufficient.LUBRICATION FREQUENCY (CONT) GEAR BOXES WITH MECHANICAL LOAD BRAKES Same as “Gear Boxes” preceding. OPEN GEARING, ETC. | As often as necessary depending on the | activity of the unit. Check at least onc@, a month. LUBRICATED ELECTRIC BRAKES particles, flush case and fill with fresh oil. CABLES Check monthly. The frequency of oiling will depend on the activity of the should be inspected daily. {! For efficient lubrication, oil level should be carried as the gauges. Oil should be Kendall 80 - 90 W Special Limited Slip brake; SAE 5 forwinter & SAE 10 for summer. Oil shouldbe when necessary to keep it in good condition. Oil gauges should be left open for several minutes after fling to see that oil does no! overflow or sink below the correct level. (See fig. 1) A-- Air vent & filler plug - gear end frame B - Oll gauge - gear end frame C- Grease corinections - use good grade solidified oil - viscos fahrenheit D - Drain plug - gear end frame nna & om es ed eS Se ee eee ee oe = oo = aPREVENTIVE MAINTENANCE BEFORE PERFORMING ANY WORK ON A HOIST 1. Advise the foreman in that particular work area, 2. Isolate the hoist so that it is safe from any interruption of other operating equipment. . Lock out power disconnect switch | Apply appropriate warning signs—at Load Block, Push Button Station, etc. Observe all appropriate safety measures. Have stable working area. ogae INSPECTION DAILY OR BEGINNING OF EACH SHIFT 1. Correct Operation a. Are all directional operations O.K.? b.Do all speed steps function as designed? c. Does hook drift excessively in either direction? d. Does the upper limit switch interrupt the hoisting circuit? Remember Limit Switches do not stop the machine, brakes do! 2. Contro! Operating Details ‘a. Master Switches O.K.? b. Push button pendants and stations 0.K.? ¢. Return springs 0.K.? d. Functional name plates clearly visible? 3. Hoisting Cable a. Are there any obvious signs of damage such as kinks, broken strands or evidence of having been crushed? Is cable following drum grooves properly? 4, Load Blocks a. Are there any loose connections? b. Has hook been deformed? A hook which has throat opening spread more than 15% of its original dimension, or twisted more than 10 degrees Is considered unsafe. c. Are sheaves and sheave guards O.K.? Note: If there is evidence of any problem, report to your foreman at once. WEEKLY 1. Lubrication of all open gearing with adhesive gear compound. MONTHLY 1. Check lubrication of ail open gearing, gear boxes and wet type brakes and hoisting cables. 2. Hoisting Cable Tackle a. Properly reeved? b. Cable for damage, wear, lubrication and anchorage? c. Load Block: hook, sheaves and cable guards for wear and fastenings? Lubrication? d. Upper sheaves and guards—wear, fastenings and lubrication? e. Winding drum-wear, cracks, fastenings, etc.? 3, Brakes—adjustment, worn parts and operator de! 4. Controts ‘a. Connections and fastenings? b. Contacts? c. Coils? ils?4. Interiocks? e. Push buttons and master switches? f. Functional markings clear? g. Limit switch contacts? 5. Conductor Systems a. Stretched wire-wear and tension? End suppo! Feeds and intermediate supports? Collect insulation? b. Rigid bar conductors—wear, spiices, feed wear, adjustment and insulation? i ¢. Flexible conductor—end fittings, cable and Note: OSHA requires monthly signed inspection cable and load block hooks as well as sling} ments. j QUARTERLY i 1. Motors | a. Brushes—wear, free in holder, seating, tensjon and pigtails? b. Brush holders—insulation, alignment, tightn nections of leads? ¢. A.C.—Collector rings—itrough or grooved, d Refinish surface to a high polish. | d. D.C. Commutator—Moderate discoloration is determine cause and correct. Refinish surfac| rators when necessary. 4 e. Leads-make sure these have tight connect pinched wires under junction box covers, et ANNUALLY 1. Motor Lubrication—Do not overgrease motors. ino grease tings, moto th, have sealed bearings or are lubricated by oil bat! 2. Axle Box and Shafting Bearings—Lubrication? 3. Magnetic particles or dye test for crane/hoist hi 4, Structural members—welds, bolts and/or rivets| ‘weakness? GENERAL COMMENT | The above suggested maintenance schedule is fig day operation. Motor Lubrication is based on apprt running time. Machines working “around the clock” actually ge{ about “3 years" servi ingle calendar year. The maintenance schdule should be adjuste| during a accordingly. 4 Page 6 its, take-ups and insulator 's—wear, adjustment al , insulators? Collectors! supports? iports to be maintained , chains and hook atta 155 On supports, tight co} lermine cause and corre: ‘good. If rough or burne} and undercut mica sep} ns, proper insulation, irom adjacent gear box. }oks recommended. iight or show any sign red for normal 8-hour pé ximate 2000-hour actu: Se ee ee ee Tn Sle1 10. " 12. 13. 14. 15. 16. 17. 18. MANUFACTURERS RECOMMENDATIONS . Hoist operation concerns the safety of many men. The operator should be alert and give his undivided attention to his duties at all times. It is recom- mended that a hoist only be operated by appointed operators, maintenance and test personnel. The operator should test the brakes frequently or each time a load approach- ing the rated load is handled by raising the load just enough to clear the floor, of supports, and check for brake action. The lift should be continued only after the operator is assured the braking system is operating properly. Test the brake by placing the controls into “off” position after a load has been lifted a few inches. if the brake does not hold, stop work until it has been adjusted. . Never work with defective appliances. Cables, chains, slings and hooks should be carefully inspected weekly. . If the power goes off, all switches should be opened and all controls moved to. “aff” position. Make sure that all controls are in “off position before throwing in the main switch. . Close controls gradually so that motors start smoothly. Do not reverse the motors too quickly. See that all loads are hooked safely. Always have hoist directly over load. Side or end pulling is dangerous. When handling loads, always make sure there is no person or obstacle in way of the load being carried. Do not carry loads over workmen. A good operator will never swing or jerk a load, or lift it when anyone could be caught between it and other objects. When pulling chains out trom under a load, see that no one is in a position to be hit by the chain. . Extreme care should be used in handling molten metal. An operator should never let his hoist or crane bump into another hoist or crane unnecessarily. .If a hoist or crane is located out of doors, the operator should lock or block the hoist or crane in position when leaving so it cannot be blown by the wind. The operator should never go, or allow anyone else to go, on top of a crane without first opening the switch and locking it open and protecting it by means of a DANGER sign. . Arepairman should never, under any conditions, go upon a crane or runway ing the operator of the crane. Before removing any part which might release the hoisting block, the block should be lowered to the floor or, if this is impossible, the gear should be blocked or wedged so that it cannot move. Load blocks should never be left at a height where a man can bump into them. CABLE MAINTENANCE The cable originally furnished on your hoist is the highest quality steel hoisting rope manufactured. Please examine it when received and if it bruised, report thi kinked, rusted or mediately to us and to the carrier. No claim for adjustment can be considered for cables showing such defects after having been in service. Before using the hoist, see that the cable lies smoothly in the grooves of the drum and sheaves. Keep it coated with a heavy oil or prepared cable lubricant. This is absolutely necessary to prevent rapid wear of the strands as the cable bends over sheaves and drums and also to prevent rust, especially in ice plants or in places where moisture or corrosive fumes are present. Follow the lubrication instructions.GENERAL INSTRUCT, TO DISASSEMBLE THE ELECTRIC BRAKE (Series| First, run the hoist in the lowering direction until floor or in case of suspended ioads such as magnet make sure there is no load on the hoist cables. Disco Loosen the check nut, retaining the spring bolt bush bushing clockwise until solid resistance is felt; this will ‘on the pressure plate Unbolt the coil pot housing that contains the brak flexible conduit and wires are not damaged. If this is flexible cable connection can be disconnected at th the coll pot housing. Remove the brake wheel by ¢I Remove the brake ring held in piace by two dowel THE GEAR END Remove the drain plug and drain the oil; unbolt ani re with the driving pinion bearing. The driving pinion, ta compound gear train can be pulled out. Notice how th stationary load brake rings at the top of the gear en! Unscrew the nut on the stop bolt about three turns This will loosen the stop bolt. The main gear cage wi pulled out. It may be necessary to use a hook in ordes main gear cage to break the grip of the oil seals. The di mately its normal position by the flanges of the bod} gear can be taken out after the two main internal gear bolts are unscrewed, THE MOTOR END ' SQUIRREL CAGE MOTORS: Unbolt the front end st rotor and bearing as one unit. D.C. OR SLIP RING A.C. MOTORS: Remove the e| and take the brushes out of the brush holders. Back ‘screws; unbolt the end shield and remove it from the tra| oF rotor in place. A.C. brush holders are attached to’ i holders are attached to a ring which can be taken out armature or rotor can now be pulled out, the motor frat ‘The motor shaft coupling with the inner race and thr Remove the screws from the armature bearing housin| by taking hold behind the bearing. Do not injure the ‘THE DRUM To remove the drum, unbolt either the motor or get through the end of the body piece. ROLLER BEARINGS The inner races for the driving pinion assembly, th assembly and the stem of the main gear cage are heat and shrunk in place. The capacity of the bearings is work to be done that they will never need to be renew or neglect of lubrication which would necessitate renes ‘The inner races will always be furnished as part of the at ofall roller bearings have a light press fit in their housin or pressed out on an arbor press. Pane & yng off the splined shi IONS 50) he load block rests on fandling, grab buckets, inect the power to the hoi Ing and turn the spring remove the spring pressi coil and support it so thle inot practical the wires ai junction box provided ins. emove the gear end he: brake discs and the enti ‘small key is placed in t ind hit the nut a light blow. ith inner race can now to get pull enough on t 1um will be held in appro» Piece. The main internd} eld and remove it with th} hd shield enclosing co loff the three bearing me, butleave the armatur }e end shield; D.C. brus| after removing nuts. Thi fe unbolted and removed. ist ring can be pulled ou and pull the housing of il seal ir end and pull the drui armature shaft coupling}! in oil to 300 degrees F 10 much in excess of the] except through accident jal of the entire assembly f! sembly. The outer races| 48. They can be jarred out]‘TO REASSEMBLE Use care in replacing parts so as not to injure the oil seals. The drum should be lifted and the main gear cage revolved slightly to have the spline engage easily. The stop bolt and its bushing should be coated with white lead or some sealing compound to prevent oil leakage. Make sure that the compound internal gear moves freely through its limit of travel and is turned to the LOW POSITION on the inclines. GEAR SETTING FOR TRIPLE TRAIN GEAR SETTING FOR DOUBLE TRAIN OF PLANETARY GEARING ‘OF PLANETARY GEARING ‘There is a prick punch mark on the side of each compound planet gear. These marks must be located just under the edge of the gear cage as shown in the above illustration when the gear train is assembled in the hoist. Itis best to hold the gears. in position with the driving pinion and assemble the entire gear train in the hoist as a unit. Revolve the driving pinion by hand and check the setting of the gears. if the gears are set properly the prick punch marks will always appear as shown, the gears will go together easily and turn freely by hand. Gear trains having planet gears only, without planet pinions, have no marks and may be assembled at random. Make sure that the compound internal gear is turned counter clockwise as far sit will go so as to be on the low part of the inclines. Replace the load brake rings and gear end head. Keep the electric brake friction linings dry and free from oil when dry type brake is used. ‘THE LOAD BRAKE The main parts of the load brake are the inclines, the ratchet and the friction discs. ‘The inclines are made of class 40 iron and are attached in pairs at three oppo- site points on the main and compound internal gears. The arrangement forms the equivalent of a roller bearing screw. The ratchet consists of a steel outer ring which carries the rotating discs and an Inner core with tapered slots. Each slot contains a hardened bearing plate and roller, the latter being held in the gripping position by a coil spring. [This type of ratchet was adopted as an over-running clutch for free wheeling in the best automobiles; there is no noise or back lash.] The friction elements are a compact set of metal and brake fabric discs. The rotating discs fit on the splined outer surface of the ratchet ring. The other discs are attached either to the hoist frame or the compound internal gear.OPERATION OF THE BRAKE The action of the load, either hoisting or lowering, giways tends to rotate th compound internal gear up the inclines and thus to set the brake. in the hoistin direction the ratchet runs free, the rollers offer practidally no resistance and al the discs are stationary. In the lowering direction the ratchet grips and the Idad is suspended until th rotating discs revolve. In the lowering, however, the action of the motor is opp site to that of the load and tends to release the brake, When the brake pressur is decreased sufficiently by the motor the load descends. If the speed of the loa begins to exceed that of the motor the brake again begins to set. In this way th lowering speed is always controlled by the speed of the motor. ' 1 1 ' { 4 f 1 1 1 1 i 1 i I 1 i I icome (5S) oun Each Industry has condi The tabulation given is only general and may be supplemented by an individual maintenance department program to meet its own particular requirements. Particular attention should be given to corrosive conditions, excessive vibrations, extreme ambient temperature variations, and rough handling conditions. PERIODIC INSPECTION AND LUBRICATION RECOMMENDATIONS The following is a checklist to be followed in performing periodic inspections and preventive maintenance on Cleveland Tramrail Equipment. It is Intended that this, checklist be supplemented with any additional instruction sheets and maintenance manuals sent with each job. ‘The frequency of the inspection and lubrication recommendations presented herein is based upon normal operating conditions of one complete handling cycle every 10 minutes throughout a 40-hour week. If the actual duty cycle of a particular unit is greater or less than this, the inspections and lubrications should be performed more frequently or less frequently in proportion. Ns peculiar to it, which may cause wear of certain parts. Questions regarding damaged, worn or cracked equipment components, should be directed to Shepard Niles Customer Service Department. The recommendations contained herein are to be supplemented by any vendor Instructions which are included with this manual. PERIODIC INSPECTION AND MAINTENANCE CODE: D- Daily 3- Three Month Intervals W- Weekly 4- Four Month Intervals M- Monthly 6 - Semi-Annually 12- Annually ower should be off and locked when performing maintenance on any part of the system. Date: 5/13/94 Rev. K-22665-1 am} itdBulletin No. K-22665-3 K-22665-4 & 4A K-22665-5A & 6 K-22665-7 & 8 K-22665-9 K-22665-10 K-22665-11A Track & Runways Bridge (Mechanical & Motors) Trolley & Monorail Carrier (Mechanical & Motors) Hoist Conductor Bar & Collectors Track Switches Lubricants Recommendations Recommended tightening torques for selected bolts* BOLT OR ‘SCREW SIZE (inches) saggr.s | SAE §R.s = sandnecs | artis 50 Ib. sie. | 10h. 1001.8] aso. | a0 waste. | 26am. | 380 1b. f. yes. | aa0ib.tt. | 600ib. 72 58 a4 78 1 250 tb. ft. 640 Ib. ft. 900 Ib. ft. 1a ‘500 Ib. ft 1201b.ft. | 1820p. n. [a s70lb. tt. | rea0ib.n. | 3160 IDENTIFICA- TION MARKS ‘ON BOLT HEADS, O |9 NO MARK * Alternate tightening method for A325 Bolts: | For tubular Unitor® brackets, use 30% of these values. | 1/3 turn past snug tight for bolt lengths up to 4 times diameter. 1/2 tum past snug tight for bolt lengths 4 to 8 times diameter ‘See latest AISC Manual for more information on turn-of-nt method, K-22665-2A ee ee eS re ee ee ee =conve (G5) raw Inspection Procedure TRACKS & RUNWAYS Track Joints End Stops Paint 12 12 12 12 ‘Check for loose bolts & cracked fittings Chair Washer Suspension Check for: plumb, equal ten- sion* of paired rods, levelness of system, loose set screws. Check roll pins top & bottom. Check for cracks. Make sure that rod swing is not impeded due to interferences. Unitor Suspension Check for: plumb, leveiness of system, cracks, loose set screws and release of brightly colored fluid requiring suspen- sion replacement. Make sure that rod swing is not impeded due to interferences. Check for rail wear (replace if raised tread is gone); Check welds for incipient cracks. Check underside of rail forwear from drive rollers. When groove is 1/8" deep, replace track. Checkside of railforwear. When width has decreased more than 1/8" replace track. Check for loose or worn rivets or if welded type, for incipient cracks. Check forloose bolts orif welded type, for incipent cracks. Clean periodically and repaint where corrosion is present. *Strike with hammer and com- pare sounds. Date: 5/20/85 Rev.End Trucks Girder Conductor Bar and Collectors Motors: Date: 2/26/98 Rev. K- 22665-4 Inspection Procedure Lubricate regreaseable wheels, check for loose wheel bearings, wheel diameter for wear (re- place when 1/4" under original diameter) Check oil level, change oil as. ambient temperature requires, check gear wear, through back- lash, check for worn bearings {excessive noise), loose bolts in gear case cover. Check for thrust washer wear, incipient cracks, loose bolts, lubricate. Check for loose bolts, incipient cracks in welds or casting. See K-22665-3 under track, joints, and end stops. K-22665-9 Feel motor, after active use, for excess heat (130° C. or 266° F. Max. with class "B" insulation). Check D.C. & wound rotor mo- tor brushes & commutators or slip rings for wear, check brush holders andsprings, motorbear- ings and oil seals, tighten loose bolts, blow out dust, lubricate. * See K-22665-11A o_o oe. | i I I I 7con (G5) ram Inspection Procedure BRIDGE Control 6 | Checkforburned contacts: bro- ken shading coils; worn or cracked arc barriers; improp- erly seated armatures; erratic timers or worn timing mecha- nisms; auxiliary contacts proper seating; check mechanical latch devices for wear. Electric 4 | Adjust air gap for wear; check Brakes lining thickness; check for bro- (Disc) ken shading coils; check rotat- ing disc at spline for excessive wear; if wet type brakes, clean outsludge and changeoil; check armature hinge pins for wear and armature guides for bind- ing. Collectors | 3 | Check for tightness of mount- ing brackets. Check for tight- ness of collector shoe on stem. Check for tightness of wire leads. Check for excessive wear of shoe. Replace when top sur- face of shoe is 1/16" above top of stem. Paint 12 | Clean periodically and repaint where corrosion is present. Interlocks | 6 | Check for wear and broken | Spray and parts. If forks do not raise fully, | Molycote Discharge adjust or replace parts. Re-ad- Point just torque limiter if excessive slip is in evidence. Check and adjust for proper limit switch operation.ano (5) ee TROLLEY & MONORAIL CARRIERS Item Inspection Procedure ‘Structural Frame & Load Bars Eye Bolts, Suspension Pins, & Ball Joint Rocker Assembly Date: 2/26/98 Rev. K - 22665-5A ‘Check for incipient cracks in welds and castings. Check for loose bolts. Check for loose or missing set screws oF lock pins. * Grease spherical bearing housing monthly through grease fitting or repack with clean grease at three (3) month inter- vals. Check for cracks and ex- cessive wear. Check for loose bearings, check wheels for proper contact and tracking on rail. Check wheel dia. for wear. (Replace when 1/4” under original dia.) Check axle nuts for tightness. Lubri- cate. Check for thrust washer wear. Check for incipient cracks and loose bolts. Lubricate. Check oil level. Change oil as ambient temperature requires. Check gear wear through back- lash. Check for worn bearings. (Excessive noise) Check for loose bolts in gear case cover. (Do not over-tighten). * NOTE: When lubricating through grease fitting or repack- ing, Eye Bolts, Suspension Pins, & Ball Joint Rocker Assembly shouldbe raised approximately 1/4" = pe eS ee ee ee ee oe(CLEVELAND ® TRAMRAIL ‘TROLLEY & MONORAIL CARRIERS Inspection Procedure Control Collectors Check motor bearings and oil seals. Tighten bolts. Blow out dust. Also see motor manufacturer's recommenda- tions. Check for burned contacts; check mechanicallatch devices for wear and freedom of move- ment. Check for lose connec- tions. Adjust air gap for wear; check lining thickness; check for bro- ken shading coils; check rotat- ing disc at spline for excessive wear; see manufacturer's rec- ommendations. Check for tightness of mount- ing brackets. Collector tubes mustbe vertical. Check for tight- ness of collector shoe on stem. Check for tightness of wire leads. Check for excessive wear of shoe. Replace when top sur- face of shoe is 1/16" above top of stem. Clean periodically and repaint where corrosion is present. Date: 5/20/85 Rev.Inspection Procedure Load Brake Motor Control Brake (Motor) (Disc) Limit Switch ‘Check for broken wires & kinked cable. Check cable anchors; lubricate. Check for hook wear or enlarged hook opening; check hook col- lar for tightness; check’ for jagged edges; loose bolts; cracked shrouds; worn or bro- ken sheave flanges; worn sheave grooves and bearings; lubricate. Check for wor grooves; worn bearings; lubricate. Check oillevel; gear wear; noisy worm bearings.; loose mount- ing bolts; cracks in housing; change oilas ambient tempera- ture requires; lubricate. Check oil level & adjustment. See manufacturer's recommen- dations. See K-22665-6. ‘See manufacturer's recommen- dations. Check contacts; tighten leads; check for loose bolts: binding; lubricate if required. —- = ee ee ee ee ee o_oaouo (5) rms HOIST (Continued) ros (cones Insp. : Lube | Date Item Inspection Procedure Last} Re Code| e Type ingp.| _Temerks Push 3 Check contacts: tighten leads; Buttons check for sticking buttons; check & Pendant ground wire continuity; check pendant cable top and bottom for broken wires; check strain chain to see that any pulling force is not put on pendant cable. Paint 12 | Clean periodically and repaint where corrosion is present. Date: 5/20/85 Rev. K - 22665-8 =)CURRENT CONDUCTOR BAR COLLECTORS Insp. Lube [bate ( i Inspection Procedure Last! Rema tem |code : Type __|insp. Bar 72 | Check forcorrosion, bowing, or sagging. Check alignment at moving gaps. Realign if neces- { sary. fms 1 — oe es Couplings | 12 | Check bolt or screw tightness; Check for corroded contact sur- faces. \ Supports | 12 | Check for loose bolts and/or | ‘screws and bent brackets. Insulators | 12 | Check for loose bolts, sheared support ears, current carrying deposits on surface. Bar 12 | Check for accidental abrasion Covering and peeled covering. Current 12 Check bolt & terminal screw Tabs tightness; check for corroded contact surface. Grounds | 12 | Check for ground continuity; check at load side of discon- nect switch (current off), with Megger, for overall system in- sulation resistance. Collectors | 4 | Check for worn wheels; wheel | + sehlone pins; orslidershoes; check lex- |areaeal type ible leads fromwheelclevispig- | Neal Grae tail or slider shoe shaft; tight- |+ (Luorpiate ness ofleadconnections;check | Brand 630- for cracked insulators; if wheel |aA or efual.} type, lubricate. On type "ST" collectors, check for free move- ment or pantograph, lubricate pivotpins as required. Collector bracket tubes should be verti- cal within 1/16". Bend or re- Place if necessary. Date: 2/26/98 Rev. K - 2665-9 Bee FS SSS Se SS SeItem Insp. Code TRAMRAIL Inspection Procedure Lube Type TRACK SWITCHES Last| Remarks Insp. Outer Frame Inner Frame Slides or Rollers Conductor Bar Jumper Harness Grounds Track Electrical 12 12 12 12 12 12 12 12 12 12 Check for loose support bolts; leveiness of frame in both di- rections. Check for excessive wear at latch holes or on latch cams. Check rollers (should not rock with level outer frame). Check latch pin or rollers for full and positive engagement. Make sure operator fastenersare tight and in proper position. Check crank and fasteners for wear and proper tightness. Clean; check forwearand lubri- cate. See K-22665-9 Check for loose or corroded connections, abrasion. Check for continuity. Check for worn ends; check for raised tread; check for track width; check for cracked welds; replace track or switch if badly worn, Check alignment at rail gaps. Should be within +1/16 vertically and horizontally. If re- alignment is necessary, adjust throw first then shim and align adjacent rails. Check control panel and/or junc- tion box terminals. Check con- tacts, tighten loose screws. Molycote — Date: 5/20/85 Rev. K - 22665- 10RECOMMENDED LUBRICANT LIS: TRAMRAIL Bushings and thrust washers with grease fittings: Multi purpose application and high temperature applicition: Bentone grease type, NLGI Grade 1 (Lubriplate|Brand 930-AA or equal Ball or roller bearings through alemite fittings: Multi purpose application and high temperature applic Bentone grease type, NLGI Grade 1 (Lubriplate|Brand 930-AA or equal Series "W" motor heads . --sesnntfaight mineral oil - SAE-50 Type "MT", “CH & "LT" tractors ...csesesenenneStraight mingral oil - SAE-50 ‘Type "GW" gantry head ... Straight minal oil - SAE-50 Type "CT tractor unit .. a multi-purpose gear oil - SAE-80 Type "HT" tractor unit : ulti-purpose Type "G" gantry head Type "GH" gantry head .. far oil - SAE-80 multi-purpose gear oll - SAE-80 --.eutMulti-purpose gpar oil - SAE-80 Special gantry drive heads ....... ..multi-purpose gar oil - SAE-80 Type “E*,"R" & "RA" motor heads ...... multi-purpose gpar oll - SAE-80 Worm gear drives «2... sesstiestestenA.G.MA, #8 compound TRD drive Compact drives Current collector wheels ... some cases as low as SAE-10), when cold weather arrives. engineer for recommended greases in acid fume atmospherd, Date:2/16/98 Rev. K-22665-11APARTS BULLETIN HES(CF)208 END TRUCK | 1-17426-200 0-75820-400 0-79278-800 0-74209-210 1-17289-000 1-17239-010 1-17203-000 _| 1-08615-000 3 0-79278-200 0-74209-220 {H]tubricate all trunnions with graphite grease at assembly. Description STRUCTURAL END TRUCK FRAME (Includes Ref. Noa.2, 3 and 4) CAP SCREW (8/4"-10 x 1-1/2" long - Hex head) LOCKWASHER (3/4") HEX NUT (8/4"-1 = ES CARRIER HEAD > COMPLETE = Pregréased Wheels ~ (Each includes Ref. Nos, 6 thru 9) ES CARRIER HEAD - COMPLETE - Regreaseable Wheels r BOLT viTH LOGKWASHER (1/2") ‘TRUNNION ‘THRUST WASHER, LOCKWASHER (3/4") HEX NUT (3/4"-18) 1 a 4 4 4 End Truck Section Bulletin RP14.350Ee ee eee eee ee eeBulletin RP19-350 Issue G Hand Power Head Section Page 4 PARTS BULLETIN ESR IDLER HEAD 5 Inch Dia, Flangeless WheelsI ee ee |CUEVELAND ‘TRAMRATL PARTS BULLETIN ESR IDLER HEAD 5 Inch Di Wheels Flangele Bet | wumber Description as T-iia0-010 | [pERR f=AD - COMPLETE - Pregreased Wheels 7 Lol7240-000 | IDLER HEAD - COMPLETE ~ Regreaseable Wheels t 1-17200-500°] [1] SIDE FRAME - ‘Standar< 2 roiaes-o00 | O! Sipe FRAME; For use with grounding snoe only a Toiradi-o10 | FLANGELESS WHEEL ASSEMBLY ~ Pregreased (Includes Ret. Nos. 3 and 4) 2 a | riraci-on0 | PLANGELESS WHEEL ASSEMBLY - Rogrenscable dL |. .... (includes Ref. Nos. 5, 4 and §) ee a g U-74212-770 SAM NUT (7/8"-14) 2 4 0-79279~-000 LOCKWASHER (7/8" 2 3 | ovraioi-t40 | GREASE FITTING - Rogrensoable whee! only (Lincoln #5093) 2 )-10449-500 LT with NUT 7 4 8 | o-tsa7e-400| LocKWASHER (1/2") 4 8 | itraoa-000 | TRUNNION - Standard 1 E-iaci-100 | TRUNNION - For use with fot brake i 1o_| 1-oe61-000| THRUST wasHER eo i “1 4317938-000 “BUMPER EARS — 7 2 To17a3s-000 | STABILIZING ROLLER - For use with 2100 rail i 117298000 | STABULIZING ROLLER - For tse with 3000 rail i Sufoto1.204 | BEARING - For use with stabilising roller (Fair #204-KD) 2 _| Soratoeto | __ GREASE FITTING = For use with stabilizing roller (Lincoln 2 in 495-400 |[Z] REMOVABLE GUIDE ROLLER ASSEMBLY - Complete (Includes Ref. Now, 12 thru 18) 4 x2 | 1-22889-00] a i 13 | tiea2s-a00 | Rowan i t4 | Lareatio| busts i 16 0-74202-180 "| STOP NUT (17/16"-20) 1 16 0-72101-531 GREASE FITTING (Lincoln #5311) 1 {HY wen using stabilizer Roller replace with 1-17200-200 a Hand P. ‘This Guide Roller Assembly - complete - is available as a kit for field replacement of 1-16425-100 Guide Roller, dust shleld, lockwasher, check nut and grease fitting. Sold ONLY ag a Kit & Roller ONLY. Head Seetion Bulletin RP19-350 Tstue G=e eee eee es aeLANL STIS 123! BU CIEE TIN CLEVELAND |=\"\0s| TRAMRAIL H - 3000 IDLER HEAD With 5 Inch Diameter Flanged Wheels for 3-1/4 Inch Wide Track PART NUMBER T= 3000 Garfist Head (Complete | Pregreased Wheels H- 2000 Carrir Head ( Complete ) Regreasable Wheels Flanged Wheel Assembly ( Pregroased ) Flanged Wheel Assombly ( Regreasabie ) 3/4" 16 N.F. Hex Head Cap Scrow (2-12 Long - Grade 5) Rotainer, TRU -ARG (2 5103-112) (0 75337112 Reference Catalog Page 210.00.2 NOTE: Whenever wheels are replaced, wheel pin locks { Item No. 3 ) should also be replaced. = 06615 = 000, = 18494 000) Bulletin RP19-200a PARTS PALLETIN CLEVELAND TRAMRAIL Niles Inc Shep. 3 ' —_ Tee7-at HEAD MOTOR HEAD SECTION EFFECTIVE DATE 6/89 PAGE 1 BULLETIN RP22-310il Type "T" Motor Drive Head Reference Numbers & Parts Locatio! | (SEE PAGE 4 for PARTS LIST) PAGE 2 iTRAMRAIL (UUETIN =(/)) O CLEVELAND PAN RIS meee eee Bn a a es a aPARTS Cuevezano [ OULILETON TRAMRAIL — Type MOTOR HEAD PARTS LIST | REF. | PART NUMBER DESCRIPTION || ry. No. ! ‘4K-25630-30__ [SUB ASSEM.T-DAIVE MTR. HEAD (PREGREASED WHEELS) 1-25830-116 [SUB ASSEM. T-OFIVE MIR, HEAD (REGREASABLE WHEELS] r 7 10-74202-180 | STOP NUT, ELASTIC (7/16") Ti q 2_|1-17227-100 | SHELD a a] -16025.800|ROLLER I g 4 1 K-22689-2 [PREGRENSED] t 4 722689-000 | (REGREASABLE) S| 0-72101-531 | GREASE FITTING ——H] ‘2K-16425.13 | GUIDE ROLLER ASSEM. PREGREASED (INC, FEF_NOS.1-4) 1-18426-400 | GUIDE ROLLER ASSEM. REGREASABLE (ING, REF. NOS. 1-5) ‘S| 0-74208-700 | HEX NUT, (1/2"- 13) ‘7 | T-28003-208 | LOCK WASHER, HELICAL SPRING (1") | a 1-17203-000 | TRUNNION PIN 1 3 1-06615-000___| THRUST WASHER 10_|—1-25899-300 | TRACK WHEEL DRIVE PINION & SHAFT 11_|0-77113-220 KEY, WOODRUFF ( 3/16" x 3/4") i 12_|—0-70102-206 | BEARING { FAFNIR #204 PP) 13| 1-25834-100 | SIDE FRAME Ti 14_| 1-25831-100 [ADAPTOR PLATE 15_|T-28003-206 | LOCK WASHER, HELICAL SPRING (@*) 1 16_|T-28011-208 | SCREW. CAP (378°. 16 HHCS) 1" LONG 17_[-0-74900-475 | MOTOR PULLEY T-39791-CBG | KEY, END (3/16"SO,) 1-5 LONG [ee 0-70255-002 | DRIVE BELT 0-75809-000_ | SCREW, HEX( 14". 30) 12° LONG. i 21_|"¥-28003-204 | LOCK WASHER, HELICAL SPRING (17) 22 | ¥-28011-010 | SCREW. CAP ( 1/4"-20 HHCS ) 1 - 1/4" LONG 23 | 1-25832-100 — | PLASTIC BELT GUARD, ‘24 | 0-70449-500_ | BOLT, SO. ( 1/0"- 13] 10° LONG. 25 | __1-25835-600__ {DRIVE PULLEY - 72 TEETH (HTD) 26 | —¥-28005-204 | HEX NUT (1/4"-20) 27_|_0-72101-740 _ |GREASE FITTING (LINGOLN #5031) ] | 28 [T-28006-314 | JAM NUT, HEX (7/8"= 14 29” | 0-79278-000__| WASHER. SPRING (7/6™ 30 T-28023-704 | SCREW ( 1/4" - 20 RSMS ) 172° LONG | ‘31 1-17210-000 | WHEEL GUARD. 1 | 32 | 2k-17218-4 [DRIVE WHEEL ASEM, - PREGREASED| ING, REF_NOS. 288.25 2-02222-200 | ORIVE WHEEL ASSEM. - REGREASABLE ( INC. REF. NOS. 27,28 © 25) 4 33_[-_1-17200-200_ [SIDE FRAME - TRAILER PAGE 4 Bo we mo