EMH Engineered Material Handling Maintenance & User Manual For Standard Wire rope hoist E & D Technical data, settings & maintenance instructions Please read the instructions supplied with the hoist before installation and commissioning | | | | | ! This document may rot be reproduced or given to third parties and ite content must be divulged or used for other purposes without the prior written permission of EMH, ‘Maintenance & User Manual Poist E8D Lest Revision : 18/06/2015 Lest Edition: 17/09/2018,Engineored Material Handling 1. Designation explanation . 2. General General notes on hazards 2. General description 2.2.1 Components 2.211 Trolley Frame 22.1.2 2.2.13 22.14 2215 2.2.1.6 2.2.17 2.22 Electrical Equipment... 22.21 2.2.2.2 2.2.2.3 2.2.24 2.2.2.5 22.2.6 2.2.2.7 22.2.8 22.2.9 2.3. Owner's responsibilities... 23.1 General safety issues. 2.3.2 Hoisting Machinery Safe Working Period (SWE)... 2.3.3 Duty group. 2.3.4 — Operating environment. 23.5 Safety during usage.. 2.4, Uses for the intended purpose "7 Intended Usage of the Product. 2.5. Liability and warranty. 2.6. Environmental aspec 2.6.1 Sound emissions... - 2.6.2 Disposal / Decommissioning. 2.7. Other notes. 27.4 Storage and Tntereption of # Operation 2.7.2 Other notes... 3. Assetnbly...... 3.1. | Mechanical Installatior Table of contents Hoist Motor with Brake... Hoisting Gear. Rope Drive. Limit of Lift Overload Limit Switch (Optional). Trolley Travelling Gear. Hoist Panel (Only electrical enclosure supplied by manufacturer), Mains Connection Line (Only supplied for a kit crane)... Mains Switch (Only supplied for a kit crane)... Crane Switch (Only supplied for a kit crane, Bus Bar Conductor. Trolley and Bridge Panel . Bridge and Trolley Travel Limit Switches (Optional) Pendant Control (Only supplied for a kit crane, Emergency stop. ‘airtenance & User Manuel Hoist EAD Last Revision: 18/06/2015 Last Edition: 17/09/2018Engineered Material Handling 3.2. Electrical Installation..... 3.2.1 Connection to the Mains. 3.2.2 Main Line Disconnect. 4. Commissioning... 4.1. Electrical Systems. 4.2. Checking the Direction of Rotation of Motors (Hoist Motor). 4.3. Inspection and Testing. 4.4. Inspection before Initial Commissioning 5. User's manual 5.1, Safety instructions for user's. 5.1.1 Personal Protective Equipment (PPE) 5.1.2 Safety instructions. A 5.13 Emergency stop. 5.2, Functions descriptior 5.2.1 Main hoist parts (E hoist) 5.2.2 Main hoist parts (D hoist). 5.3. Main Functions... 53,1 Lifting function 5.3.2 Description of lifting function 5.3.3 Travelling function 5.3.4 Description of travelling function 5.4, — Operator Instructions. 5.4.1 Operator responsibilities. 54.2 Checks to be done before every wor! 5.4.3 Operational Checks with the emergency stop button pushed down. 5.4.4 Controller Setup... : 5.4.5 Operational checks with controller enabled 5.4.6 Movements of Wire rope hois 5.4.6.1 Load handling .. 5.4.6.2 Estimate the carried load.......... 5.4.6.3 Balancing of the carried load. 5.4.6.4 Shock of the carried load. 5.4.6.5. Means of lifting the load. 5.4.6.6 Lockable hook 5.4.6.7 — Load handling .. 5.4.6.8 — Liftins 5.4.7 Travelling Movement: 5.47.1 Explanations.. ; Load control 5.4. 8 Prevent Load swing. Waintenance 4 User Manual Holst E&D Lost Revision : 18/06/2015 Lest Edition: 17/09/2018Enxgineored fal Handling 5.4.9 Safety Procedure after Using the Product 6. Maintenance manual 6.1. General comment 6.14 — Services & maintenance personnel 6.1.2 Crane Log book 6.2. Safety instructions for maintenance personnel.. 6.21 Fall protection. 6.2.2 Main Isolation swite! 623 Safety during maintenance 6.2.4 — Lockout - Tag-out procedure. 6.3. Inspections. 6.3.1 Daily inspections 6.3.2 Periodic inspections. 63.21 General... 6.3.2.2 Limit devices. 63.23 — Electrical components. 63.24 Motors & geor... 6.3.2.5 Mechanical components.... 6.3.2.6 Pendant or remote controls 6.3.2.7 Rope Wedge Protrusion... 6.3.2.8 Rope state of wear, / Replacement criteri 46 6.3.3 Inspections following major modifications. 6.4. — Lubrication 6.4.1 General lubrication instructions. 6.4.2 Lubrication layouts. 6.4.3 Quantities of Lubricants (Gear & travelling gear). 6.5. Wire rope & rope guide. 6.5.1 Removing the Wire Rope and the Rope Guid 6.5.2 Installation of a New Wire Rope and Rope Guid 6.6. Hoisting Gear Brake... 6.6.1” Description of brake structur 6.6.11 —ZFB version. 6.6.1.2 — ZFG/ZFL version Description of brake function Reinovirig the Brake... Retnoving the Brake unit Molinting of the brake. Adjustment of the Air-Gap. Emergency Lowering of Loa ‘Maintenance & User Manuel Hoist E&D Last Revision! 18/06/2015 Last Edition: 17/09/2018EM FH Engineered Material Handling 6.6.10 Functional dimensions... 62 6.6.11 Tightening torques 6.7. Trolley Brake... 67.1 Dismantling of the Brake Type EFB 2 / EFB 3 6.7.2 Assembly of the Brake Type EFB 2 / EFB 3. 6.7.3 Adjustment of the Brake, Type EFB 2 / EFB 6.7.4 Setting table of the Brake, Type EFB 2 / EFB 3 7. Adjustment Instructions for Hoist Limit Switch FGR24&l Typ 7.1. Limit switch description (3 switch points)... 7.2, Adjustment Instructions (3 switch points)... 7.3, Adjust Switch Points.. 7.3.1 Switch Point 1 Emergency Limit Switch Lifting’ 7.3.2 Switch point .3 "Limit Switch Lifting-Upper position" Switch point .2 "limit switch lowering’, Hysteresis (Bo) table. 74,3 Settings table 4/1, 2/1 & 6/1. 7.43.1 Settings & Hysteresis table 4/1, 2/1 reeving HL: Settings & Hysteresis table 4/1, 2/186/1 reeving HL 7.43.3 Settings & Hysteresis table 4/1, 2/186/1 reeving HL 7.4.34 Settings & Hysteresis table 4/1, 2/146/1 reeving HL4: 7.44 — Settings table 4/2 scan 7.441 — Settings & Hysteresis table 4/2 reeving (equivalent frame HL1). 7.442 — Settings & Hysteresis table 4/2 reeving (equivalent frame HL2).... 7443 — Settings & Hysteresis table 4/2 reeving (equivalent frame HL3).... 7.4.4.4 — Settings & Hysteresis table 4/2 reeving (equivalent frame HL4)....73 8. Identification (serial numbers). 8.1, Manufacturer plate for wire rope hoist 8.2. Manufacturer plate for Lifting motor. 8.3. Manufacturer plate for Travelling motor. 9. Tightening Torques ‘Maintenance & User Marcal Holst ED . Lest Revision: 18/05/2015 Last Eaition: 17/09/2018Engineered Material Handling 1. Designation explanation EMH6250 L6-46 4 41 100 E 1990 Whee diameter (rm) Wheelbase Gam) Trofey type: FE, D,DQA, U, SU ‘Model sencation Hook pat m) Rope eeving ‘Motive power unit group Ns Rope speed (ima) ‘Type ot motor Load onpecty (xg 109) Medal size f ‘Maintenance & User Manuel Hoist 64D Last Revision: 18/06/2015 Last Edition: 17/09/2018 i |Engineered Material Handling 2. General ea General notes on hazards Except for products designed solely for operction 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, Severe personal injury or damage to property may oceur as a result of: + the forbidden removal of covers + improper use * incorrect operation ‘+ inadequate repair ord maintenance Feilure to comply with the safety instructions given in this Maru! may lead to injury or even to fatal accidents, The product may present hezards to life and limb if itis operated other then for the intended purpose or by ron- trained or inadequately trained personnel “The operator of the product must ensure that operation and maintenance personnel are instructed in goad 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 jewellery. Rings tmust not be worn when working on the product! Persons under the influence of alcohol, drugs, or medicines impairing their reactions must not perform ary work on or with the product. ‘The product must not be operated in hazardous ctmospheres except where the product has been specifically During operation: Compliance with all the precautions required by this Manual before, during, and after cotnmissioning and all the general safety requirements, especially those concerning operationel 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 o sufficient safe distance from ‘moving or rotating components to prevent pants 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, oll, 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 ta insulation or parts of the equipment. 2.2. General description 221 Components 2211 Trolley Frome ‘The E&D series electric wire rope hoists are equipped with a trolley frame made from welded steel sheets ‘The € series have cn integrated counterweight. The track width can be adepted to mest girder widths. For the b series, the connection between the main girder and the trolley track girder is jointed to ensure that all four wheel are evenly loaded when the hoists in not loaded 2212 Hoist Motor with Brake ‘The hoisting gear is driven by « 12 pole; dual speed squirrel cage motor with integral D.C. rectified mogretic dise broke, Insulation class F, protection type TP 54 or IP 55 (optional). Due to the pole charging there:is a standard ‘Maintenance & User Manual Holst E&D Last Revision: 18/06/2015 Lest Edition: 17/09/2018Engineered Material Handling precision hoisting speed in the ratio of approx, 1:6 to the main speed. The asbestos-free brake lining achieves @ service life of epprox. 1x106 stops. 2213 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 ond run in a closed oil bath with lifetime lubrication. 2214 — Rope Drive The rope drive corresponds to the FEM (European Federation of Material Handling) calculation rules for series hoists, None of the bearing points require maintenance even drums bearing (optionel). The rope guide is made of weor resisting material and provides trouble-free rope reel-off and coreful treatment of the rope and the rope drum, The high-tensile hoisting rope is a special design thet hes considerably higher breaking resistence end life ‘than o rope of conventional design and structure, That is why only original wire ropes from the manufacturers should be used as replacement parts. 2215 Limit of Lift ‘The lift is limited in the highest ard 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: + Emergency limit safety switch - lifting ($31.3) + Upper limit safety switeh - lifting ($31.2) ‘+ Lower limit safety switch ~ lowering ($31.1) ‘The emergency limit switch ($31.3) interrupts power to the mainline contactor (Kt). This switch point is set by the mnanufacturer, and must only be reset by authorized personnel. If for any reeson the upper limit switches (6312), fils to limit the travel of the bleck in the up direction, the power from Kito the crane is shut down by the ‘emergency limit safety switch ($31.3), Subsequent operation of the hoist should only be attempted by « trained service technician. Tf the hoist is run to the highest hook pasition ($3.2) the lift travel will stop and only the lowering circuit will operate until the hook hes travelled sufficiently to reset the $31.2. The lowering limit switch (631.1) 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 travelled sufficiently to reset 31,1. The upper limit (531.2) and the lower limit (531.1) should be checked prior to the start of each shift. For adjustment of the hoist limit switch see Section 10 of this anu, 2.2.1.6 Overload Limit Switch (Optional) ‘This device is installed to prevent exceeding the load capacity of the electric wine rope hoist. This switch is checked durirg the load test after the initial installation. Adjustments to this switch con be mode 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. ‘witch is a micro-switch located on the fixed point cross head for the rope dead end socket. Details of overload safety device are given in the separate operating instructions attached. 2217 Trolley Trovelling Gear ‘Maintenancé-free, gecr driven flanged wheels made by drop-Forging steel and positioned in roller bearings assure ‘good, smooth running trolley, The trolley drive wheels are driven via « pinion gear by 1, TEFC duel wourd squirrel cage motors, D.C. rectified dise brakes are included as stendard, 222. Electrical Equipment. 2.2.21." Hoist Poel (Only electrical enclesure applied ‘by manufacturer). ‘The hoist pate is installed dn the eréne and protections is 1°66 (EN 60 529 /10.91), Reversing contactors are fitted with mechanical interlocks. Allelectric wires are cétviected in junction box installed on the hoist, All aire rope hoists are equipped'with menual motor starters for moter protettion that are set at the factory in accordance with the rated motor current. Tf maintendnce is required, contactors may be reniovéd from their mounts after disconnecting the wiring. ‘Maintenance & User Manuel Hoist EAD Last Revision: 18/06/2015 Last Edition: 17/09/2018,Engi red Material Handling 2.2.2.2 Mains Connection Line (Orly supplied for a kit crene) Conductor cross sections for power supply circuits from the distribution assembly via the mains switch to the contact conduetor 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, 2.2.2.3. Maing Switch (Only supplied for a kit crane) In accordance with FEM Specifications: it must be possible to disconnect a crane or hoist and to lack out the Power supply using a mains switch, A crane disconnect mechs, either a current-reted cireuit breaker or motor rated switch, lockable in the open position, shall be provided in the leeds 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), 2.2.2.4 Crane Switch (Only supplied for a kit crane) ‘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 « contactor coded Ki". 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 ard de-energized with the emergency stop button, (See cireuit diagram). 2.2.2.5 Bus Bar Conductor The bus bar conductor systems are used for solo trolleys and crane systems and arer't supplied by manufacturer Three copper bus bars (three phase conductors + protective earth) 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 ond 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. 222.6 Trolley and Bridge Panel Ina standard configuration, the trolley pare| is installed on the wire rope hoist, the bridge panel is installed on ‘the bridge girder or bridge end truck and both have TP66 (EN 60 529 /i0.91) protection, In the case of wire rope. hoists installed on solo trolleys, the trolley pone! houses standard fuses as the main fusing (F1), the main contactor (Ki) and a control transformer with fine fuses on the primary and secordary sides in accordance with the transformer rating, When a bridge ponel is provided the abeve components will be located in it, All wine rope hoists are equipped with manual motor starters for motor protection that ere set at the factory in accordance. with the rated motor current and sealed. Tf maintenance is required, contactors may be removed from their mounts after disconnecting any wiring, 2.2.2.7 Bridge and Trolley Travel Limit Switches (Optional) ‘Advance slaw-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 cgainst the end stops at high speed, which could cause severe locd 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 ct 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, 2.22.8 — Pendant Control (Only supplied for a kit crane) Motors are operated using two-stage spring-loaded switches, It is recommended to use the first stage for load positioning work, Frequent inching may darnage the motors and switch gear. A mechanical interlock is provided to Prevent simultaneous operation of the controls for both directions of travel 22.2.9 — Emergency stop Sean ie + Tf the crane travel motors fail to obey normal control commands and a hazardous situation may occur, + Tf the crane operator leaves the control position, ‘Maintenance & User Manual Hoist E&D Last Revision: 18/06/2015 Last Edition : 17/09/2018Engineered Material Handling 2.3. Owner's responsibilities sivcsur cic approval ‘resporslbility far dccidents which hh Information «| A Werning ‘Maintain safe conditions under the load ‘Ouners SHALL make it clear to all parties (including operator, service personnel and visitors), that no-one must ever venture underneath the load for ‘ary reason, This rule must be respected at all times, ‘Maintain the lighting ‘Owners SHALL ensure that there is adequate lighting, in good working order, at $ the operating site so that the equipment can be operated safely and efficiently at all times, ‘Maintain walkways and service platforms Owners SHALL ensure that there ore adequate walkways and service platforms on the equipment and/or adequate equipment at the operating site for servicing and inspecting the equipment. Walkways and service platforms must be kept ina safe condition and free from obstructions. ‘Maintain operating and safety requirements Quners SHALL ensure thet the equipment meets the applicable (local and global) safety and operating requirements. ‘Keep’ the. product in-a safe condition ‘Owners SHALL ensure that the equipment is kept in a safe condition, For exemple ell warring devices must be kept in goed working order. Fire safety i | | Owners SHALL ensure that personnel ere prepared in case of fire and that thé . correct firefighting equipment is available énd maintained, ile i First aid; ‘ ‘Owners SHALL ensure'that, in accordance with local regulaticrs, personnel are Prepared in case of accidents and that a suitable first-aid kit is available ond » Lmaintained, = ‘Maintenance & User Manual Hoist EAD Lest Revision : 18/06/2015 Last Edition: 17/08/2018| Emergency Stop devices Owners SHALL ensure that they, and the operators, know the locations of . "=p | emergency stop devices so that they can be activated in emergency situations, 1 Emergency stop devices should never be used as a substitute for mcking proper use of the direction controls, Routinely using the emergency stop button increases wear on the product components and can couse the load to swing Keep the working site clean ‘The working site should be kept free of clutter and dirt, Oil spills must be. =< cleaned up immediately to reduce the risk of slipping. 2.3.2 Holsting Machinery Safe Working Period (SWP) Based on how the hoisting machinery will be used and on the actual hoisting machinery hardware supplied, the i manufacturer will agree the anticipated hoisting machinery lifetime or safe working period (SWP) with the customer at the time of purchese. ‘The total lifetime of hoisting machinery consists of one or more Safe Working Period (SWP) where each SWP typically losts around ten years when the equipment is used in accordance with the designed usage. Tt is possible for different hoisting machineries on the same crane, for example main and auxiliary, to hove a different SWP, The SWP is the period in which, provided the equipment has been used and maintained in line with the original expectations, the equipment con be safely operated. 00% om swe = Safe Working Pead : B30 = Pradloted General Ovettssul i 450 = Abtual General Qverbau! Tr = Tine In practice the lifetime of the equipment can vary due to changes in the environment and usage of the equipment. For safety, in cecordance with the LSO 12482-1 standard, it is Important for authorized service personnel to periodically check the equipment duty group and operating conditions regularly For any changes, then to revise the remaining SWP% upwards or downwards accordingly. This action ensures that the equipment is kept operating for 2s long as it is safely possible before « General Overhaul must be conducted. 2.3.3. Duty group Selection Crite + What is the moximum weight of load? + What speed must be lifting the load? + What's the true height lifting? + What are the operating conditions? ‘The following criteria are necessary for classify an electric wire rope hoist into @ certain driving gear group acc ‘to DIN 15020 or FEM 9.511 and for selecting the suitable type. Maintenence & User Manual Hoist E4D Lest Revision : 18/06/2015 Lost Edition: 17/09/2018‘Engineered Material Handling dium operating time per work 2 x mean stroke (tn) x eyele (1/h) x working time (h/day) 60 x lifting speed (m/min) , 2. Nature of feed: This load can be estimated with the cid of 4 ideal collections : (kecubic mean value of the collective load in relation to the load capacity). Load- 7 ‘Mean operating time tm per ene Definition of load collective svorking day tn h 1 light) | (s0.5) only exceptionally peak ‘stress, mainly very low strain, smell decd load. 2 | 24 | 48 | et6 | 16 2 (medium) | (0.5:ks0.63) Frequently peck stress, permenent low strain, medium dead load. 1 | te | 24 | 48 | ate 3 (reavy) | (0.63:k:0.8) Often peak stress, permanent medium strain, heavy dead load. os |ost} rz | 24 | 4a Avery | (08k) heavy) | Regulary max. stress, very heovy dead lod. 0.25- i 025 | Oe | ost | te | 24 | hetepe me | uty group-aée.'to BIN or FEM 9,811 dem | iam) 2m] 3m | 4m | ‘Authorized serviee personnel m i | group. Owners and operators seul ttecognize that any: changes to produét uistige could, if left unchécked, raise overall maintenance costs and considérably reduce the safe operating lifetime’of the product. Changes to any of ‘the parameters and Variables can require the duty group to be revised. Tf there will be ‘significant permanent changes in the product usage, authorized service personnel must revise the duty group and SWP as necessary. Changes to hardware or servicing frequency may be required ‘Maintenance & User Manual Hoist EAD Last Revision: 18/06/2015 Last alton 17/09/2018Warning Engineered Material Handling 2.3.4 Operating environment A Using the e “Thulllredu If the operating environment deviates from the environment specified when the equipment was ordered, contact the manufacturer or manufacturer's representative, Solutions are available to enable the equipment to work ina wide range of operating environments, If the equipment for general use will be used in exceptional ambient conditions/temperatures or to handle dangerous materials, consult the manufacturer or manufacturer's representative. Examples of exceptional ambient conditions include windy areas, earthqucke zones and corrosive atmospheres, Molten metal is considered to be a dangerous material. ‘The equipment for general use may be used in.a normal default industrial environment only, with the following limitations Tadeor products must be situated indoors, protected from outdoor weather conditions. + The maximum ambient temperature must not exceed +40°C (104°F) / +65C on a short-time (10 min). ‘+ The minimum ambient temperature must not go below -B°C (14°F). = The air must be clecn in accordance with EN standard 1461-1 1999. + The equipment must not be exposed to any corrosive chemicals or an explosive atmosphere. = The equipment must not be located in an area prone to earthquakes. + The air relative humidity must not exceed 85%, 2.3.5 Safety during usage ‘The operator training is under the responsibilities of the Owners, Owners SHALL ensure that operators are properly trained, Operators must know how to operate the equipment safely before sterting to work with the equipment. 2.4. Uses for the intended purpose / Intended Usage of the Product ‘The system described in this document is fit for the carnying and lifting of loads subject to the maximum load capacity and the FEM (European Federation of Material Handling) or load group for which it has been designed. Load capacity, FEM group, and load group are: indicated in the data sheet or test book of each product, ‘The hoisting machinery for general use is suitable for use in general manufacturing only: itis not suiteble for use in horsh environments. Refer to "Operating environment", Please contact the manufacturer or manufacturer's representative in case of doubt. ‘Among other things, equipment is not considered to have been used for the intended purpose if + the maxirum admissible load capacity is exceeded + loads are pulled diagonally + loads are torn away, dragged or pulled + itig.used to catch falling loads + itis used to lift persons with or without loads + inching operotion «reversing operation (operation of opposite direction when system is in motion) + intentional operation against emergency end stops (See also "Sefety Instructions for Users") ‘Waintenance & User Manual Hoist E&D Last Revision : 18/06/2015 Lest Edition: 17/09/2018Engineered Material Handling 2.5. Liability and warranty The manufacturer will assume no liability for cry damage to the crane or hoist resulting from abrormal operation ‘or work performed improperly or by unauthorized personnel or for claims by third parties. For the safe and reliable operation of the product and for the retention of warranty rights, i is essertal to use orginal ports when you need spare parts. Safe operction is only possible within the service life stated if the cerane/noist is operated within its rating and the manual 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. ‘The products must be maintained and repaired only by trained, authorized, personnel. 2.6. Environmental aspect 2.6.1 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 distence of 4m (14 feet) inthis case), The sound power level may be used to calculate the sound pressure level at ary distance (under free field conditions + 2d (A)). 832 62 ; 82 2063, 66 86 3125 67 87 5160_ oa | 88 6250 68 2.6.2 Disposal / Decommissioning Waste material from installation, maintenance or regulations. ismartling shell be handled and disposed of eceording to local THe prefered waste healing methods are, staring withthe most preferable prevention, reuse, recyele, Fecovery, dhd as a final Fesort, Safe disposal. 1 “As woste regulations and types of avilable recovery and dipobal methods vary regionally, ro general detailed guidance can be giver. Alwcys use licensed waste-handling companies. In mary cases, multi-metal scrap is the avellable hendling method, Before that, eléetric parts and lubricants must be removed and handled separately, ‘Mainterance & User Marval Poist E4D Last Revision: 18/06/2015 Last Edition: 17/08/2018Engineered Material Handling When the products ere ne longer needed, they may be disposed of in an environmentally compatible way. the 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: Crane brigdes Track girders Separation of materials Trolley frames | Metals Recycle by remelting Motors Gearboxes Drive component 7 Broke linings ‘Multi-purpose ‘On special landfills in according with components applicable local regulations Protection hoods Recycle by remelting |, Celllose buffers Plastics incineration Housings or to special landfills ‘Treatment or disposl in according Lubricants ils ond greases with regulations, eg, incineration 1 Cables, Housings Rubber, PVC, ‘Seporetion of materials Connectors Silicone Pendant controls Pep Recycle by remelting Electronicx Plastics, Metals (On special landfills in according with components Elektrolytes applicable loca! regulations Pointed products must either be recycled on disposed of on special landfills in accordance with the epplicable local regulations, 2.7. Other notes 2741 Storage and Interruption of Operation If the crane system cannot be installed directly af ter being delivered, or if the crane system will not be used for «longer period after being installed, or if there are longer periods of intermission, the crane system has to be stored in a cleen, dry area, The crane system and its components hove to be protected against damage, dirt, end corrosion, EF necessary, ask the manufacturer for appropriate measures, 27.2 Other notes ‘The installation, operation and maintenance instructions must always be stored near the hoist 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 owner of ahoist is responsible for supervising operating personnel to ensure that travelling cranes are properly operated The products are manufactured ond tested and must be operated in accordance with the requirements of Europeans codes, stardards and regulations. Maintenance & User Mancol Holst E&D Last Revision: 18/06/2015 Last Edition : 17/09/2018 | | | | |Engineered Material Handling ‘The following codes, standards and regulations are opplicable 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: UNE-EN98/37/Mechinery Directive. UNE-EN292-1/2 Security of machines FEM 9.511 Classification of mechanisms. FEM9.661 Dimensions and design of rope reeving components. FEM 9,683 Selection of lifting and travel motors. FEM 9.785 Measure for achieving safe working periods for motorized serial hoist units (S.W.P). FEM 9,761 Lifting force limiters for controlling the loading of motorized series holst mechanisms. FEM 9,811 Electric wire rope hoist specifications. FEM 9,901 Rules for the design of series lifting equipment ond crenes equipped with series lifting. The product will oniy continue te perform reliably to your satisfaction in the long term if It is operated, ‘maintained, and repaired by persons essigned to these tasks by the operating establishment. Such persons must be familiar with the installation, operation, and maintenance instructions ond the applicable safety regulations ord ceccident prevention regulations. ‘The‘operating instructions must be available to the personnel responsible for repair and maintenance work at all times, ‘The 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. Maintenance & User Maral Poist E4D Last Revision : 18/06/2015 Last Edition: 17/09/2018Engineered Material Handling i | EM-H a Caution 3.1. The installation of electric wire rope hoists must only be carried out by authorized persons, Electric wire rope hoists are supplied correctly reeved with hook block and counter-weighted if required, ‘Monorail hoist trolleys are delivered pre-adjusted for the specified Flange width, The clearance between the beam and wheel flanges should amount to 2.5 mm on each side, ‘The trolley gauge is adjusted to the desired gauge width of the double girder crane. The lateral play between the trolley track and the wheel flanges should amourt to 7 mm on each side. Tf necessary, corrections can be made by inserting washers or by reducing the length of the spacer tubes. If the beam is open at the ends, the trolley can be pushed on, Bumpers trolley for end stops must be installed on runway ond are available from your manufacturer if they are not in place. If it is not possible to push the hoist on to the end of the beam, the trolley bolts must be loosened and trolley frame split. The hoist must be properly secured and lifted into place. See attached drawing for hanging points. The trolley bolts and nuts must then be re-tightened, Rubber wheel stops must be used as end stops, During commissioning, it may be found that not all of the four wheels are in contact. Tn this case, the trolley must be adapted to the track. To do so, attach a load of about 25 % of the load capacity to the load hook and lift it about 5 cm, Then loosen the nuts of the four tension bolts one turn and then tighten them with the specified torque (see next chapter). 3.2. Electrical Installation ‘Switch off power supply before starting work at any electrical installation, Have work carried out by trained personnel only. Connect the cables in the bri Hn inthe circuit diag Y, Conmect the cables In the br in og ee ~ Caution ft 3.21 Connection to the Mains The operating establishment must connect the system te the mains power supply 3.22 Main Line Disconnect ‘The mainline disconnect switch must be wired so that it will switch of fall 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. | ‘Maintenance & User Manual Holst €&D Last Revision: 18/06/2015 Lost Edition: 17/09/20184. Commissioning Before starting to operate the new installation, check the following points: + Have all fastening devices been properly tightened and locked? © Check the evel in the holsting gear! (See lubrication chapter) + Has transport coused damage to the wire rope? — + Make sure the wire ropes fit tight at the rope clamps on the rape 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? Tn case of @ 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, + Does the hoist limit switch cut off the at highest and lowest hook position? For adjustment of the het limit ewitch see next chapter of this manual i ve crare systemmusibe h must be sched aff ards severe the sir tch ogcinst unauthor zed a laced oe fone i oe f 4.1. Electrical Systems ‘The service life of electrical switch gear depends on the way in which itis operated. The erane operator must be informed thet inching Is not the best way of reaching.a precise position. Since the crane has two or more speeds, inching operation can largely be avoided, 4.2. 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 LZFTING 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 conducters of the power supply cable must be interchanged, ZF you do not ensure that the hoist motor rotates in the correct direction, damage may occur. Comprehensive knowledge of the mechanical and electrical systems of overhead cranes, 2 sufficient experience it the assembly and repair of cranes. : : = Comprehersive | lniiedge ‘af the state of the art of crane festing ahd of the opplicabie codes and standerds that opply and of safety regulations e.g. accident prevention regulations The requirements of all applicable fatona, ‘state ond local regulations must also be taken into consideration during the testing and inspection 4.4, Inspection before Initial Commissioning Waintenarce & User Manvel Hoist EAD ‘Last Revision: 18/06/2015 Last Edition: 17/09/2018Waterial Handling = MH | ‘The acceptance test before initial commissioning must be performed by the inspector on a crane ready for operation under rormal operating conditions. During the inspection, no-one must be exposed to avoidable risks, Personnel required for operation durirg the inspection including crane operators and load handlers must be provided by the organization operating the crane and must be suitably quelified for the work which is involved. All persons involved in the inspection must be able to communicate effectively with each other during the. inspection, TF direct communication between control points and load handling points are not possible, the orgenization operating the crane must provide suitable communication systems, ‘The inspection must include at ¢ minimutn 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 ond all brakes for proper operction and ef fectiveness, | «Inspection of any required safe distances, ‘Dynamic lood test at not less than 1.1 times the rated load copacity of the crane, The following test must be conducted in accordance with National Regulation or if it not exists according FEMS.751: = Dynamic load test at 110 % of the rated load capacity of the hoist/erane, + Inthe cose of slewing jib cranes, the most unfavourable position is the position with the jib fully extended, + In the case of all other cranes, such as bridge cranes, celing-mounted travelling cranes and suspended monorail systems each movement with the dyrainic load test must be made on all the running distance available. + Lf the crane contrél system allows several simultaneous mavernents (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, * Static load test (no Further movement apart lifting movernent). This test has also to be carried out under most unfavourable conditions. The most unfavourable position is with the trolley positioned at the centre of the spon, If there are 2 trolleys on same beam and if they con be used at same time, the unfavourable position is when they are together at center of the span, In this case make static test simultaneously. + Crones must be tested at 1.25 time rated load, ‘The load must be lifted slowly until itis just above ground level. There must be no permanent deformation or evident defects in the crane, ‘The acceptance test in cccordance with ar ete ce AG ereaured ate ara cl guns Sh se ian ta ance te re ae eee acon Caution nas pene etiae een ni ‘Maintenance & User Manual Hoist E&D Last Revision : 18/06/2035 Last Edition: 17/09/2018Engineered Material Handling 5. User's ‘manual Safety instructions for user's Personal Protective eee (PPE) he a wc ert fo erst ‘ki Srthiment shall be fl owe, For safety, the operater or others in close proximity to the product mey be required to weer Personal Protective Equipment (PPE). Various types of PPE are available ond must be selected according to the requirements of the working environment. Some examples of different types of PPE are: apt Appropriate clothing must be selected for each task. For example: + Fine-resistont clothing must be worn when welding, flame cutting or using an angle grinder. + Tear-resistant clothing must resist damage from sharp edges in the steel structure. + Anti-statie clothing must be worn when working on electrical circuits so thot components do not get damaged by a discharge of static electricity. + When working with lubricants, clothing must prevent direct skin contact with the lubricant ‘+ Clothing should be chosen with consideration to the temperature at the working site. 5:2. Safety instructions Release all locking devices before starting crave. Switch aff the ain ine sconnect switch In hazardous situation. At the end af the hrk ay, put te lad supendion devices sucha grab or magnet on thé grou, pl up the empty hook, and home the crane. Any; locks, which are avallable, must be operated and the main line disconnect switch must be switched off, i All accident prevention regulations and regulations issued by local authorities, especialy the operating instructions for cranes indi¢ated on the respective plate have to be-adhered to when operating or attending to the crane. The instruction plate hos to be affixed in a pasition where itis clearly visible ta the crane operator ot any time, Maintenance & User Manvel Hoist 64D Last Revision: 18/06/2015 Last Edition: 17/09/2018EMH fs Engineered Material Handling ‘These notes meinly consist of excerpts from the, "German Accident Prevention Regulations, VBG 8", The term “crene* which will be used in the text below, also stands for trolleys running on rails, “Crane Operator" is the person operating the erane wherecs "crane attendant” means the person responsible for the maintenance of the ‘erane 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, + Before the initicl 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, + Cranes must be inspected by an expert commissioned by the operating establishment ct 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") ‘+ Results of such inspections must be put down in writing and Kept on file, + The following groups of persons may be employed as crane operators or crane attendants: + Persons who have completed their 18th year of oge. * 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 thein qualifications to the company. ‘+ Persons who can be expected to reliably Fulfil the tasks assigned to them. These persons ore required +o have been appointed crane operators or attendants by the establishment. + 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 ony 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, ‘+ The crane operator must stop crane operation as soon as any defect jeopardizing operational safety becomes apparent. + The crane operator must notify the resporsible supervisor at the time of detection and also at'the end of his shift, the relief operctor - of any defect detected on the crane. + Controlling equipment must only be operated from operating stands or locations, +The crane operator has to make sure that + Before releasing the power supply to the drive units, all control units cre 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. + Inthe event of « storm or when finishing work, the crane operator must make sure that cranes exposed to wind ore properly secured by means of locking devices, ‘+ If the crane operator cannot observe the load in all crore 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 opply to program-controlled cranes, | + Tf need be, the crane operator must give warning signals, | + The load must not be lifted ever passenger creas unless, detachment or faling of the load or parts of the load from the load suspension device are excluded. + Tormove 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 whe has been appointed by the operating establishment. Insofar as the communication with the crane operator requires the use of signals, the signcls must have been previously cgreed upon between the crane operator and such competent person. Thaintenance &User anual Poist EBD Lest Revision 18/06/2016 Last Edition : 17/09/2018Engineered Material Handling + As long as the load Is suspended from the hook, the crave operator must keep the controlling unit(pendent or ‘radio control) within eosy reach, + Regular crane operations approcching the final position, whichis limited by an emergency stop device, are only ‘adinissible if an additional stopping device is series connected, With program-controlled cranes, all working and traffie areas must be safeguarded in such « wey that the crane in motion or any felling objects will not ‘cause damage to persons or property. + Crane loads may not exceed the admissible maximum weight capacity of the crane or hoist. + The operator has to make sure that when placing objects ‘to be lifted near the crane there is a safe distance. of ot leest 1.5 feet between the external movable parts of the erane end these objects, + Inthe event of an overlap of the working rorges of several crares, 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, ‘+ Tf 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. + Maintenance work must only be carried out after the crane has been switched off. Ary maintenance work that ‘cannot be carried cut from the ground must be affected from working stands or platforms. When carrying cut maintenance of repair work at the ercne, the crane must be unloaded and the mainline disconnect or isolating switch must be switched off and protected from unauthorized switching (locked out), Eech 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, For the maintenance of and repair work at crares with no servicing platform a stationary or movable working platform must be available, ‘+ For repair and maintenance work on cranes and in the crane travelling crea, the operating establishment or his ‘gent must see to ond supervise the following safety measures: +The crane must be switched off and safeguarded against erroneous or unauthorized re-energizing, + Tf there Is any risk of objects falling down, the risk area underneath the crane must be closed of for by posting guards to the site, + The crane mist be sofeguarded against collision with other cranes by meors of rail stops limit switches ‘or by statioring 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. ‘+ Lf 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 arvange for different ‘or supplementary measures to be taken and supervise the execution thereof. + ‘Unauthorized pefsons are not allowed to walk onto a crane, + Crahes that are being operated by a crane operator shall only be entered or left with the consent of the ‘erane operator or when the crane has come to-a standstill, +" Before hoisting a load, make sune you know @ safe and effective path for the load, Ensure that the load will not collide against objects or people. » Tt ls strictly prohibited to carry passengers together with the load or by means of the load suspension ‘devices, ‘Maintenance & User Marual Hoist 4D Last Revision 18/06/2015 Last Edition: 17/09/2018Engineered Material Handling ai + Donot go under the hook or load, Do not move the hook or load over @ person, A load must never be lifted ina way that ean injure « person if the load crops. ‘Th. +The load mey not be directly slung by means of the hoisting rope or chain; hoisting ropes on chains or such shall not be bent or pulled over sharp edges. * Before hoisting, check that the hoisting devices are securely positioned on the bearing surface of the hook ‘and that the safety catch on the hook is clased. + Ensure that the lood's mass centre is on the centre line of the hook forging so that the load does not bend ‘the hook neck, + Ensure that the force is applied only to the hook's bearing surface (the lowest point of the hook). Force epplied to other parts of the hook black will eause undesired stresses, Forces on ramshorn hook have to be equal on both bearing surfaces OMe ‘+ Before hoisting, check that the load is balanced and sofely fastened at the lifting points. x + Before hoisting, ensure that the load cannot slide, slip or detach itself when suspended ‘+ Ets prohibited to drag or to pull the load sideways or to move vehicles with the load or the load suspension device ‘Maintenance & User Manual Holst €&D Last Revision: 18/06/2015 Last Edition: 17/09/2018Ty Ay Caution + When using a lifting accessory (sling, belt etc}, always follow the instructions provided by the lifting accessory manufacturer ‘+ Tf two cranes are needed to handle a load, a balancing beam must be used to equolize the loading, Combined hoisting with two cranes must be supervised by a foreman knowledgeable about cranes, or by @ crane ‘specialist, whois then in overall charge of the lifting operation, + Start and stop the travelling motion at low speed to prevent the load from swirging excessively. Avoid swinging the hook or load during travel motion, + Dorot opercte the hoist if you know that medication, a alertness or working ability. Iness, injury or other such handicap impairs your ‘+ Reise the load high enough to prevent it from hitting objects during travel. However, do not raise it higher ‘than is necessary for the situation, Do not raise the hook to the top sofety limit. ‘+ During hoisting and travel motion, ensure that the hook, the load, the crane and its moving parts do rot collide with object or people, + Tf the hoist is provided with @ horn, sourd the horn when you move the load in the vicinity of people who are rot paying attention to the moving load. + Do not move the load until you have received a sighal from the person attaching the load to the hook or lifting Appliance. + Donot use the overload protection for weighing the load. + Stop all hoisting and travel motions before the safety limit switches, ‘+ ..De not adjust or bypass the limit switches or warning devices in order to go past motion limits. Do not use the _hoistif the limit switches are inoperative ‘+ “Tf the manually-adjusted backup limit switch in the holst has triggered, call a serviceman to the hoist ard osk | hit to determine why the normal safety limit switch did not function. + Do hot use the hoist if there are visible defects in or damage t0 the hoist, the hoisting rope, or any other hoist structure ot hoist function: Stop operating the hoist if it operates abrorinally (for example, a high noise level, uneven starting oF malfunctions). Using feulty equipment ls strictly prohibited, +. Tf defects have been roticed ithe holst, carry cut the neeessary ispections and servicing Ensure thet the holetGpertes properly Before you strt fous tojin © Do not use the limit switches #0 stop. the motions of the hoist. Hoist indtieha Hust bo ‘stopped with the. «01 pushbutton eontfollet or other cbntrol device intended! for the purpose. © "Use the proper pushbuttons intended for controlling the hoist. Tf you feel'you dre losing control of the hoist motions, press the emergency stop button. Zn a potentially dangerous situation all hoist motions-ean be Waintenance & User Mancal Hoist EAD Last Revision: 18/06/2015 Last Edition: 17/09/2018Engineered Material Handling stopped by pressing the emergency stop button, but do rot use the emergency stop function unnecessarily Ensure that it is safe to re-commence working after the emergency stop button has been pressed ‘Avoid short, jerky motions, Unnecessary short starts cause the hoisting motor to overheat quickly, The last controller step is for normal drive, The intermediate steps are normally used for short durations only. Do not switch the controller back and forth unnecessarily because it causes wean, — J, Gi ab yo = Leite 7 Avoid violent collisions into others hoists or against bumpers. Do not leave a suspended load unattended, Do not lower the hook so far that the ropes become slack. co L l Does not use hoist motions to remove the lood from the hook, De not veld on « hook that is not isolated. Do not fasten a welding electrode to the hoisting rope. Do net change the size of fuses. A qualified electrician should carry out all electrical work. ‘At the end of work time, Raise the empty hook or loading device high enough to avoid it causing a hazard to ‘traffic, but not to the top safety limit Leave all controls in the O-position, Press the emergency stop button to open the main contactor. Turn off the safety switches for control current and main current. (Close any mechanical brakes, such as rail elamps, ete, Inform your foreman of ary defects you have noticed, Inform the next operator of all cbnormalities in equipment or operation that you noticed. ‘Maintenance & User Manual Holst E&D Last Revision : 16/06/2015 Lest Edition : 17/09/2018Engineered Mati Handing ‘After repair or maintenance work or after any work carried out in the erane travelling area (runway), crane. operation shall only be started if the operating establishment or their agents 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 erane have been restored + Ail persons having participated in such work have left the crane and travelling area, When operating additional crane/hotsting equipment, the corresponding special instructions may have to be followed, IF additional equipment is subsequently installed on the crane, itis the responsibility of the operating establishment operating the crane to check whether such additional equipment is admissible and Suited for the crane installation, Moke 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. ‘The operator must ensure that the workplace is adequately lit. 513 Emergency stop 4 { yp I In the event of a equipment malfunction or other emergency situation, all motions can be stopped immediately by pressing the red emergency stop button located on the cortreller. Zn normal operation, the emergency stop button should not be used instead of making proper use of the direction controls, Routinely using the emergency stop se the load to swing. ‘Wainebhorce & User Wariel Feist EED “Last Revision : 18/06/2015 Last Edition: 17/09/2018Engineered Material Handing ae | 1 lor 2_| Travelling motor Composed of Gear, Motor & Brake Fe 2or4 | Drive wheels (on option 4 drive wheels) 1 3 2or0 | Idler wheels | i" Composed of frame, Lifting unit (Motor, Gear & 4 | ft [Satbre | Brake), Drum, Rope guide lifting limit switch | 1 | SA* Travelling Composed of frome & counter weight : i i, Travelling shaft 1__| Pendant or remote control _| Remote control on option 74 Hook 1 Rope | 10 1 Electrical hoist enclosure ‘SAM Sub-Assembly 5.22 Main hoist parts (D hoist) i 1_| 2 _ | Traveling motor Composed of Gear, Motar & Brake 2 | 2 | Traveling unit Composed of steel body d wheels (drive & idler) __ | Composed of steel bracket & a bar (for return | - te eee or bere sheave/equclizer sheave / Dead end point) eZ Tacs Ura atl PED (eat Revin 1706/2015 Lest ton: 1709/0018 |Engineered Material Handling Composed of frame, Lifting unit (Motor, Gear & BH Secor: Broke), Drum, Rope guide & lifting limit switch 5 | _1__[Hook 6 [i Rope 71 | Pendent or remote control | Remote contral on option | 1 | Electricol hoist enclosure 5.3. Main Functions 53.1 Lifting function 1 Brake: 8 End point (Wedge box) 2 | Motor 9 | Hook, [3 | Gear 10_| Sheave 4 | Rope Guide 11 | Emergency stop button [5 | Drum SHED 12 _| Pendant (or remote control 6 | Rope clamp 13 _| Electrical enclosure ] [7 TRope 5.3.2 Description of lifting function +. When the relevant buttoris activated on the pendant or radio controller (12), the hock (9) moves vertically provided that certain conditions are met, ‘+ The product has 4 variety of automatic built-in safety Features which, for example, prevent lifting overload, limit travelling hiovements'dd prevent all the movements if the emergency stop button (11) is engaged, In addition, there can be operating Hite (set by the owner/operator) which also limit movements under certain conditions. “Whe the hoisting buttot (s activated on the controller (12), a commend elget to the electric panel (13). + +The direction (up or down) of the hoist depends of which button is pressed, The speed of the hoist depends onwhich step is ectiveted. | ~The electric panel (13) controls the brake (1) and motor (2) in accordance with ies: from the operator, | fogether ith signals from jhe sensors and safety devices. ing riven; the breke (1) holds the motér in place, preventing't from turing Unintentionally and the loca! from sliding down, Waintenance & User Manuel Hoist E&D Last Revision: 18/06/2015 | Lest Edition: 17/08/2018Enaineered Material Handling + When a signal is transmitted from the controller (I), the electric panel (13) supplies power to the motor (2) and releases the brake (1). + The motor (2) drives the hoisting gear (3) which drives the hoisting drum (5). The hoisting gear (3) reduces ‘he rotation speed and increases the torque to lift the load, ‘+The wire rope (7) wraps of urrolls when the hoist drum (5) rotates, The rope guide (4) guides the wire rope | into the correct grocve of the drum, + At the end of the wine rope is fixed to the hoisting drum (5) with « rope clamp (6). The other end of the wire ‘rope is connected to the wedge box (end point-8), + The rope posses around the rope sheaves (10) into the rope anchorage (8). The hook block move up and down when the wire rope is rolled or unrolled onto the helsting drum (5), + Tnnnormal use, when the up om down control is released on the controller (13), the control clases the main brake and brings the hoist to-a gradual, controlled stop. + Inemergency situations, the emergency stop button (11) on the controller (13) can be activated. This causes Caution "Gear Rail Drive wheel Emergency stop button Pendant (or remote contrel) Electrical enclosure. Brake ‘Motor 5 6 7 8 5.3.4 Description of travelling function + When the relevant button is activated on the pendant or radio controller (1) the trolley will move on the rail horizontally along the track (6). ‘+The product has a variety of automatic built-in safety features which, for example, limit trvelling movements or prevent all the movements if the emergency stop button (13) is engaged. In edition, there can be operating limits (set by the owner/operator) which also limit movements under eertain conditions, + When a traveling button or joystick is activated on the controller (i), a command is sent to the electrie panel @). ‘+The horizontal direction of the hoist depends on which button or joystick is pressed, The speed of the trolley depends on wich step is activated. Maintenance & User Manual Holst EAD Last Revision : 18/06/2015 Lest Edition: 17/09/2018Engineered Material Handling ‘+The electric panel (2) controls the brake (3) and motor (4) in accordance with inputs from the operator, ‘together with signals from the sensors and safety devices. +. When the motor (4) is not being driven, the brake (3) holds the motor in place, preventing it from turning unintentionally. + When a signal is transmitted from the controller (1), the electric pane! (2) supplies power to the mator (4) ‘and releases the brake (3), + The motor (4) drives the travelling gear (5) which drives the wheel (7). The travelling gear (5) reduces the ‘rotation speed and increases the torque to move the trolley. ‘+ Innormal use, when the travel direction control is released on the controller (1), the travel motion moves to a gradual, controlled stop ard sets the perking brakes (Inverter), *Tnemergency situctions, the emergency stop button (8) on the controller (1) can be activated, This eauses an instant stop of all movements by cutting power to the motors and applying the brakes, 5.4. Operator Instructions 541 Operator responsibilities Hoists are used for various purposes, handle different types of loads and are operated different ways by many ‘operators, Many workers, as part of their regular job responsibilities, normally operate hoists as non-dedicated operators, Because the manufacturer of the hoist has no direct invelvement or control over the hoist's operation and ‘pplication, confortning to good safety practices is the responsibility of the owner, and the equipments operating personnel, Only those Authorized Personnel and Qualified Personnel who can demonstrate that they have read and tundersteod this manual ard that they understand the proper operation and maintenance of the praduet should be permitted to work with it. ‘Operators SHALL be trained by the owner of the equipment om a qualified designee ‘nd be competent for the task. Operators SHALL learn how to operate the equipment safely before actually starting to work with it Operators SHALL know all the controls ard must be abe to use them correctly ond safely. Operators SHALL learn how to control the movements of the hook end load, Operators SHALL be aware of any risk of accident posed by the operating site. Operators SHALL familiarize themselves with the signs and warnings merked on ‘the equipnienty * ‘Maintenance & User Manuel Hoist EAD | Last Revision: 18/06/2015 1.1 Last Edition 17/09/2018Engineered Material Handling Operctors SHALL use this manual to familiarize themselves with the equipment and equipment's controls EMH = | Operctors SHALL learn the hand signals for directing equipment's movements. Operators SHALL be familiar with proper rigging procedures. Operators SHALL carry out deity inspections Always follow the local regulations, Operators SHALL NOT operate the equipment when under the influence of alechol co drugs, Alcohol and drugs can impair judgment and thereby cause « hazard, ‘Operators SHALL NOT operate the equipment when under medication which may cause a hazard to the operator or others. TF unsure, consult your doctor or Pharmacist. Always comply with local regulatiors regarding working under the influence of medication. ‘Operators SHALL NOT operate the equipment while suffering from any illness or injury which might impair their ability to properly use the equipment, 5.42 Checks to be done before every work Before every work but also at the beginning of each shift and when « new crane operator starts work during a shift, the operator SHALL make the following checks to ensure that the product is in a safe operating condition, By carrying cut these simple checks, the operator can identify potential problems at any early stage, thereby enhancing safety ond minimizing down time. Werning Visually check the operating environment to moke sure that there are no new hazards which might prevent safe use. ‘Maintenance & User Manual Holst E&D Last Revision : 18/06/2015 Lest Edition : 17/09/2018Engineered Material Handling Visually check to see if there are any oil lecks From the product. ee Visually check the ropes or chains for any deformation or damage (For exemple, broken wires, broken strands, kinks). For more details, refer to appropriated chapter, Visuelly check the rope reeving, The ropes should al be properly seated in the grooves cof the rope drum and rope sheaves. Check that rope is not twisted and thot the ropes are not touching ech other. Inspect the hook for nicks, gouges, deformation of the threat opening, wear on saddle or load bearing point. Check that safety latch is working properly. Check free rotation of hook Forging. Verify that nobody is doing maintenance work on the product. Check that the product is not locked or tagged out. follow locel safety procedures. Check that the emergency stop buttén is working properly 5AB Operational Checks with the emergency stop button n pshed down Turn on the main power igolation switch. ‘After-the main coation switch has been *urned on, the product becomes operational (energized); i : j ‘aintenance & User Manuel Poise EAD : 7 Last Revision 7/06/2018, al © Last Edition : 17/09/2018Emergency stop button pe Fe | oe With the emergency stop button pushed down, check that the product does not move ie when the direction controls are pushed. This verifies that the emergency stop button is | working properly. ae Control devices without power Check for smooth mechanical operation of each pushbutton or safety switch on the controller. ] . ‘t ‘These devices should press and release smoothly, without sticking “The operator should be able to feel the positions where the pushbutton would engage higher speeds, 5.4.4 Controller Setup Never celecse the emergency stop buon ond deve the re antl ‘abet Make sure that the main power isolation switch is ON. a ‘\ ‘The product only becomes operational (energized) after the necessary steps have been, , followed to established communication between the product and controller. KE To prepare the controller for operation, release the emergency stop button by turning it clockwise (or, if itis push-pull button, by lifting it up) so that itis in the raised position. Erengize the product by pressing the start pushbutton, Information |= 545 Operational checks with controller enabled Before every working, all of these checks must be done with the emergency stop button released and with the power turned on. Werning devices Check that all warning devices (For example, pilot lamps, LEDs, displays, horns, gongs, bells, sirens, beacons and strobe lights) are working correctly before using the equipment. Control devices with power Starting at low speed, check that movements correspond to the controller labels. Check that the brakes operate in all dinections and that speed increases as it should do in relation to the control Listen for unusual noises. ‘Maintenance & User Manual Holst E&D Lost Revision: 18/06/2015 Lest Edition: 17/09/2018Engineered Material Handling Upper (primary) limit switch Check for corect operction of the upper (primary) limit switch by raising the hook up and stopping it before the limit switch activates. Slowly inch the hook up until the lint switch activates and prevents further upward movernent. | Safety latch Check to ensure that the hook safety latch is on the hook, isin good condition and closes automatically 54.6 Movements of Wire rope hoist ‘The hoist moves in the followi directions by the thee vet 8 € charger button afd contac The components are controlled by a variety of electrical circuits called “drive circuits”. The motors can all be:driven by the same type of drive circuits or a mixture of types, Before lifting.” i ‘After securely attaching the load to the lifting device, the hoisting imachinery must be correctly positioned and | attached to perform the lift. The following steps must be followed before lifting. { Waring » Waittenarce X User Mamie Holst EAD, Last Revision : 18/06/2038 « t Last Eaition: 17/09/2018Engineered Material Handling 5.4.6.1 Load handling ‘Handle the toad dately-aF ll Hines! During oveinente/ enauee that the . moving port call lew hob jects or people: = Failure te do. s injury. 2 Warning Correct load handling allows ieee imave loads quickly and sefel Hf 5.4.6.2 — Estimate the carried lead To’prevent overloading, the operator shall determine the weight of the load before lifting, The operator shall only lift the load when he or she is sure that it weighs no more than the permitted load of the product and: accessories. ‘The product's overload device shall not be used to determine whether the load can be lifted, Never attempt to lift a load that weighs more than the maxinum permitted load of the equipment and accessories. 5.4.6.3. Balancing of the carried load The hook, slings end harnesses must be positioned so that the pulling Force of the product lies on the load's center of gravity so that the load is balanced. When the operator begins to hoist « lead, he or she shall check that itis properly balanced before lifting it high off the ground. If the carried lead is not balanced, lower it down and adjust the lifting point, Lifting centrally of the carried loads ‘The center of gravity will usually be in line with the center of the lead. Provided that the contents of the container cannot move around, the balance of the load stays the same. Lifting un-centrally of the carried loads ‘The center of gravity of cn un-centrally carried load will usually be towards the heavier end of ‘the load, Provided that the contents of the container cannot move around, the balance of the load stays: the same. As Warring radius sevousingury. 5.4.6.4 Shack of the carried load The product and accessories are designed to move up and down the weight of loads gradually and steadily, They are not designed to withstand sudden increases or decreases in the apparent weight of the load, Shock loading can : ‘oceur in any situation where the load on the product suddenly increases or decreases, Some examples of how shock leading can occur are shown below. Change of load balance AA change in load balance can suddenly pull on the hoisting rope, paz ‘Maintenance & User Manual Hoist E&D Last Revision: 16/06/2015 Lest Edition : 17/09/2018Unstable load If the load is unstable, it can exert sudden force on the hoisting rope. ‘The contents of packing cases should be securely fostered so that they canrot move arourd during lifting Rapid load reduction ‘A sudden loss of the load can cause the jump of trolley/hoist. q 546.5 Means of lifting the load The loed is usuolly attached to the product by means of some kind of under-the-hook Ii The mest common under-the-hook lifting devices are cheins, wine rope slings ard lifting belts, ‘The operator shall select « lifting device designed for the product being transported, 54.6.6 Lockeble hook Ta lockable hook block is used, itis possible to lock the hook forging in steps of 90 degrees, to prevent load handling problems cused by rotating the load. 5.46.7 Load handling “To avoid damaging the hook, lifting devices must only be positioned on the load ‘bearing surface of the hook. | That i, the lowest point of the hook, Forces on ramshirn hocks must be equal on both loed bearing surfaces Ensuite thatthe hook sofety: latches are clased, Check that the'safety latch is not subjected to any force by the load. ‘The weight of the load must be centred on the center line of the heok forging s0'that the'load does not Berd the néck of the hook. Never try to lit anything with the tip of the hook! ‘Maintenance & User Manuel Hoist EAD Peril Last Revision: 18/06/2016, 7 5 Last Edition : 17/09/2018Engineered Material Ty ‘Check that the load is balanced and safely fastened at the lifting points, The load must not be able to slide, slip or detach itself when suspended, ‘The hoist must be positioned directly above (perpendicular to) the load so that there are no side-pulling forces, Do not drag or pull the load along the ground or from the side The operator shall ensure that the product or the load does not collide with ‘anything or fall from the lifting device. | ‘Check that yeu have a clear view from the controller position, Remove ary visual obstructions, Ensure that everything is ready for lifting Tf the equipment has « horn, push the horn pushbutton to warn people nearby that a load is about fo be moved, Gently push the UP control to slowly toke up the slack from the. chains or sling before lifting the load from the ground. ‘Maintenance & User Manual Holst E&D Last Revision : 18/06/2085 Lost Edition : 17/09/2018Information. Nate z oe Sse ee ane Engineered Material Handling Continue to gently push the UP control until the load is just clear of ‘the ground, Push the UP control further to lift the load at a higher speed. Release the UP control gently when the load is at the desired height. be not raise the load higher then is needed to avoid colliding with objects. 547 Travelling Movements 5AT1 Explorations ‘This chapter describes the use of the controls sq that you can drive the product properly and avoid hazards 1. Trolley movements 2 Bumper end stop General information about trovelling movements Slow speeds should be lsed only for short periods, for example during precise pasitioning. Most movements, especially over longer distances, should be performed at higher speeds t0 improve ventilation of the motors, Butfer stops are fitted to the runway to limit travel of the trolley. Buffers are fitted to absorb the impact if the ‘rolley runs into the buffer stops. Buffers are clso fitted to prevent collisions between multiple trolleys, ‘Stops and buffers are intended for emergency use only. Do not use buffers and, stops as an operational means +o stop travel duritg normal operations. ‘Thé'brodiet ie Fitted withthe following devices which work in conjunction with trolley movements 2 Step for stop limit switeh ~ & Waintenance 4 User Manuel Holst EAD = ‘Last Revision 18/06/2015 Last Edition: 17/09/2018Engineered Material Handling { ‘The bridge has 2-step limit switches at both ends. ‘The first step changes the trolley speed from fast to slow when activated. The second step stops the trolley when activated, With inverter use, the trolley does not stop immediately but decelerates to a stop. lectronic Potentiometer cor Inverter control stops the trolley smoothly by means of a preset deceleration ramp. ‘The brake only activates AFTER the trolley has stopped moving ' The operator must understand how the trolley behaves when decelerating to avoid overshooting the target on causing load swing. 547.2 — Load control The operator must use the correct techniques to properly contro| the load at all times to prevent uncontrolled movements such as load swing or rotation Tf the load has a tendency to rotate or swing, « third person can guide the load with a tag line, provided thet it is safe to do so. Werning 547.3 Load swing Load suing is caused by sudden speed or direction changes in the trolley or bridge movements, When starting up or accelerating, the load lags behind the bridge or trolley. When stopping or decelerating, the load tends to swing chead, pulling on the product, Tf the product moves at high speed and then decelerates quickly, violent swinging may result, ‘The load will swing further on a long rope than on a short one, b 5.48 Prevent Load swing Load swing can be prevented or minimized-by: * Accelerating and decelerating as gently as possible * Moving the product at « speed appropriate for the load (higher speeds increase the likelihood of swinging) ‘+ Transporting the load close to the hoisting machinery with short ropes ‘Maintenance & User Manual Holst E&D Last Revision: 18/06/2015 Lest Edition : 17/09/2018 | |+ Coming to.a complete stop before changing direction ‘The operator can prevent swinging by taking advantage of the leading pull of the load when bringing it to a stop: Anticipate the swing and stop the preduct: Anticipate the swing of the lood and stop the travelling movements just before the final setting point of the load. ‘Accelerate to catch up with the load: ‘At the instant the load is directly over the setting point, accelerate the travelling movements so that it catches up with the position of the load. Stop over the setting point: The load and travelling movements can both be stopped simultaneously over the setting point: B49 Safety Procedure after Using the Product The following checks must be done after every working to ensure that thé product is left in a safe condition, Ensure that there is no load on the lifting device, Park the hook or other lifting device where it will not present a hazard to people or trafic but db not park at the top safety limit. ‘Above head height isrecommended."° Tf epplicable, park the prodiict in an approved parking erea, * Bp ay Hance User Wana le ED es - Last Revisor 18/06/2015, ee Last Eaion: 17/03/2018Engineored Material Handling Engage the emergency stop button. Turn off all controls on the controller. ‘Turn off all power to the product with the main isolation switch, Tf applicable, close mechanical brakes (rail, clamps, storm locks etc.) Visually check the product, dy Report all observed defects and abnormalities in equipment er operation to the foreman and to the next operator. frm ‘Maintenance & User Manuel Hoist E&D Lost Revision : 18/06/2015 Last Edition: 17/09/2018Engineered Material Handling 6. Maintenance manual 6.1. General comments This the product ouner’s responsibility to organize proper regular inspections maintenance to ensure long-term safety, reliability, durability, operability and warranty for the product. Keep this manual in a safe, accessible location during the whole lifetime of the product, The owner must keep a record (log book) of all maintenance activities and usage relating to the product. Different maintenance actions must be carried out ot different intervals and by different persons, all of whom must be qualified and authorized to perform the checks which relate to them. Dally checks and minor lubrication must be carried out by operators. These checks are very important to catch small faults before they become major faults. ‘Maintenance actions, excluding the daily actions performed by operators, must be done by service personnel who ‘are authorized by the manufacturer of manufacturer's representative, ‘The owner shall ensure that replacement parts and materials meet the specifications defined by the product ‘manufacturer ‘The following maintenance schedule applies to the entire crane, The maintenance intervals stated are besed on single shift operation, Multiple shift operation will require more frequent maintenance and inspections. Operation in shifts affects both inspection and maintenance intervals, Hoists must be mointained in accordance with the appropriate hoist maintenance instructions, During maintenance, any excessively worn or faulty parts must be replaced, Crore trolley wheel bearings ard crane motor gearboxes heve permanent lubrication and do not require ary maintenance. Gearbox fluid levels should be checked periodically. 61.4” Services & maintenance personnel Only authorized service personnel or an experienced service technician is authorized to pesform the examinations necessary for scheduled maintenance, Such exomintions must be pétformed in accordance with the Inspection and maintenance plar provided by the product's manufacturer, ‘The owner‘ or operator of the product must perform the dally checks and, if required, deily lubrication. Service personnel authorized by the owner tay also lubricate the product at the necessary intervals. 61.2. Crane Log book The crane log book is'stipplied ini the interest of accident prevention. This on integral part of the equipment and shall be kept up-to-date and with equipment all the times. aligeronce 4 User Marval oie FAD ‘Last Revision | 18/06/2015 (i ee Se ee 5 Last Edition: 17/09/2018Engineered Material Handling Do not remove or discard any parts of the log book for any reason. The log book records the complete maintenance history of the equipment and it must be transferred fo the new ‘owner when ownership of the equipment changes. The log book consists of the following items: + Product reference data’ detcils of the product, its ownership and persons who are quolified to work with it + Faults noticed in daily inspections, together with corrective actions + Records of service inspections and lubrication. + Records of repairs + Records of condition monitoring unit or hour counter. ‘+ Calculations of safe working period and remaining lifetime, According to the ISO 12482-1 standard, records of the crane usage must be kept, so that the usoge can be. ‘compared to the suppliers design principles and desigh limits, Records shall also be kept for all maintenance, inspections ond urusuel occurrences (e.g. unexpected loads from operational error, extreme climatic conditions, etc), breakdowns, repairs and modifications. Where complete records aren't evailable, it shall be inspected in accordance with Annex A of ISO 9927-1 and ony requirements as a result of that inspection shall be carried out before further use of the equipment. 6.2. Safety instructions for maintenance personnel 6.21 Fall protection While personnel are performing inspection or maintenance work ot heights, they must follow fall protection procedures as required by local regulations. Fall prevention practices and fall protection equipment aim to protect personnel working on or around the equipment from exposure to fal Tf the equipment does nat have a service platform or handrail, personnel must use a properly fitted safety harness thet is attached to the dedicated fixing points on the building or equipment in order to prevent falls If the product does not have dedicated fixing points for fall protection, itis the owner's responsibility to make sure that there are suitable fixing points in the building structure, Tf ladders must be used, personnel must practice setting and securing the ladders before using them for actual work, : A typical fall protection program may include: ‘+ Documented and established site policies and procedures. + Conducting site assessments for fall hazards. ‘+ Selection of the proper fall protection system and equipment. ‘+ Training on fall protection procedures and the proper use of fall protection systems. ‘+ Inspection and proper maintenance of fall protection equipment. + Measures to prevent falling objects. + Rescue Plans, ‘Maintenance & User Manual Hoist ED Last Revision: 18/06/2015 Lest Edition : 17/09/2018If necessary, contact your supplier o” service organization for assistance with designing your fall protection program, 622 Main Isolation switch ‘The product can only be driven when power Is turned on, The owner must identify and document the location and. function of the main isolation switch and must communicate this information to all operators ‘When the main isolation switch is turned on after being placed in the of position, the set-up Hl must be followed before the product can be used. 62.3 Safety during maintenance Before and during product maintenance, the following precautions should be taken by maintenance personel Choose a safe working location ‘The preduet should be moved to a location where it will cause the least disturbance and where it can be eccessed easily, Prevent unauthorized access to the site Prevent unauthorized persons and bystenders from walking on or below the work site. For example, you can lock doors, install barriers and display notices. Ensure thatthe secured area 's spacious enough to prevent injuries which could occur as a.resultiof falling components oF tools: Tnform that equipment will be undergoing maintenance Before starting mainterance, people imust be properly informed that the equipment is being removed from operation: Ensure that there is no idad on the lifting device Before starting maintenance there should be ro load on the hook or lifting. deviee, Park the hock'on the:ground if there ig any chance that the hoisting brake will be opered during maintenance. A raised empty hock will fll to the | goin if the hoisting bakes pened Maintenance & User Manuel Holst EAD. Lest Revision : 18/06/2015" Lest Edition: 17/09/2018Engineered Material Handling Turn all controliers and main switches off All controllers and main isolation switches must be placed in the of position before starting maintenance. Lockout - Tag-out ‘The product power source must be locked out and tagged out when necessary, in accordance with local regulations, See chapter "Lockout ~ Tagout Procedure” Verify that power is completely disconnected ‘Mecsure between the phases and between each phase to ground to ensure that power is completely disconnected from the product. Use hand lines for lifting and lowering tools Hand lines, securely attached ta the building structure, should be used for lifting or lowering materials and tools. Use proper safety equipment to prevent objects from falling when working in high places. Safety devices must be restored to operational status Ensure that any safety devices which have been bypassed for testing purposes have been restored to full operational status before allowing the product to be used for normal operation, “Minimize the risks of moving machinery ‘Secure the area so that personnel are not ot risk From the movements of ‘machines, automatic doors or adjacent cranes at the installation site, Ensure that machinery and equipment cannot start up accidentally and cannot rove during installation and servicing, Be prepared in case equipment moves in ‘the wrong direction during testing, Perform regular inspections and preventive maintenance To ensure ongoing safe and efficient operation of the product, carry out regular inspections and preventive maintenance in compliance with the instructions. Keep a record of all inspections and servicing. If in doubt, contact the supplier of the product. Returning the product to operation after overload or collision After cn overload or collision incident, the appropriate inspection and repair operations must be discussed with the supplier of the product, Pay special attention to all safety-critical components The brakes, limit switches, hook, rope and controller are all safety-critical items which must always be kept In good order. Ensure that safety devices (overload protectors, limit switches, ete.) work properly so that they provide protection against human error. ‘Maintenance & Uses Manual Hoist E&D Last Revision: 18/06/2015 Lost Edition : 17/09/2018Engineered Material Handling Beware of high temperature components ‘Some components of the product, such es the meters, cen become very hot during use, Check that components are cool before working on them. During installation, inspection and maintenance, lockout-tag-out procedures must be followed in accordance with local regulations and the documented site lockout-tag-out policy. The owner must ersure that the operators are fully eware of the applicable lockout ~ tag-out practices, Lackout-tag-out procedures are primarily intended to protect personnel by preventing accidental starting or exposure to electric shocks, Individual locks and tags are placed on cortrels te prevent thelr use until the person who installed the lock or tog removes it +) When the uée'of lockout ~ fagiout is permitted. 4. Tdentification of each of the switches, controls, valves and other energy isolating devices present ai the site, The role of each device should also be explained, ‘© ‘The lockout - #ag-but sequences to be followed before, during’and after maintenance. + Safety and operational eonsiderations regarding other products on the some runway ot on adjacent runways 6.3.» Inspections: = ‘The operator/owner of a product shell carry out regular inspections to ensure the safe operation. ‘The product's owner shall algo keep record of the inspections and findings. ‘Maintenance & User Maral Hoist EAD “ Lest Revision: 18/06/2018) Last Edition : 17/09/2018Enolneered Material Handling | Periodic inspections must be carried out by authorized service personnel, experienced service technician or | external control compen. Inspections must be cerried out according to manufacturer's instructions, 6.3.1 Daily inspections Daily inspection items are listed in chapter "Operator Instructions", In most cases these checks will be performed by operators. i 6.3.2 Periodic inspections Periodic inspections are normally performed every twelve months but must be performed every time thet i ‘ervironment hes charged (working environnent/harsh candition/Crash or technical problems). 6.3.2.1 — General fa Visually check the general condition ond accumulation of t Visually check that covers are not damoged. Check paint coating and rust (repair if necessary). ‘Test by hard that all covers are fixed. Tnstructiong and log | Visually check product documentation, books: Verify that the user and owner are avore of the decumentation and it I available for them, Check vlity of log book, 6.3.2.2 Limit devices “Tolley buffers ‘Check condition of tralley bunpers and bumpers end stops. Check condition of rail sweeps if ory. “Tolley traveling lini? | Check visually that traveling liit switches are operating in correct position. switches ‘heck wiring Check that thein function looks good ong travel Tit ‘Check visually that travelling limit switches are operating in corvect position switches (Inkit erere | Check wiring case) Check that their function looks good Geer limit switch ‘Check visually the condition of gear limit switch “Test the operation of lit switch. “Weight operated ‘Check condition of the weight operated init awiteh limit site Check wiring. (optional) “Test the proper operation of the weight operated limit switch ‘Overload profection | Check condition and free movements of mechanical parts. In the case of electromechanical eyerlecd protection devices, grease the dise spring packages as required Maintenance & User Marsal Hoist E&D Lost Revision; 18/06/2015 Lest Edition: 17/09/2018Engineered Material Handling Condi operation Ts of overoed device according To oa repleiansf reqred eon an bite lever echave Electrical components ‘Check that the emergency button is clean and rot domaged, Ereroeter st Test the operation of emergency button ‘Check that the main switch is clean, clearly marked and no? damaged, Main ewiteh for holst | Test nanualy that main sutch wll suitch off the holst Follow the power supply ond visually check potential arecs Fer damages. Check wiring for any signs of wear, crushing, breaks, cuts oe Check visually that cable bushings are tight. 7 Check visually that conrectars are not damaged, Test by hard that cable bushings ard connectors are tight check tightness of screms at terminal blocks and connections of other comperents randomly, Contactors ‘Check visually that cortactors are clean and ro visible damages: (Over-current esse Check adjustment of over-current protectors, ay ‘Check viually that fuse holder ard fuses are clean and no visible damages, Check correct amperage rating Braking resistors (with some frequency | Clean all dust or dirt from braking resistors converter model) ‘Check that wires are securely fastened. Hoisting inverter ‘Check fault code records, ‘Check operation and cleanliness of cooling fan, ‘Traveling inventor XA (option) Condition monitoring Unit option) ‘Check that wires are securely fosFened, Check fault code records, Check operation and clearliness of cooling fon. ‘Check visually that UX. ig clean and ra visible damage, check wiring Check that their function looks good ‘Check operation mode. ‘heck fault code records, Lift akrown load and verify that the unit reads the load within 8% of the load. 6.3.24 Traveling motor Motors & gear Gheck that the eooing-ris surface Is elean, Check vevally that all motor eomection sevens are tight ard motor is properly ont postion Drive and check thatthe traveling motor operates properly. Check for any excessive noise; vibration and/or heat. heck tht 1 eaoliog fet is working properly iF any. t Hoisting motor ‘Check thatthe éoolng-ribs surface is clean Check visually that ell mofor comection serews are tight ard motor is properly ont postion Deivé and check'that the hoisting motor operctes properly when leaded. {hee for any excessive noite, vibration and/or heat, rec tnt the coolng fans working properly Traveling brake ‘Check that there Ie to viible damage, - Check that the outside surface of the brake Is clean ‘Test that broke operates smoothly and braking time and distence is acceptable. ‘Measure the air gop, clean ard adjust the brake If needed, Poisting brake ‘Cheek that there is ro visible damage, Check that the outside surface of the broke Is clean. ‘Test that lifting and lowering will broke smcthly and broking ime ahd distance is acéeptable, Measure the air gap; clean and adjust the breke if needed, | Wanial Brake release for hoisting motor (optional) ‘Check that manual brake release tools are available. Check that eperating instructions are eveilable Tainterance & User arual Potet EAD Lest Revision: 18/06/2015.» 2, bast Elion 17/09/2018Engineered Mat Han ‘Second brake (optional) ‘Check that there is ro visible damage, ‘Check that the outside surface of the brake is clear. “Test that second broke operates after the main brake. Lifting and lonerieg will brake smoothly anc braking time and distance is acceptable. Tf neaded inspect the broke disk and clean the brake. Drum Broke @ptional) Check cleanliness of drum brake. ‘Check visually the brake condition: ~ Broke bands are on cerrect position. ~ Com spring is goo. - Achiator mecherim is clean and moves fre2ly ‘Test that the cam operates correctly when lifting and lowering ‘Test that electric eniteh wil stp the motions, Lubricate the cetuator ei cam mechanism if needed, Treveling gear Check visually the gearbox fastenings. Check the gearbox visualy for leckage. Check visually torque support mounting ard rubberbushing if any. Test the running sound are vibrations with lad Check that breather-plug breaths freely Check temperature of travelling gearbox by han. heck oil eve! if ol filed traveling geer. Lubricate the open transmission if en. “Hoisting gears | Moter/ear coupling ‘Check visually the gearbox fastenings (Check the gearbox visually for leakage. ‘Test the running sound and vibrations with lad, Check that breather-plug breaths freely, Check temperature of hoisting gearbox by hand, Check oil level if oil filled hoisting gear. CCheck the tightness of bolted joints, especialy the tightening torques of the long bolts conrecting ‘the motor housing ond the gearbox on holst lifting ond trolley travel motors Lubricate and replace If any. Note: The coupling has an exceptional inspection interval defined according to the environment, Tt normal environment (-20..+40 °C), the Interval is 4 years . En harsh, arctic or tropic ervirerment, the Interval is 2 years, 63.2.5 ‘Mechanical components | Repe drum ‘Check condition and cleanlinese of rope dru, Check the grooves of the drum. Check visually that connection rods ore straight and fixing serens are tight, ‘Check proper rotation of drum end éandition of bearings, Pay attention to running sound of rope drum bearings and Check that the rope deum does not touch with machinery end plates or other parts, Lubricate the drum surface, LLubsicate drum bearings are lubricated long-life. Rope guide (@ressed roller in option) [Rope sheaves ‘Check condition of the rope guide. Check for loose on missing fittings. Check pressure bearing condition if any. ‘Test proper operation of the rope guide, Clean the rope guide or pressed roller. Lubricate the rope guide. ‘Check condition of sheaves, Tnspect fhe measures if wear (Check condition of rope sheave support structure, CCheck that the sheave support shafts are correctly n their slots and correctly locked ‘Test by driving the smocth rotation of the roze sheaves. Rope camp renirg of rope clamp. Check that the rope clamp bolts are tight. | Ensure that there are the friction turns when the hook is at the lowest position, ‘Make sure the rope end protrudes fram the last clamp a specified distonce Rope wedge ‘Check the rope wedge protrusions (see next chapter) Vainterance & User Manual Hoist EAD Lost Revision 18/06/2018 Last Edition: 17/09/2038Engineered Material Handling Dead end point ‘Check condition and correct position of rape anchorage. Ensure that the rope Is assembled inside the rope enchorage correctly Check thatthe rope clamp nuts are tight. Ensure that the rope has not sipped inthe repe anchorege by comparing t reminal measures, ‘Make eure the rope end protrudes from the rope anchorege es specified. Check the condition of the wire rope near the rope anchorage, ‘Check the anchorage shaft locking, Lubricate the pivot bearing surfaces of rope anchorage if needed Wire rope ‘Check rope for damage ond wire breck. (See next chopter for acceptable state oF wear) Inspect the rope(s). Lubricate the rope. Gear lint switch | Check clearlivess, security and fastenings of cover. Hook block ‘Check operation and cordion of hook Block. Check visuelly that: = Stickers exist ard are readable, = Sheaves covers have ot ary damages ord do rot touch te sheaves or rope. = Hook hangs perpendicularly. Lift empty hook and test that: - Hook does not rotate. + Empty hook do tot tit. “Test that rope runs smcethly on sheaves with and without lead, Return sheave bar | Check condition of ber ring, iF any by tilting the hook Forging Equalizer cheaye bar | Gheck condition of different parts subjected tothe iting force. Dead end ber Insert grease to cross ber. ‘Open tte cross bar and lubricate the pressure bearing if needed. Hock safety loth “Test by hand thet safety latch is not damaged and spring keeps if closed Hock Forging ‘Check condition of hook forging, CCheck cracks ard permanent deformation ‘Measure the hook forging opening if needed. Trolley wheels ‘Check condition and cleanliness of trolley wheels Visually check the wear of trolley whee! surfaces and flanges if ery. Check adjustment of rail width oF rail gauge -mecsure, ‘Test trolley wheel operation. Pay attention to running sound of bearings. If needed lft the trolley and ‘test by hand the free and smooth rotation of trolley wheels. Check that wheels are correctly aligned and check possible wear caused by miselignnent. Toad carrying structure, ‘Check candition of bolted joints and load carrying structures. Visually check secured bolt and weld connections and back up comperents like mounting of derailment catch if any. 6.3.2.6 Pendant control Pendant or remote controls ‘Check condition ad functionality of push buttons and switches: ‘Cheek ell markings and signs that they are readable.» | Drive all movements, Test all functions, i L Remote control ‘Check condition end Functionality of push buttons and switched, ‘Checkcall markings ahd signs that they are readable. j Drive all movement, Test all functions. t. Information — Lt Waintenarce & User Manual Hoist £4D Lost Revision : 18/06/2015 Last Edition: 17/09/2018Engineered Material Handling ep sue rope dai vee ‘The spacing must be checked during annual inspections. If the maximum dimension is exceeded, the rope socket ‘ond wedge mist be replaced. 6.3.2.8 Rope state of wear, / Replacement criteria, Load carrying ropes shall be inspected along their full length, but particular attention shall be given to certain rope parts, Each wire rope shall be examined in the areas which are mast regularly flexed over the rope sheaves during normal operation (The bending radius should approximately correspond to the rope pulley radius), and at the rope end near to the wedge housing, Carefully clean the examination areas before inspection Waintenance & User Manual Hoist ED Last Revision: 18/06/2015 Last Edition: 17/09/2018Engineered naling In order to check the wire rope for breckages, the load must be removed and the rope be manually bent on the workplace in order to better recognize wire breckoges ond make them clearly visible, The bending radius should approximately correspond to the rope pulley redius. Manufacturer-electric rope hoists are equipped with long-lay pre-formed high-strength wire rope with steel cores specific for this application and which have a high degree of breaking strength. When replacing a wire rope, make sre only original replacement ropes are used. They can be directly obtained from your manufacturer. The wire rope must be replaced in the following case (hot exhaustive list): + Tf the number of visible wire breckages on one of the reference lengths achieves the value indicated in ‘the table: Wire breaks on a rope length of 6x rope diometer Wire breaks on a rope length of 30x rope diameter am MS 3-6 Number} Rope | Number of wire | length | of wire breaks |” (mm) | brecks m= MB 3m=M6 Rope length (nm) tam = M4 Working up Am = MA (rm) | of the rope Number of wire breaks Rope | Number length | of wire (rm) | brecks Rope length (rom) S16 8x19 Antigir7x28 48 48. SIG 8x25 Antigir 7x28 | FIG 8x25, Attigir7x28 | FIG 8x25 | “Artigir7x28 24 24) FIG 8x25, Antigir 7x32 Wehtarence & User Meni] Hoist Ea mA Lat Revision 18/0672018 ' Lest alton 17/09/2048Caution 7 ‘+ Tfallocat reduction in the rope diameter or in any part of the rope is an indication of internal or external wear or damage: To accurately measure the diameter at any point of the rope, rotate the vernien caliper around the rope to record ‘the maximum dimension, Weraing Warning + Tf Basket (bird cage) deformation occurs when there is a difference in length between the rope core and outer strands, Warning A Warning + Tf any-bend on rope appeared. Weintenance & User Manual Hoist E&D Last Revision : 18/06/2015 Last Edition : 57/09/2018EMH a Engineored Material Handling Bends and other angular deformities in ropes are normally caused by external influences. Mild bends can often be removed by carefully bending the rope by hand to straighten out the bend. 6.3.3 Inspections following major modifications Following ary major modifications to a ercre system, the system must be inspected by a qualified inspector before it is recommissioned, Examples of major modifications are (but not limited 40): ‘+ Changes in the type of power supply ‘+ Replacement of trolleys + Conversion or modification of motors + Increases in the load capacity of « crane + Extension of a crane runway ‘+ Moveinent 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, ‘rare runway supports, crane girders, trolley track ginders, trolley frames, ete + Changes in operating conditions including the duty cycle and the load range of the erane 6.4, Lubrication 6.4.1 General lubrication instructions “lubrication. han ae qt Information © ‘The following table provides advice on the lubrication procedures which should be followed. Usage’of & low grade oF incompatible|lubricant can damage the gearing or bearingé, Use only lubricants recommended by the product’s manufacturer. See the lubricant tables for more information, Use only fresh oil/grease. Different kinds of lubricants shall not be mixed: Information abotit each cheinieale safe handling, risks and hahdling as vaste ore desctibed In the Safety Data Sheet that is’available from manufacturer of the lubricant. Note: equipment may have synthetic lubricant as a factory instelled lubricant. Pleose refer to'otder confirmation Hardie lubricants carefally: Prevent leakages to waters, Sewers, Cellars and other clased places, Keep lubricants away from heat and open fires. Da not.stnoke. wher herdling lubricants... e ‘Avsid contact with skin, Protection gloves and safety goggles shall be worn when hordling lubricants, Hands shall be washed thoroughly after lubrication, ‘Maintenance & User Maraal Foist EAD Lest Revisidn: 18/05/2015 Let Edition: 17/09/2018Engineered Material Handling Keep lubricants away from food and drink. Do not inhale any fumes or swallow lubricarts, Used lubricant shall be handled os hazardous waste following local legal requirements. ee, ‘Store used lubricant in containers indicated for the purpose and dispose by a licensed ae compary, Keep grease nipples clean, | | | All slide becrings must be depressurised for the grease to be able to penetrate. While lubricating, check the functioning of the bearings and observe whether there is any | bearing slackness. cd ‘The specified lubrication periods apply in Favourable conditions and rormal use, More a ‘frequent lubrication is recommended in more demarding conditions and in heavy use, particularly of the slide bearings, Verify that the gear teeth of the open gear transmission are entirely lubricated, Tnformetion Seon ce ae 6.4.2 Lubrication layouts Dead end Nleus | Meleus Grafloscon point/avle | Amol | gus | 195 St ps _| Urol EPL Lifting gear | B75 | Seggq” | Omatncil | Mabilgear | spartan | EME! | beret |-Faeon yeors | G66 | 680 63s | erss0 | OR | cemisso | c6e0 | ‘fetine/ Retinax Eliber past | lissando | Littingpinion | ifetime | Retin] petinox Lx 4ema4oi | meP2 i zi : Waleus “rafioseon | Bop Monthly a refer | oi ra ' Halles | Molle Grafioscon | Rope drum | Monthly | Malus | Malou reeset | rat a i Sat acct etn Taber pat) Sands | Preset FeAl ie trina ee | ene e 4emR4ol | mere i Drive Retin liber pest | Glisando Bearing Monthly | “uxe _| Retinex xe ‘4eme-4o1 | mere Heck beck! Uifetime | Retinax uber pest | Giisando pect | ibriated | Le | Renn 2 4emR4o1 | MEP2 | Traveling ‘anual | Yo220, | Onalaot | Mobilgear | Spartan | F*8"6! T kuberoil | Foleon | gear G20 | “20 630. | ev2a0 | 8% cemi-zz0 | cap220 Traveling wal Retinax Kluber past | Glissando | pinion annual | pyg | Retina be acnn4or | mere Yainterance & User Wonal Hoist EAD Lest Revision 18/06/2016 Last Edition: 17/09/2018Engineered Material Handing ‘Maintenance & User Mancol Holst EAD Last Revision: 18/06/2015 Lat Eiition: 17/09/2018‘Engineered Material Handing 6.4.3 Quantities of Lubricants (Gear & travelling gear) | =M-H - | | | FGA423 1000) Foa423 1000 | FGAG23 1000 FGA423 1000 180 Feai353 | 2800 N-A FGAi353 | 2800 1 Viscosity class for trolley drives - V6220 6.5. Wire rope & 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, 6.5.1 Removing the Wire Rope and the Rope Guide Type 2/1 and 4/1 Maintenance & User Manual Holst €&D Last Revision: 18/06/2015 Last Eaition: 17/09/2038Engineered Material Handling Figure 6 Figure 7 «Set the hoist limit switch se that lowering beyond the lowest hook position becomes possible, ‘+ ‘Lower the bottom block and place it e.g, on the working platform or on the Floor. '# Remove cotter bind (1, 4 Fig.5) at the fixed point bar (3 Fig.5), remové the rope socket retaining axle (2, 5,9 Fig) and detach the rope ends (6, 7,8 Fig.) ‘+ Remove the two Allen head screws on the side of the rope guide éleat (4 Fig.6) remove the guide cleat (3 Fig.6) of the rope guide ring + Turn the rope guide ring and remove Allen head screws (6 Fig.6) and springs (7 Fig.6). ‘+ Remove the two parts (1 Fig.6), of the rope guide and remove the spring (2 Fig.6) + Run.the rope off the drum slowly, when there is anprox. two wraps remaining locsen the rope clamps (9 ._ . Fig.7) on the drum (12 Fig.7) by backing off the screws (10, 11 Fig.7) + > Pull the rope’ fromunder the clamp and finish removing the ret ing rope from the drum (12 Fig.) ‘Maintenance & User Manual Poist EAD Last Revision : 18/06/2015. Last Edition : 17/09/2018Engineered Material Handling 6.5.2 Installation of a New Wire Rope and Rope Guide Reeve Fig. 9 * Pay out the new original spare rope on the groufd under the electric rope hoist, Make sure the rope is ‘twist-and buckling-free. (fig, €) Figure 8 + Cleon the rope drum (12 Fig.7) and evenly spray it with grease (See Lubrication Table). «Push the wire rope (Fig.7) from below and under the rope clamps (9 Fig.7) so that the rope end protrudes by approx. 3 em beyord the last clamp. Tighten the fastening screws according to the prescribed torques. Section 3.3.5 +. Wind the rope around the drum approximately 6-8 turns: make sure the rope is taut and twist-free, + Install the two halves of the rope guide ring and connect the spring, Install the Allen screws and rotate ‘the ring 180 Degrees, Align the rope guide cleat and install the two bolts Install the second set of Allen head screws, Make sure that the rope is engaged in the groves of the drum prior to and after the ring is installed + Reeve the free rope end without twisting and fosten it in the rope sockets (6-9 Fig.5) of the fixed point tie-bar (3 Fig 5), The live end of the rope SHALL align with the pin (6 Fig.5). A minimum of 6” of wire rope shall be protruding out (dead end or tall) of the dead erd side of the rope socket. Place the U-bolt clamp mid-way on the TATL of the decd end, For reeving, see Figure 9. + Completely coll up the rope on the drum (do not allow the rope guide to strike the side of the drum A Warning + Adjust the hoist limit switch to the highest 2 positions and lowest position, See Section “Adjustment Instructions for Hoist Limit Switch’. Warning + Figure 9 shows the correct reeving Maintenance & User Maraal Holst E&D Last Revision: 18/06/2015Engineered Material Handling Information Warning oft Figure 9 Maintenance & User Manual Holst EAD Lest Revision ; 18/06/2015 Last Edition: 17/09/2018EMH Enginoored Material Handling 6.6. Holsting Gear Brake 6.6.1 Description of brake structure 6.6.11 ZFB.version Rotor with brake liners ‘Aemature plate Broke coil Pressure spring ‘Magnet bod) Hub Hollow core bolt co] xen] o]as]o ‘Serew 66.12 ZF6/ZFL version Rotor with brake liners Plug, Hellow core bolt Broke coll ~ Flange / friction plate __ O-ring Hub 1 2 3 4 5 ‘Screw 6 7 8 9 ‘Armature plate 10 Pressure spring 11_| Tab connector (only ZFL) 12 egret bod) 6 7 8 9 10 11 12 Maintenance & User Manual Holst E&D Last Revision 18/06/2015 Last Edition: 17/09/2018Engineered Material Handling 6.6.2 Description of brake function Warning The electromagnetically released spring-opplied brokes ZFB, ZFS and ZFL are failsafe brakes with two friction surfeces, The braking torque is generated by means of spring force. 4 ‘The pressure springs apply pressure to the axially movable armature plate, trepping the rotor which is keyed to i ‘the machine shaft against the motor flange. ‘The braking torque is generated. | ‘A magnetic force is produced through applying a direct voltage to the magnet body via the field winding, Sold magnetic force draws the armature disk to the magnet bedy. “The brake rotor is released. Tf brakes are designed with manucl release, the brake rotor can be released mechanically, e. if there is a power failure, By pulling the manual release handle the armature disk is mechanicelly pulled against the magnet bedy. ‘The brake rotor is releesed, ‘The spring-pressure brakes are supplied pre-assembled. The standard type is delivered with e fixed broking torque. For the ZFB-breke the option with central adjusting ring is possible, The nominal breking torque has been adjusted as soon as the ring firmly contacts the magnet housing. Screwing out will result ina step-by-step reduction of the broking torque Manual release Adjusting ring (only ZFB) ‘Maintenance & User Manual Holst EAD Last Revision: 18/06/2015 Lest Edition: 17/09/2018Engineored Material Handling 6.6.3 Removing the Brake 1413 14 8 6 16 fT) 10 715 9 20 23 me | J) i a ASG S| t | \ i 141847 19 4 3 5 12 2 21 22 i Brake end shield 13 Distance bushing 2 Magnet body. 14 Washer 3 Armature plate 15 Plug 4 Rotor with brake liners 16 Sealing ring 5 Pressure spring _ 17, ‘tion plate 6 Hollow core bolt 16 Fixing screw / friction plate 7 Fixing screw / brake. 19 Dust protection ring 4 a | betas th = SS 2 an # = 12 Securing ring Peace When disassembling the brake, proceed in the following manner (depending on the madel, certain working steps can be dropped): ‘+ Disconnect the power supply and secure it egainst restert. + Remove the manual release lever (10) + Loosen the fastening screws and remove fan cover (20), + Remove the dust protection ring (19) from the magnet body (2) groove and pull over the brake end shield + Remove friction dust with pressurized air. #---Remove-the securing ring (22).———-———-~ a - + Pulloff the fan (23). + Remove the key (21), + Disconnect electric plug from magnet body (2). Maintenance & User Manual Hoist E&D Lost Revision 18/06/2016 Last Edition : 17/09/2018