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operation, maintenance and safety manual

1. eere 13 TAKING OUT OF OPERATION 13 SHUTTING DOWN eret 13 DISMANTLING 4 6e eren hte ete 13 DISMANTLING THE CONTROL VALVE 13 HOIST 5 guae uet 14 FILTER SILENCER SERVICE UNIT 14 MAINTENANCE intei tette 14 MAINTENANCE AND INPECTION INTERVALS 32 Lider 14 CLEANING AND CARE eene 14 SPARE PARTS 2er eere 14 INSPECTION AND REPAIRS 14 RECORDS AND REPORTS 14 PERIODIC INSPECTION eene 14 TROLLEYS NOT IN REGULAR USE 15 FILTRATION ipte ente 15 TESTING THE BRAKE MOTORISED TROLLEYS oroen tte titm 15 TROUBLESHOOTING ener 15 2 Page SAFETY INFORMATION This manual will refer to existing legal requirements and engineering practices as known when this document was written Should any such legislation or practices change or be expanded upon then due consideration must be taken Various standards have been used to assist in compiling this document and will be listed where applicable The use of lifting equipment is subject to certain hazards that cannot be overcome by mechanical means but only by the exercise of intelligence care and common sense It is therefore essential that personnel involved in the use and operation of equipment must be competent careful physically and mentally qualified and trained in
2. Records and Reports An inspection record should be maintained for each hoist listing all points requiring periodic inspection A written report should be made monthly on the condition of the critical parts of each hoist These reports should be dated signed by each person who performed the inspection and kept on file where they are readily available to authorized personnel Frequent Inspection On hoists in continuous service frequent inspection should be made at the beginning of each shift In addition visual inspections should be conducted during regular service for any damage or evidence of malfunction 1 Operation Check for visual signs or abnormal noises grinding etc which could indicate a potential problem Make sure all controls function properly and return to neutral when released Check chain feed through the chain guides and undercarriage If chain jams wedges jumps are excessively noisy or clicks clean and lubricate the chain If problem persists replace the chain sprockets or chain guide Do not operate the hoist until all problems have been corrected 2 Hooks Check for wear or damage increased throat width bent shank or twisting of the hook Replace hooks which exceed the throat opening specified in Table 2 or exceed a 10 degrees twist see Figure 4 If the hook latch snaps past the WWW ELEPHANTLIFTING COM tip of the hook the hook is sprung and must be replaced Check hook support swivels f
3. Remove the three hoses from the throttle hose connector Unscrew the four bolts attaching the throttle hose connector to the motor housing Remove the gasket Examine all components for wear replacing damaged or worn components Replace all gaskets and O rings before re assembly Remove all sharp edges and burrs from components Wipe all components with SAE 10W oil before re assembling in the reverse order to stripping Dismantle of the Control Valve Pilot Pendent Control 1 If the hoist has a pendent control remove the three pendent control hoses Unscrew the four bolts attaching the control valve to the motor housing Remove the control valve from the hoist Remove the gasket Examine all components for wear replacing damaged or worn components Replace all gaskets and O rings before re assembly Remove all sharp edges and burrs from components Wipe all components with SAE 10W oil before re assembling in the reverse order to stripping 16 Page CALL TOLL FREE 888 844 6113 Technical Data NumroffalsotCmm t 1 j a1 1 MotorPowerOupe kW 14 14 14 14 Weight withstandardit ropecontrol kg 5 5 z 34 Weight of imeterofcham g 1 1 1 1 Chaindimension mm 7x21 7x21 7xz1 9x27 Awprssue mar 4 6 46 4 6 4 6 Air consumption at full load mmn t5 15 m am Air hose connection J 3A BSP Arhosedmenion in
4. 4 Page CALL TOLL FREE 888 844 6113 ATS 2000 cannot know of nor provide all the procedures by which product operations or repairs may be conducted and the hazards and or results of each method If operation or maintenance procedures not specifically recommended by the manufacturer are conducted it must be ensured that product safety is not endangered by the actions taken If unsure of an operation or maintenance procedure or step personnel should place the product in a safe condition and contact supervisors and or the factory for technical assistance Safe Operating Procedures The following warnings and operating instructions are recommended are recommended and are intended to avoid unsafe operating practices which might lead to personal injury or property damage ATS2000 recognize that most companies who use hoists have a safety program in force in their plants and factories In the event you are aware that some conflict exists between a rule set forth in this publication and a similar rule already set by an individual company the more stringent of the two should take precedence Safe Operating Instructions are provided to make an operator aware of dangerous practices to avoid and are not necessarily limited to the following list Refer to specific sections in the manual for additional safety information 1 Read the manufacturer s instructions before operating the hoist 2 Never lift a load greater than the rated capacity
5. C In these cases cooling times must be observed in order not to exceed the permissible surface temperatures NOTICE All Special Conditions must be followed for this product to conform to the ATEX Directive and for the ATEX Declaration of Conformity to be valid T O Zg ATS 2000 PTY LTD sS se 2001 004302 07 TEL 27 011 887 2605 P O BOX 1899 708 OLD PTA RD FAX 27 011 440 5382 BRAMELY WYNBURG Email info ats2000 co za 2018 SANDTON SOUTH AFRICA Sinc 76 Special Conditions for Safe Applications Operations and Maintenance e Non compliance with any of these Special Conditions could result in ignition of explosive atmospheres Refer to ATS 2000 s specification supplied with the pneumatic hoist or trolley for proper filtering and lubrication in air supply line Proper lubrication and maintenance are required to prevent premature component failures Follow the recommendations in the lubrication and maintenance sections of the manual supplied with the hoist or trolley Air pressure above 7 bar 700kPa at the inlet may result in a source of ignition caused by premature failure of bearings or other components due to excessive speed output torque or force Do not operate the hoist or trolley with the air pressure at the inlet below 4 5 bar 450kPa Low air pressure to the hoist or trolley may cause the brake to partially engage during operation resulting in elevated temperatures The entire hoist system from the tro
6. Thereafter the engagement is to be adjusted as described lOlPage Flank Clearance Height adjust bolt Figure 4 Rack height adjustment COMMISIONING THE TROLLEY CONNECTING THE CONTROL HOSES In case the control device is delivered separately for your guidance short hose pieces have been put into the plug in connections at the factory Their colour or numbering corresponds to that of the hoses to be connected enabling you to connect the hoses one after the other REMOVING THE HOSE PIECES e Press down the locking ring 1 with a suitable tool for example screwdriver pulling out the hose piece 2 at the same time 1 Air connection on the left 2 Main air connection 3 Air connection 2 travel speed 4 Control port on the right ATTENTION Please ensure that the hose is not bent when inserted e Put the loop of the strain relief wire rope into the existing eyebolt e Put the end of the corresponding hose into the hole of the corresponding plug in connection e Push the hose in as far as the stop e Check the connection by pulling on the hose If air escapes from the connection during operation try to push the hose concerned even further in CONNECTING TO THE MAIN AIR SUPPLY Check air connection for contamination and clean if necessary Blow through compressed air hose in order to remove foreign bodies Attach the compressed air hose to the connection on the hoist or on the service unity Tighten
7. accordance with the requirements of ANSI ASME B30 16 should be established and records maintained 1 Page CALL TOLL FREE 888 844 6113 Preface ATS2000 PTY LTD warrants to the user its hoists and other products to be free from defects in material and workmanship for a period of one year from the date of purchase ATS2000 will repair without cost to the user any product found to be defective including parts and labour charges or at ATS2000 s option will replace such products or refund the purchase price less a reasonable allowance for handling in exchange for the product Repair and replacements are warranted for the remainder of the original warranty period If any product proves defective within its original one year warranty period it shall be returned to ATS2000 PTY LTD with proof of purchase and the original test certificate This warranty does not apply to products which ATS2000 has determined to have been misused or abused improperly maintained by the user or where the malfunction or defect can be attributed to the use of non genuine ATS2000 parts ATS2000 PTY LTD makes no other warranty and its maximum liability is limited to the purchase price of the product and in no event will ATS2000 PTY LTD not be liable for any consequential indirect incidental or special damages of any nature arising from the sale or use of the product whether based on contract or otherwise It is ATS2000 PTY LTD policy to pr
8. are designed to provide a MINIMUM of 5 to 1 safety factor It is the responsibility of the customer to ensure that the structure to which the hoist is attached and any load attaching devices are capable of handling the static and dynamic loads imposed on the structure by the hoist and its attachments when lifting the rated load If in doubt consult a registered professional structural engineer 3 Page CALL TOLL FREE 888 844 6113 Lifting equipment is subject to different regulations in each country These regulations may not be specified in this manual Whenever a conflict arises between the contents of this manual and any other applicable legislation standard or procedure the more stringent of the two must be applied The Occupational Health and Safety Act and Mine Health and Safety Act and other recognized safety sources make a common point Employees who work near cranes or assist in hooking on or arranging a load should be instructed to keep out from under the load From a safety standpoint one factor is paramount conduct all lifting operations in such a manner that if there were an equipment failure no personnel would be injured This means keep out from under a raised load an keep out of the intended path of any load ATS 2000 industrial and mining air hoists are manufactured in accordance with the latest ISO9001 standards The Occupational Safety and Health Act of 1993 section 10 states 10 1 Any person
9. even breakage of the chain causing severe injury death or substantial property damage Hoist Dismantling Disconnect the air supply hose before performing any maintenance or repairs on this hoist Check fault list for problem solving Do not disassemble the hoist any further than necessary to replace or repair damaged parts unless major service is due Whenever grasping a component in a vice always use aluminum covered or copper covered vice jaws to protect the surface of the component and help prevent damage This is particularly true of threaded members and housings Do not disassemble this hoist unless you have a complete set of new gaskets O rings and seals on hand for replacement These are available in the Overhaul Seal and Gasket Kit and parts list Do not attempt to recondition by washing out sealed bearings We recommend that all bearing vanes amp O rings be replaced when the hoist is reassembled Dismantle of the Control Valve Cord Toggle Control 1 Unscrew the four bolts attaching the Control valve to the motor housing Remove the gasket Examine all components for wear replacing damaged or worn components Replace all gaskets and O rings before re assembly Remove all sharp edges and burrs from components Wipe all components with SAE WWW ELEPHANTLIFTING COM 10W oil before re assembling in the reverse order to stripping Dismantle of the Control Valve Direct Pendent Control 1
10. for information on load chain inspection Excessive chain wear cannot be detected by casual observation The chain is case hardened to a depth of 0 25 to 0 30 mm deep or Heat treated to Grade 80 specification depending on application however excessive wear will considerably reduce the strength of the chain Further the chain will no longer fit the load sheave properly greatly increasing the chance of malfunction and chain breakage The load sheave will outlast several chains if the chain is replaces as recommended The use of a worn chain will cause the load sheave to wear rapidly If the chain is visibly damaged examine the load sheave and chain guides and chain stripper Install a new load sheave amp chain stripper if the old one is visibly worn Install new centre piece guides if the old one is excessively worn broken or distorted WWW ELEPHANTLIFTING COM Chain Sprokect C 2 2 L4 bi Wheel Ne AF Chain Weld To Outside On j Powered Chain Wheels For Single Fall Hoists 1 Disconnect the slack end of the chain from its anchoring bolt on the side of the chain guide or remove the chain stopper and buffers 2 Remove the hook from the other end of the chain by removing the bottom hook bolts Remove the buffers 3 Run the hoist slowly until the end of chain passes over the load sheave and comes out of the hoist 4 Remove the brake housing by slacking the 3 brake housing screws Remove the bra
11. or not at all Control lines Have lines repaired leaking or bent 151Page Motor vanes worn Replace motor vanes Control valve on motor faulty Have control valve repaired Two way valve in the motor defective Have shuttle valve repaired Air pressure too low Increase air pressure or hose section Plug in connection of control lines not properly plugged in Check plug in connection try to press hoses in further Track of trolley too narrow Adjust the clearance between the wheel flange and the outside edge of the bottom flange of the trolley girder Trolley speed reduces when operated for a long period or the motor stops Brake piston setting too tight Correct adjustment of brake piston At high ambient temperatures perform adjustment with the motor warmed up accordingly Trolley can only be moved slowly or not at all Brake does not bleed fully Brake lining and or brake piston worn Increase air pressure to 6 bar Check brake seal for leaks and replace seal if required Replace brake lining and or brake piston Trolley is repeatedly blocked at the same place Tracks are uneven or rail joint displaced Curve radius too small Rectify track faults Increase curve radius 161Page
12. the safe operation of equipment and the handling of the loads Serious hazards are overloading dropping or slipping of the load caused by improper hitching or slinging obstructing the free passage of the load and using equipment for a purpose for which it was not intended or designed Such actions can cause serious injury or death Operators of ATS2000 Hoists are also under obligation to ensure safe and hazard free operation This can be achieved through the following measures e Keep the operation manuals available at the hoist operating site Perform regular training Perform regular inspections at least once annually Implement an inspection log and make regular entries Regularly check personnel for safety and hazard awareness during work ATS2000 PTY LTD fully realizes the importance of proper design factors minimum and maximum sizes and other limiting dimensions of the chain and its fastenings sprockets and similar equipment all of which are designed with safety in mind The condition of the equipment or material can vary depending on environmental factors This may result in increased corrosion and or wear It is in light of this that the hoist be maintained and repaired under the supervision of a competent person This person must be 1 Qualified by virtue of his knowledge training skills and experience to organize the work and its performance 2 Familiar with the legal requirements which apply to the work to be per
13. the union nut LUBRICATION All ATS Indu Series air hoist motors are designed for lubrication free operation Excessive oil in the inlet may cause damage to the motor and may result in difficulty starting and premature motor failure While a small amount of hydraulic oil or oil designed for vane type air motors is acceptable under no circumstances should automotive type detergent oil be used Detergents will de laminate the motor vanes and cause premature motor failure STARTING OPERATION If the trolley is operating with an ATS2000 Hoist the operation manual of the mounted hoist hoist system has to be observed before putting into operation the section Pre start checks also applies INSPECTION Careful inspection on a regular basis will reveal potentially dangerous conditions while still in the early stages allowing corrective actions to be taken before the condition becomes dangerous Any deficiency revealed through inspection must be reported to an appointed person A determination must be made as to whether a deficiency constitutes a safety hazard before resuming operation of the hoist The results of the inspection must be recorded in the inspection log 111 Page INSPECTION BEFORE INITIAL OPERATION Hoists mounted into trolleys have to comply with the regulations for the prevention of accidents valid for cranes Before beginning to use a crane for the first time and after any major modification before starting to
14. usage Keep accumulative written records of periodic inspections to provide a basis for continuing evaluation Inspect all the items in Frequent Inspection Motor If performance is poor disassemble the motor and check for wear or damage to bearings vanes cylinder end plates and other parts The parts should be cleaned lubricated and reassembled Replace worn or damaged parts Supporting Structure Check for distortion wear and continued ability to support the load Trolley Check that the trolley wheels run properly on the beam and that the distance between wheel flanges exceeds the beam flange size by 4 5 to 6 mm Check that wheels and rail are not excessively worn and inspect the side plates for opening up due to bending Do not operate the hoist until any problems have been identified and corrected Nameplate Check for presence and legibility Replace if necessary TROLLEYS NOT IN REGULAR USE e hoist which has been idle for period of one month or more but less than one year should be given an inspection conforming with the requirements for Frequent Inspection prior to being placed into service e A hoist which has been idle for a period of more than one year should be given an inspection conforming with the requirements of Periodic Inspection prior to being placed into service e Standby hoist should be inspected at least biannually in accordance with the requirement of Frequent Inspection In abno
15. work with it again it has to be checked by a qualified person See also ZH1 27 Principles for the Testing of Cranes The test has to include the orderly erection equipment and the readiness of service etc The suitability of operation of the ready to operate equipment has to be safeguarded e By a dynamic test with 1 1 times the maximum carrying capacity under normal working conditions lift load just above floor e If necessary by a static test with 1 25 times the maximum carrying capacity with motorized equipment Note The static test is not applicable for hand operated cranes e During these tests no permanent deformation distortion disturbances of performance or other failures may occur As according to BGG ZH1 27 hoists in trolleys do not represent a ready to use installation on delivery the manufacturer only supplies a declaration of incorporation EC conformity cannot be issued until the ready to operate installation has been checked by an authorized person If necessary further tests on the basis of national regulations have to be executed In case of testing loads higher than those mentioned in this manual please contact ATS2000 If the control circuit of the installation allows several movements at the same time the dynamic test has to be executed with combined movements For trolleys with rack and pinion drives sufficient flank clearance approx 0 3 mm must be set between the drive pinion and th
16. 000 co za 2018 P O BOX 1899 SANDTON SOUTH AFRICA Service Notes Made in South Africa ATS 2000 PTY LTD essec 2001 004302 07 TEL 27 011 887 2605 P O BOX 1899 708 OLD PTA RD FAX 27 011 440 5382 BRAMELY WYNBURG Email info ats2000 co za 2018 SANDTON SOUTH AFRICA Sinc 76 DECLARATION OF CONFORMITY Supplier s Name ATS2000 PTY LTD Address 708 OLD PRETORIA MAIN ROAD WYNBERG SANDTON Declare under our sole responsibility that the product ATS 2000 Series Air Chain Hoists Trolleys Model ATSi Rigga To which this declaration relates is in compliance with provisions of Directives 2006 42 EC Machinery 94 9 EC ATEX as well as SANS 1638 ASME B30 16 By using the following Principle Standards EN 292 1 EN 292 2 EN 418 EN 983 F E M 1 001 F E M 9 511 EN 13463 1 pr EN 13463 5 EN 1127 1 Serial Number Range 9012 and up Date August 2014 Approved By Ey Glenton W Rebello ATS 2000 PTY LTD South Africa Managing Director This operation manual edition 01 2015 covers maintenance and operation of the following ATS Trolleys Manual trolleys Reel chain trolleys Motorized trolleys It must be read carefully and in its entirety before operating any trolley For trolleys with a built in or suspended hoist for motorized trolleys and for hoist systems this manual is only valid together with the operation manual for the respective hois
17. Bm B5 Liftingspeedwithout load mmn 37 375 Loweringspeedwihfulload min 30 Standardit mm 53 Length of corkrolforstandard t m 2 Noise level Load Limiters fitted Standard G j D Amin headroom mm 347 347 347 am PB mm 1 14 140 vs 6 m gt nm 8 er nsi in 347 99 99 174 202 E mm 23 25 E 445 22 1 2 Hook wath mm 22 17 Page WWW ELEPHANTLIFTING COM CALL TOLL FREE 888 844 6113 o gt z o gt c zi 2 Number of falis of chain Metorpoweroutput Weight with rope control and standard Eft of 1meter of cham ATA sp see Ax consunionstfwlload OOOO Air hose connection Ai hose dimension tmgspeedatfullload Lifting speed without load gt lLowermgspeedwithfulload Standardift Lengthof cortrolforstandardift INoselevel 1 sadaAQim 0 0 0 00 Load Limiters fitted Standard l i pe T type Sten azon ston oon ton 575 609 646 802 8 mm w 272 266 271 o m 4 193 Er nm 4 4 40 49 5 ee mm so 40 40 40 53 231 294 Hnookwidth mm 30 37 37 37 4 7 mm 0 gt 18 Page WWW ELEPHANTLIFTING COM CALL TOLL FR
18. EE 888 844 6113 Proudly manufactured in South Africa within an ISO facility WWW ELEPHANTLIFTING COM CALL TOLL FREE 888 844 6113 ATS 2000 PTY LTD 03600 2001 004302 07 TEL 27 011 887 2605 P O BOX 1899 708 OLD PTA RD FAX 27 011 440 5382 BRAMELY WYNBURG Email info ats2000 co za 2018 SANDTON SOUTH AFRICA Sinc 76 Form ATS ATEX1 Edition 2 August 2014 PNEUMATIC HOISTS and TROLLEYS Intended for use in Potentially Explosive Atmospheres The EC Declaration of Conformity in this manual states that these Pneumatic Hoist and Trolley models are in compliance with European Community Directive 94 9 EC for equipment intended for use in potentially explosive atmospheres commonly referred to as the ATEX Directive Standard Pneumatic Hoist and Trolley models conform to and are marked for use as defined by ATEX designation Ex II 2 GD IIA TA X 3 GD IIB TA X Standard version ATS 2000 air hoists are category 2 devices Guideline 94 9 EC for use in zone 1 and 2 for gases of explosion group IIA These devices are also suitable for use in zone 2 in the presence of gases of explosion group IIB provided that the substances hydrogen sulphide and ethylene oxide can be excluded and additionally in zones 21 and 22 for dusts with glow temperatures above 210 C or ignition temperatures above 202 C provided that no light metal or other impact sensitive dusts are present Pneumatic Hoist and Trolley models with the additional specia
19. ELEPHANT nl 1r G LIFTING PRODUCTS PNEUMATIC OPERATION MAINTENANCE AND SAFETY MANUAL ATSI INDUSTRIAL SERIES LME 155 pie U DOL on 150 9001 LIFTING amp PULLING EXCELLENCE ASME B30 16 AND SANS 1638 COMPLIANT WWW ELEPHANTLIFTING COM Contents Preface Safety Information Legal Requirements Safe Operating Procedures Installation Air Supply Operation Initial Operating Checks Hoist Controls Operation of Air Hoist fitted with Load limiter Inspection Records and Reports Frequent Inspection Periodic Inspection Hoist Not In Regular Use Filtration Lubrication Troubleshooting Maintenance Load Chain Care Chain Replacement Hoist Disassembly and Reassembly Appendix Dimensions Specifications WWW ELEPHANTLIFTING COM 21 21 THIS MANUAL MUST BE READ BEFORE USING OR REPAIRING THESE PRODUCTS This manual contains important safety installation operation maintenance and repair information Make this manual available to all persons responsible for the operation installation maintenance and repair of these products Do not use this hoist for lifting supporting or transporting people or lifting or supporting loads over people Always operate inspect and maintain this hoist in accordance with South African Bureau of Standards Specification number SANS1638 2008 pneumatically powered chain hoists and SANS 1639 2010 Reconditioned pneumatically powered chain hoists and any other safety c
20. YS WITH LOAD BOLT OVER 2 TON WLL INTO GIRDERS WITH OPEN ENDS 1 Mount the trolley at one end of the girder For rack and pinion drive the drive pinion is to be lowered first in order to be released from the rack and pinion 2 Secure both ends of the girder with end stops to prevent the trolley from falling They must be designed for the impact load occurring in the event of a collision with full load and full speed 3 The end stops have to be equipped with a buffer We recommend the ATS Series of clamping buffers For rack and pinion drive engage the drive pinion see section ADJUSTING THE RACK AND PINION DRIVE Page 10 4 The hexagonal nuts 1 2 of the distance spacers 3 and the load bolt 4 at the rear side plate 6 have to be loosened so far that the trolley can be pushed over the bottom flange of the girder If necessary the rear side plate including the outer distance washers 7 have to be completely dismantled For rack and pinion drive the drive pinion is to be lowered first in order to be released from the rack and pinion 5 Inthe case of running gears without distance spacers the retaining rings must be removed from the hexagonal nuts 2 of the load bolts and the hexagonal nuts 2 at the rear side section must be loosened so far that the trolley can be pushed over the bottom flange of the girder If necessary the rear side plate must be completely dismantled 6 Positionthe trolley possibly including the hoist with r
21. and the procedures to be followed in the case of an accident involving such substance Where a person designs manufactures imports sells or supplies an article or substance for or to another person and that other person and that other person undertakes in writing to take specified steps sufficient to ensure as far as is reasonable practicable that the article or substance will comply with all prescribed requirements and will be safe and without risks to health when properly used the undertaking shall have the effect of relieving the first mentioned person from the duty imposed upon him by this section to such an extent as may be reasonable having regard to the terms of the undertaking It is the owner s and user s responsibility to determine the suitability of a product for any particular use It is recommended that all applicable industry trade association and legislation be checked Read all operation instructions and warnings before operation 4lPage This manual has been produced by ATS 2000 Pty Ltd to provide agents fitters and company personnel with the information required to install operate maintain and repair the products described herein It is extremely important that fitters and operators be familiar with the servicing procedures of these products or similar products and is physically capable of conducting the procedures These personnel shall have a general working knowledge that includes Proper an
22. ar Check Pendent control lever or Rope Control valve for free movement Inspect clean and replace silencer disc in Pendent Control or motor silencer Check for worn motor bearing cylinder end plates and vanes damaged Load continues to move when hoist is stopped DOWN direction Pendant valve or rope control valve is sticking or bypassing air Brake is slipping Hoist is overloaded Pendent Lever Check Pendant control handle or Rope control valve for free movement Check brake spring O rings and brake disc linings for wear See MAINTENANCE section Reduce load to within rated capacity Check Pendent lever or chain Worn load sheave chain crack etc Incorrectly reeved twisted load chain Hook lowers No air supply to Check air supply and but will not hoist or too little connections in air supply raise volume and air line pressure Hoist is Reduce load to within rated overloaded capacity Pendent Control Check pressure at air inlet valve connection on pendent and malfunction the travel on the valve Hook can be Low air Check pressure at control raised but not pressure valve inlet Raise pressure lowered to rated capacity Check pressure at air inlet Pendent Control connection on pendent valve malfunction Load chain No oil on load Check Lubricator on motor jumps on chain which in turn lubricate the sheave or is chain See maki
23. ation operation and or maintenance of these tools when used in potentially explosive atmospheres Made in South Africa ATS 2000 PTY LTD see 2001 004302 07 TEL 27 011 887 2605 P O BOX 1899 708 OLD PTA RD FAX 27 011 440 5382 BRAMELY WYNBURG Email info ats2000 co za 2018 SANDTON SOUTH AFRICA Sinc 76 These ATEX designations define the applications type and duration of the potentially explosive atmospheres type of protection and the maximum surface temperature This symbol indicates certification for use in an explosive atmosphere and is followed by other symbols indicating the details of that certified use l Indicates Equipment Group I Mine use Il Indicates Equipment Group II Non Mine Use 2 Indicates Equipment Category 2 Equipment Category 2 is intended for use in areas in which explosive atmospheres caused by gases vapours mists or air dust mixtures are only occasionally likely to occur Protection level is very high during normal use and in the event of frequently occurring disturbances or equipment faults 3 Indicates Equipment Category 3 Equipment Category 3 is intended for use in areas in which explosive atmospheres caused by gases vapours mists or air dust mixtures are unlikely to occur Protection level is normal during intended use and in the event of infrequently occurring disturbances or equipment faults M2 These products are intended to be de energized in the event of an explosive atmosph
24. before performing any maintenance or repairs on this hoist e Check fault list for problem solving e Do not disassemble the hoist any further than necessary to replace or repair damaged parts unless major service is due e Whenever grasping a component in a vice always use aluminum covered or copper covered vice jaws to protect the surface of the component and help prevent damage This is particularly true of threaded members and housings e Do not disassemble this hoist unless you have a complete set of new gaskets O rings and seals on hand for replacement These are available in the Overhaul Seal and Gasket Kit and parts list e Do not attempt to recondition by washing out sealed bearings We recommend that all bearing vanes amp O rings be replaced when the hoist is reassembled DISMANTLING THE CONTROL VALVE e If the hoist has a pendent control remove the three pendent control hoses e Unscrew the four bolts attaching the control valve to the motor housing Remove the control valve from the hoist Remove the gasket 131Page e Examine all components for wear replacing damaged or worn components Replace all gaskets and O rings before re assembly e Remove all sharp edges and burrs from components Wipe all components with SAE 10W oil before re assembling in the reverse order to stripping DISPOSAL ATS2000 Hoists contain a range of materials which on expiry of the service life must be disposed of or recycled w
25. ble practicable that the article or substance will comply with all prescribed requirements and will be safe and without risks to health when properly used the undertaking shall have the effect of relieving the first mentioned person from the duty imposed upon him by this section to such an extent as may be reasonable having regard to the terms of the undertaking It is the owner s and user s responsibility to determine the suitability of a product for any particular use It is recommended that all applicable industry trade association and legislation be checked Read all operation instructions and warnings before operation Rigging It is the responsibility of the operator to exercise caution use common sense and be familiar with proper rigging techniques This manual has been produced by ATS 2000 to provide agents fitters riggers operators and company personnel with the information required to install operate maintain and repair the products described herein It is extremely important that fitters riggers and operators be familiar with the servicing procedures of these products or similar products and are physically capable of conducting the procedures These personnel shall have a general working knowledge that includes 1 Proper and safe use and application of fitter s common hand tools as well as special or recommended tools 2 Safety procedures precautions and work habits established by accepted industry standards
26. d safe use and application of fitter s common hand tools as well as special or recommended tools 2 Safety procedures precautions and work habits established by accepted industry standards ATS 2000 Pty Ltd cannot know of nor provide all the procedures by which product operations or repairs may be conducted and the hazards and or results of each method If operation or maintenance procedures not specifically recommended by the manufacturer are conducted it must be ensured that product safety is not endangered by the actions taken If unsure of an operation or maintenance procedure or step personnel should place the product in a safe condition and contact supervisors and or the factory for technical assistance Identification The nameplate mounted on the side plate identifies the type of ATS2000 trolley and contains important rating data If you have any questions concerning the operation of ATS2000 trolleys which are not addressed in this operation manual please contact us at the following address ATS2000 PTY Ltd 708 Pretoria Main Road Wynberg Sandton South Africa Phone 27 11 887 2605 Fax 27 11 440 5382 E mail GlenR ats2000 co za 5 Page MAIN COMPONENTS ATS2000 trolleys and running gears consist of the following main components Side plates Rolling wheels Width spacers Load bolts clevis load bar Air motor drive reel chain drive fore running wheels or rack and pinion Exception no drive with ma
27. drag the load chain or hook on the floor 20 Be certain there are no objects in the way of a moving load 21 Be certain the air supply is shut off preferably locked out or disconnected before performing maintenance on the hoist 22 Do not swing a suspended load 23 Keep the load block overhead when not in use 24 Properly secure the hoist before leaving it unattended 25 Only allow personnel trained in safety and operation of this product to operate the hoist 26 Avoid collision or bumping of hoists 27 Do not operate a hoist if you are not physically fit to do so 28 Pay attention to the load at all times when operating a hoist 29 Never splice a hoist chain by inserting a bolt between links or by any other means 5 Page CALL TOLL FREE 888 844 6113 30 Do not force a chain or hook into place by hammering 31 Do not allow the chain to be exposed to extremely cold weather Do not apply loads to an extremely cold chain Installation Pre use Check 1 Check that the hoist has been delivered free of damage Damage may occur during shipping 2 The hoist is supplied with a test certificate and an instruction maintenance and parts manual When initially receiving the hoist check that the serial number on the hoist and certificate correspond 3 Ensure that the hoist s serial number and working load limit rated load are clearly marked on the hoist 4 Check that the hoist that has been delivered
28. e of bearings brake or other mechanical components If elevated temperatures or elevated vibration levels are detected shut the hoist and or trolley off and discontinue its use until it can be inspected and or repaired Do not use a pneumatic hoist or trolley that exhibits rust or rust films that may come in contact with aluminium magnesium or their corresponding alloys Do not perform maintenance or repairs in an area where explosive atmospheres are present Do not clean or lubricate a pneumatic hoist or trolley with flammable or volatile liquids such as kerosene diesel or jet fuel A potentially explosive atmosphere may be created Hoists and trolleys with ATEX certification are intended for general industrial material handling use in conformance to their labelled designation and these special conditions Special assessments for other specific applications requiring increased protection should be requested by written inquiry to ATS 2000 PTY LTD NOTICE To safely use this product and conform to the provisions of the Machinery Directive 98 37 EC all instructions given in the accompanying literature in addition to all conditions notices and warnings given herein must be followed Made in South Africa ATS 2000 PTY LTD 6300 2001 004302 07 TEL 27 011 887 2605 P O BOX 1899 708 OLD PTA RD FAX 27 011 440 5382 BRAMELY WYNBURG Email info ats2000 co za 2018 SANDTON SOUTH AFRICA Refer to appropriate winch Parts Operatio
29. e rack along the entire track If the setting is too close the drive pinion could be damaged or even break FREQUENT INSPECTION On hoists in continuous service frequent inspection should be made at the beginning of each shift In addition visual inspections should be conducted during regular service for any damage or evidence of malfunction OPERATION Check for visual signs or abnormal noises grinding etc which could indicate a potential problem Make sure all controls function properly and return to neutral when released Check chain feed through the chain guides and undercarriage If chain jams wedges jumps are excessively noisy or clicks clean and lubricate the chain If problem persists replace the chain sprockets or chain guide Do not operate the hoist until all problems have been corrected RULES FOR THE SAFE OPERATION OF TROLLEYS In addition to the rules listed in the operation manual for ATS2000 air hoists and ATS2000 monorail hoists the following rules have to be observed e If several trolleys are working together the customer has to set up the conditions for safe operation e If the local conditions or the work to be performed make it necessary the customer has to define operating instructions e Maintenance and inspection work may only be performed once the people in charge are convinced that the trolley and the hoist monorail hoist are cut off from the energy supply and that measures have been ta
30. e the hoist is centred below the trolley 2 Check for air leaks in the supply hose and fitting to the pendent and from the pendent to the control valve block 3 When first running the hoist or trolley motors some light oil SAE 10W or 27 32 Centistoke should be injected into the inlet connection to allow good initial lubrication 4 Check that the lubricator is feeding oil constantly as the initial injection will only lost for a few minutes 5 Check that the air filter is not blocked clean out when necessary 6 When first operating the hoist and trolley it is recommended that the motors be driven slowly in both directions for a few minutes 7 Operate the trolley along the entire length of the beam ensuring that the air supply hose cannot kink 8 Test hoist and trolley performance when raising moving ad lowering test load s Hoist and trolley must operate smoothly and at rated specification prior to being entered into service 9 Check that trolley if equipped and hook movement is in the same direction as arrows on the pendent control 10 Raise and lower a light load to check operation of the hoist brake 11 Check hoist operation by raising and lowering a load equal to the rated capacity of the hoist a few centimeters of the floor 8 Page CALL TOLL FREE 888 844 6113 12 Check operation of the hook travel buffers These operate in conjunction with the load limiter 13 Check to see that the hoist
31. e track girder by pushing the running gear onto the girder so that the running wheels roll on the bottom flange After mounting the clearance between the outer edge of the bottom flange of the girder and the wheel flange must be between 1 and 1 5 mm on either side DANGER At the largest girder width the clevis load bar must be at least flush with both side plates on the outside MOUNTING TROLLEYS WITH CLEVIS LOAD BAR INTO GIRDERS WITH CLOSED ENDS By turning the clevis load bar a pre adjustment takes place to mount the trolley onto the bottom flange of the girder The trolley is first pushed onto one end with two wheels and then adjusted by turning the clevis load bar so that the opposite wheels are also placed on the bottom flange After mounting the trolley the clearance between the outside edge of the bottom flange of the girder and the wheel flange should be set to between 1 and 1 5 mm on either side DANGER Incorrect suspension loading of the load bar i e over the flat cross section causes danger of fracture and is therefore not permissible After the running gear width has been adjusted the clevis of the load bar must be positioned centre to the girder as shown in Figure 2 The load hook of the lifting equipment can now be attached to the clevis 9 Page Figure 2 Capped beam Assembly DANGER Do not drop lifting equipment equipment should always be placed properly onto the floor MOUNTING TROLLE
32. ed no more than 3 m from the hoist The air line lubricator must be set to deliver a minimum of 1 to 3 drops per minute when the hoist is running at full speed The recommended lubricant is a light oil ie SAE 10W or 27 to 32 centistokes Do not use automotive type detergent oil These oils will delaminate the motor vanes and cause motor failure Shut off air supply before filling the air line lubricator 7 Page CALL TOLL FREE 888 844 6113 Air Line Filter Dirt or grit entering the hoist motor will cause severe damage to the internal components We recommend the installation of a 100 micron air filter as close as possible to the hoist where it is not internal The filter should be cleaned weekly to prevent excessive pressure drops due to constriction of the filter element Filters incorporating a water trap are also recommended Moisture entering the hoist motor reduces the efficient operating life of the hoist and should be removed via line water traps separators Storing the Hoist 1 If the hoist is to be stored for a long time spray anti corrosion spray or SAE 10W or 27 32 centistoke oil into the air inlet port and run the hoist slowly for a few seconds This will compensate for the slight delay of the oil coming from the lubricator and stop moisture rusting the bearings 2 Plug hoist air inlet port 3 Always store the hoist in a no load condition 4 Wipe of all dirt and water 5 Oil the load chain hook p
33. ed that the minimum inner diameter of the supply hose to the hoist be between 19 and 25 0mm For supply hose lengths to the hoist in excess of 30m use a larger diameter hose Before connecting the hose to the hoist remove any dirt from the hose by blowing compressed air through the hose into the atmosphere Do not point the hose at anyone while doing this In order to reduce pressure drops in the supply hose which can affect hoist performance the supply hose should be WWW ELEPHANTLIFTING COM kept as short and straight as possible Keep the number of hose fittings to a minimum size of 16mm as they cause unnecessary restrictions Always use an air line filter lubricator unit with an ATS2000 air hoist if not already fitted in the hoist or hoist control valve system Air Line Lubricator The lubricator must have inlet and outlet ports at least as large as the inlet on the hoist motor Install the air line lubricator as close to the air inlet on the hoist motor as possible Refer to Accessories in the PARTS section for the recommended Filter Lubricator Where hoists are frequently moved from one location to another particularly in the mining environment we recommend the use of the portable filter lubricator assembly shown in Figure 3 The use of a pressure regulator is also recommended for pressures higher than 7 Bar since it allows for constant pendent control sensitivity and hoist performance In line lubricator must be install
34. emainder of the original warranty period If any product proves defective within its original one year warranty period it shall be returned to ATS2000 PTY LTD with proof of purchase and the original test certificate This warranty does not apply to products which ATS2000 has determined to have been misused or abused improperly maintained by the user or where the malfunction or defect can be attributed to the use of non genuine ATS2000 parts ATS2000 PTY LTD makes no other warranty and its maximum liability is limited to the purchase price of the product and in no event will ATS2000 PTY LTD be liable for any consequential indirect incidental or special damages of any nature arising from the sale or use of the product whether based on contract or otherwise It is ATS2000 PTY LTD policy to promote safety of all persons and equipment in the workplace All equipment manufactured is thoroughly checked packed and inspected before dispatch Any loss or damage which occurs during shipment while en route must be reported to ATS2000 immediately Should any item be delivered to you in apparent good condition but upon opening the container loss or damage has taken place while in transit notify ATS2000 PTY LTD immediately All transport costs will be for the account of the user These instructions are prepared by ATS2000 PTY LTD for the purpose of maintenance repair and the use of its air hoists No responsibility for failure of
35. equipment due to manufacturing procedure will be assumed if these instructions are not carried out Only original ATS2000 supplied spares are to be used in all repairs llPage Contents SAFETY INFORMATION cene 3 DANGER WARNING CAUTION amp NOTICE 3 SAFETY SUMMARY cene 4 MAIN COMPONENTS enne 6 PRODUCT DESCRIPTION s 6 INTENDED USE Eon NUS SIL 6 OPERATING CONDITIONS ees 7 TRANSPORT AND STORAGE c 8 STORAGE CONDITIONS ces 8 MOUNTING THE TROLLEY 8 MOUNTING usa 9 MOUNTING TROLLEY WITH CLEVIS LOAD BAR INTO GIRDERS WITH OPEN ENDS 9 MOUNTING TROLLEYS WITH CLEVIS LOAD BAR INTO GIRDERS WITH CLOSED ENDS 9 MOUNTING TROLLEYS WITH LOAD BOLT OVER 2 TON WLL INTO GIRDERS WITH OPEN ENDS ae peneste 10 ADJUSTING THE RACK AND PINION DRIVE E 10 COMMISIONING THE TROLLEY 11 CONNECTING THE CONTROL HOSES 11 REMOVING THE HOSE PIECES 11 CONNECTING TO THE MAIN AIR SUPPLY 11 LUBRICATION aiena npe 11 STARTING OPERATION eere 11 INSPEGTION iere eet ien rite 11 INSPECTION BEFORE INITIAL OPERATION 12 FREQUENT INSPECTION eee 12 OPERATION te tree hp dettes 12 RULES FOR THE SAFE OPERATION OF TROLLEY S 2 tee e Red 12 CONT ROBES unite reiten 13 PILOT PENDANT CONTROL 13 EMERGENCY STOP
36. ere Protection methods must be incorporated to provide a high level of safety G Indicates evaluation for explosive atmospheres caused by gases vapours or mists D Indicates evaluation for explosive atmospheres caused by dust T Indicates the maximum surface temperature Class X Indicates that there are special conditions for safe application installation operation and maintenance which must be followed for the certification to apply This designation refers to explosion protection details in the operation manual EX II 2 GD IIA TA X Il 3 GD IIB T4 X or EX II 3 GD IIA TA X This designation does not permit use in the presence of the extremely flammable substance hydrogen sulphide and ethylene oxide or in the presence of light metal or other impact sensitive dusts or in the presence of dusts with glow temperatures below 210 C or ignition temperatures below 202 C The permissible ambient temperature range Ta extends from 20 C to 70 At carrying capacities above 20 tons continuous operation of the hoists is not permitted if the ambient temperature exceeds 50 C In these cases cooling times must be observed in order not to exceed the permissible surface temperatures EX II 2 IIC TA X or EX II 2 GB IIB TA X The permissible ambient temperature range Ta extends form 20 C to 70 c At carrying capacities above 20 tons continuous operation of the hoists is not permitted if the ambient temperature exceeds 50
37. erify hoist holds the load without slipping If slipping occurs disassemble Remove brake disc as described in the MAINTENANCE section Check and clean the brake parts each time the hoist is dismantled Replace the brake disc if the thickness is less than 5 mm Supporting Structure Check for distortion wear and continued ability to support the load Trolley If equipped Check that the trolley wheels run properly on the beam and that the distance between wheel flanges exceeds the beam flange size by 4 5 to 6 mm Check that wheels and rail are not excessively worn and inspect the side plates for opening up due to bending Do not operate the hoist until any problems have been identified and corrected Nameplate Check for presence and legibility Replace if necessary Load Chain and Anchors Ensure both ends of the load chain are securely attached to the hook swivel or chain stopper Secure if loose repair if damaged replace if missing Load Chain WWW ELEPHANTLIFTING COM Measure the load chain for wear and stretching as shown below and compare to the allowable limits in Table 3 Take care to take the measurements on that part of the chain which comes into contact with the load sheave most often If the measurements exceed the maximum values shown below replace the chain Always use the load chain recommended by ATS 2000 for the desired application Chain d xt 7x21 9x27 11 2x34 13x36 16x45 Dimensio
38. formed 3 Trained to recognize any potential or actual danger to health and safety in the performance of the work The instructions given in this manual must be interpreted accordingly and sound judgment used in determining their application This operation manual is intended to help the operator to become familiar with ATS2000 trolleys and how to use them properly This operation manual contains important information for the safe proper and efficient operation of ATS2000 air hoists Observance of the manual helps to avoid hazardous situations to reduce repair costs and downtime and to ensure the specified service life of the ATS2000 air hoists Always keep the manual readily available at the location where the ATS2000 trolley is being used All persons charged with operating maintaining or repairing ATS2000 trolleys must read and follow the instructions in this manual DANGER WARNING CAUTION amp NOTICE Throughout this manual there are steps and procedures which if not followed may result in an injury The following signal words are used to identify the level of potential hazard Danger is used to indicate the presence of hazard which will cause severe injury death or substantial property damage if the warning is ignored Danger Warning is used to indicate the presence of a hazard which can cause Severe injury death or substantial property damage if the warning is ignored Caution is used to indicate t
39. he presence of a hazard which will or can cause minor injury or property damage if the warning is ignored Notice is used to notify people of installation operation or maintenance information which are important but not hazard related Notice 3 Page SAFETY SUMMARY Do not use this trolley or any equipment attached to it for lifting supporting or transporting people or lifting or supporting loads over people ATS INDU series of trolleys are designed to provide a MINIMUM of 5 to 1 safety factor It is the responsibility of the customer to ensure that the structure to which the hoist is attached and any load attaching devices are capable of handling the static and dynamic loads imposed on the structure by the hoist and its attachments when lifting the rated load If in doubt consult a registered professional structural engineer Lifting equipment is subject to different regulations in each country These regulations may not be specified in this manual Whenever a conflict arises between the contents of this manual and any other applicable legislation standard or procedure the more stringent of the two must be applied The Occupational Health and Safety Act and Mine Health and Safety Act and other recognized safety sources make a common point Employees who work near cranes or assist in hooking on or arranging a load should be instructed to keep out from under the load From a safety standpoint one factor is paramount c
40. he applicable ANSI ASME B30 volume that addresses that type of equipment It is the responsibility of the owner user to have all personnel that will install inspect test maintain and operate a hoist read the contents of this manual and applicable portions of ANSI ASME B30 16 Safety Standard for Overhead Hoists and OSHA Regulations If the trolley is installed as part of a total lifting system such as an overhead crane the applicable ANSI ASME B30 volume that addresses that type of equipment must also be read by all personnel If the trolley owner user requires additional information or if any information in the manual is not clear contact Harrington or the distributor of the hoist Do not install inspect test maintain or operate this hoist unless this information is fully understood A regular schedule of inspection of the hoist in accordance with the requirements of ANSI ASME B30 16 should be established and records maintained Preface ATS2000 PTY LTD warrants to the user its hoists and other products to be free from defects in material and workmanship for a period of one year from the date of purchase ATS2000 will repair without cost to the user any product found to be defective including parts and labor charges or at ATS2000 s option will replace such products or refund the purchase price less a reasonable allowance for handling in exchange for the product Repair and replacements are warranted for the r
41. hen the buttons are released the control valve shuts off the air supply to the hoist thereby applying the brake and stopping the hoist Direct Pendent Control With this system the main air supply to the hoist controlling lowering or lifting is regulated at the direct pendent handle The further the control lever is rotated WWW ELEPHANTLIFTING COM the more air flows to the motor and the faster the hoist operates Releasing the lever stops all air flow to the hoist and the brake will automatically be applied for hoist mounted on motorized trolleys a separate Direct Pendent is mounted alongside the hoist Direct Pendent Toggle Cord Control To operate a toggle control hoist pull on one of the chains attached to the control handle on the control block The two handles are marked for lifting or lowering The harder the chains are pulled the faster the hoist operates When released the control handle return to its neutral position and shuts off the air supply to the hoist thereby applying the brake and stopping the hoist Please note that this type of control is not recommended for horizontal rigger operations as the control ropes or chains can easily be twisted in the load or load chains and result in no control of the air hoist Operation of Air Hoists fitted with Load Limiters The load limiter torque slip clutch is factory set to operate at between 1096 and 3096 overload and is protected from tampering by a tamper resistant co
42. here appropriate in accordance with statutory regulations Please note the following list of materials used HOIST e Ferrous materials o Steel o Nodular cast iron e Non ferrous metals o Bronze e Plastics o Polyethylene Polyurethane Polyamide Natural rubber Epoxy resin Polyacetal Thermoset moulding compound Asbestos free brake lining 00000 9 O0 FILTER SILENCER SERVICE UNIT Zinc die cast Brass Nitrile rubber Aluminium Polypropylene Polyurethane Glass fibre reinforced plastic Steel Polyacetal Polythylene MAINTENANCE MAINTENANCE AND INTERVALS ATS2000 trolleys are extremely robust and require little maintenance Compliance with maintenance and inspection intervals is of great importance in order that the trolleys operate safely and reliably over a period of INPECTION many years If the trolley is being operated in a harsh environment that leads to accelerated wear then the intervals should be reduced Maintenance work on ATS2000 trolleys must only be performed by trained and qualified personnel In the case of maintenance work exceeding normal service and maintenance please contact ATS2000 CLEANING AND CARE If your ATS2000 trolley has to work in dirty surroundings remove coarse dirt from the trolley SPARE PARTS If during repair work the replacement of components is necessary only original ATS2000 spare parts may be installed INSPECTION AND REPAIRS ATS2000 rec
43. ins and hook latch 6 Store the hoist in a clean dry environment 7 Before returning the hoist to service follow instructions for hoists not in regular service in the INSPECTION section Operation The four most important aspects of hoist operation are 1 Follow all safety instructions when operating hoist 2 Allow only people trained in safety and operation of this product to operate hoist 3 Subject each hoist to a regular inspection and maintenance as outlined in this manual under the section Inspection 4 Be aware of the hoist capacity and weight of load at all times Operators must be physically competent Operators must have no health condition which might affect their ability to act and they must have good hearing vision and depth perception The hoist operator must be carefully instructed in his duties and must understand WWW ELEPHANTLIFTING COM the operation of the hoist including a study of manufacturer s literature The operator must thoroughly understand proper methods of hitching loads and should have a good attitude regarding safety It is the operator s responsibility to refuse to operate the hoist under unsafe conditions Initial Operating Checks Hoists are tested for proper operation prior to leaving the factory Before the hoist is placed into service after repair the following initial operating checks should be performed 1 After installation of trolley mounted hoists check to ensur
44. is capable of performing the required task 5 Record the hoist s serial number in a log book especially for the cording of hoist inspections All the hoists transmission components are lubricated internally by the factory on assembly It is essential that the motor lubricator is filled so that the load chain will lubricated when the hoist is put into service e Before installing the hoist the owner and user of the hoist should consult any safety information or regulations pertaining to the particular type of installation in which the hoist will be used e The raising and lowering of loads is potentially hazardous task by virtue of the fact that raised objects store large amounts of potential energy Safety is therefore of prime importance Read the section on SAFETY INFORMATION before installing the hoist WWW ELEPHANTLIFTING COM Mounting of the Air Hoist Proper initial installation of the hoist will ensure long trouble free service and will also limit the possibility of accidents occurring The hoist must be attached safely to secure structure of sufficient strength The structure should be able to hold at least 5 times the hoist chain rated load Preferably use a shackle or a sling to attach the hoist to the structure The anchorage fittings and framework must not show any signs of distortion when the hoist is lifting its rated load Hook Mounted Hoist Installation For hook mounted hoists ensure that the sling shac
45. is directly over the load for vertical lifting operations 14 Check to see that the hoist is securely connected to the overhead crane monorail and trolley or supporting member 15 Check to see that the load is securely attached to the hook and that the hook safety latch is engaged 16 Check to see that the load being lower can reach the floor before the chain stopper on the opposite end of the chain will be reached Only allow personnel trained in safety and operation of this product to operate the hoist hoist and trolley e The hoist is not designed or suitable for lifting lowering or moving persons Never lift loads over people e The hook latch is intended to retain loose slings or devices under slack conditions Hook latches are not intended to support any load but to ensure load point in the hook is achieve Hoist Controls Pilot Pendent Control The hoist is operated via a two button pilot pendent control The two buttons control the lifting and lowering of the hoist For hoists mounted on motorized trolleys a four button pilot pendent control is supplied which controls the horizontal movement of the trolley in addition to the lifting and lowering of the hoist The pilot pendent control allows for precise spotting and variable speed control and has arrows indicating the direction of movement of the lower hook and the trolley The harder the pendent buttons are pressed the faster the hoist or trolley will operate W
46. ke disc brake piston and springs as per BRAKE STRIPING PROCEDURE 5 Push a piece of steel wire through the chain passage in the chain guide Attach this piece of wire to the last link of the chain 6 Pull the wire so that the first link lies flat the load sheave pocket Also ensure that the welded section faces outwards form the load sheave 7 Turn the brake disc coupler by hand until the chain has fed through the chain guide 8 Replace the buffer Attach the slack end of the chain to the sprocket housing chain guide if applicable taking care not to twist the chain or replace the chain stopper 9 Replace the buffer and attach the chain to the hook swivel using a new nut to secure the bottom hook pin For Double Triple and Quad Fall Hoists 1 Install the chain as in Steps 1 through 9 of the instructions for single fall hoists 2 Ensure that the chain is straight and not twisted 3 For double fall hoists feed the end of the chain through the undercarriage making sure that it seats on the load sheave The welded section of the chain must face outwards from the undercarriage load sheave 4 Keeping the chain straight replace the buffers and attach the free end of the chain to the chain sprocket housing using the doubling down bolt double fall hoists or the undercarriage 15 Page CALL TOLL FREE 888 844 6113 A twisted chain can jam as it passes over the load sheave which can result in damage to the hoist or
47. ken to prevent the unauthorized supply of energy The same applies to maintenance work and any changes in case personnel in the working area of the trolley may be exposed to danger If there is a danger that parts may fall down the corresponding area has to be barricaded and protected by suitable guards Other risks from neighbouring installations also have to be safeguarded against After completion of the work operation may only recommence following release by the operator Before release the operator must be convinced that all work has finally been completed that the whole trolley including hoist hoist system is in a safe condition again and that all personnel involved have cleared the installation See also Rules for the safe operation of hoists in the operation manual Air hoists monorail hoists If components other than ATS2000 components are used danger may occur Such an application can only be allowed after having received ATS2000 agreement 12 Page CONTROLS PILOT PENDANT CONTROL The hoist is operated via a two button pilot pendent control The two buttons control the lifting and lowering of the hoist For hoists mounted on motorized trolleys a four button pilot pendent control is supplied which controls the horizontal movement of the trolley in addition to the lifting and lowering of the hoist The pilot pendent control allows for precise spotting and variable speed control and has arrows indicating the direction
48. kle or hoist support member rests in the saddle of the hook This will minimize the chance of accidental disconnection Do not support the hoist from a member that tilts the hoist to one side The hoist must not be prevented from moving into its natural operating position when under load Make sure hook latch is engaged Rigid Mounted Trolley Hoist Installation The hoist attachment cradle will be attached to the hoist when shipped from the factory The cradle must be attached to the trolley using both the hoist support shafts Spacers must be installed between the cradle and the trolley side plates to ensure the correct wheel spacing The distance between the wheel flanges must be 4 5mm to 6 0mm larger than the flange size of the beam The same number of spacers must be installed on both sides of the cradle to ensure that the hoist is centered under the l beam Install at least one spacer between the cradle and each side plate and between the side plates and the support shaft nut The support shaft nuts must be securely fastened After installation allow the hoist to lift its rated load about 200mm off the ground and move the trolley along the entire length of the beam to ensure correct operation before usage e The hoist must be centered under the trolley when spacer driven are increased or degrease to match I beam This will prevent unbalanced loads damaging the trolley and the hoist e When the hoist is mounted rigidly to the t
49. l spark proof design package of spark protection conform to and are marked for use as defined by ATEX designation Ei 2 GD IIC T4 X n 2 GD IIB TA X ATS 2000 hoists of the version with special spark proof design protection SP satisfy additional explosion protection requirements With the exception of carbon disulphide temperature class T6 they can be used in presence of all gases in zones 1 and 2 and dusts with glow temperatures above 210 or ignition temperatures above 202 in zones 21 and 22 and can be marked For further operating conditions see instructions for safe operation ATS 2000 trolley running gear with Special spark proof design protection For use in zone 1 in the presence of gases in explosion group IIC bronzed running wheels or running wheels made of bronze are also used The highest possible designation for this version SPR is EX II2 GD IIC T4 X the same as for ATS2000 hoists with Special spark proof design protection These ATEX designations define the applications the type and duration of the potentially explosive atmospheres the type of protection and the maximum surface temperature Hoists intended to be used in underground parts of mines as well as those parts of surface installations of such mines endangered by firedamp and or combustible dust are marked for use as defined by ATEX designation M2 IIB T4 X The X indicates that additional special conditions are required for safe applic
50. lley or load hook to the bottom hook the control pendant and the payload shall be earth grounded at all times to prevent ignition hazards from electrostatic discharge A resistance to earth of less than 108 Ohms is required Do not disconnect or insulate any grounding or strain relief cables When using a nonconductive sling or harness or a nonconductive link or barrier an independent ground must be applied Never use a Standard pneumatic hoist or trolley when there is any possibility that a gas like hydrogen sulphide ethylene oxide or Carbon Disulphide or light metal dusts or dusts sensitive to impact may be present These atmospheres cause a high probability of explosion Never use a Special Spark Proof Designed pneumatic hoist or trolley when there is any possibility that a gas like Carbon Disulphide or light metal dusts or dusts sensitive to impact may be present These atmospheres cause a high probability of explosion Do not allow hard contact of the bottom block hook and load chain or pendant control against other objects The impact of any hoist or trolley component beyond normal use may cause an ignition hazard from sparks The maximum expected surface temperature of the hoist or trolley is 135 C measured during brake malfunction Inspect the hoist or trolley for air leaks and proper brake engagement prior to operation Check for abnormally elevated temperatures during operation that may be an indication of overload or potential failur
51. me of air or pressure Throttle valve or control handle sticking Pendent malfunction Hoist is overloaded Load Limiter clutch is slipping Motor is damage Brake is not releasing section for correct quantity m3 min and minimum of 4 pressure bar Check control handle throttle valve for free movement Check pressure at pendent Minimum operating pressure in pendent line is 4 bar Reduce load to within rated capacity Reduce load weight Repair or replace See MAINTENANCE section Check brake assembly release circuit brake O ring seals and pressure at the brake inlet 2 bar minimum Load continues to move when hoist is stopped UP direction Pendant valve or rope control valve is sticking or bypassing air Pendent lever sticking Control spring faulty Check Pendant control handle or Rope control valve for free movement or control valve for air leakage Check lever and restore free movement Check and refit control spring is sticking Rope Control lever and restore free movement Hoist will not lift Hoist is Reduce load to within rated rated capacity overloaded capacity No air supply to hoist or too little volume of air or pressure Pendent Control valve is restricted Exhaust restricted Motor is Check pressure at control valve inlet Refer to SPECIFICATIONS section for correct quantity m3 min and pressure 4 B
52. mon sense It is therefore essential that personnel involved in the use and operation of equipment must be competent careful physically and mentally qualified and trained in the safe operation of equipment and the handling of the loads Serious hazards are overloading dropping or slipping of the load caused by improper hitching or slinging obstructing the free passage of the load and using equipment for a purpose for which it was not intended or designed The above can lead to fatal consequences ATS2000 PTY LTD fully realizes the importance of proper design factors minimum and maximum sizes and other limiting dimensions of the chain and its fastenings sprockets and similar equipment all of which are designed with safety in mind The various conditions of the equipment or material can vary depending on the environment they are used in which may cause corrosion or wear and any other variables that may arise in each individual application It is in the light of this that the hoist be maintained and repaired under the supervision of a competent person 1 Who is qualified by virtue of his knowledge training skills and experience to organize the work and its performance 2 Whois familiar with the legal requirements which apply to the work to be performed 3 Who has been trained to recognize any potential or actual danger to health and safety in the performance of the work The instructions given in this manual must be interpre
53. n 0 25 0 50 mm which will cause excessive wear in the motor Lubrication To ensure continued satisfactory operation of the hoist all points requiring lubrication must be serviced with the correct lubricant at the proper time interval Correct lubrication is one of the most important factors in maintaining efficient operation The lubrication intervals recommended in this manual are based on intermittent operation of the hoist eight hours each day five days per week If the hoist is operated almost continuously or more than the eight hours each day more frequent lubrication will be required Also the lubricant types and change intervals are based on operation in an environment relatively fee of dust moisture and corrosive fumes Use only those lubricants recommended Failure to observe this precaution may result in damage to the hoist and or its associated components Whenever ATSi INDU Hoist is dismantled for overhaul or replacement of parts lubricate as follows 1 Coat all motor parts with a light film of SAE 10W or 27 32 centistoke or good quality hydraulic oil before assembling Do not use automotive type detergent oil Detergents will de laminate the motor vanes and cause motor failure 2 Apply a coating of grease to all gearing before assembly Neglect of proper lubrication will lead to bearing failure The recommended greases are as follows DIMOL GR 2 EP CASTROL SHEEROL EP2 and SHELL ALVANIA EP2 If the
54. n A max 11 x t inside max 5 link inside max Dimension B max 249 2 320 5 429 2 536 235 8 303 2 404 3 505 3 107 8 22 1 28 4 35 8 37 9 47 4 Dimension C max Dimension D max 6 3 8 1 10 1 11 7 14 4 36 1 46 4 57 8 63 6 79 3 Dimension in mm 12 Chain Bag Container Check for damage or excessive wear and that chain container is securely attached to the hoist Secure or replace if necessary Ensure correct positioning of the chain bag Hoists Not in Regular Use 1 A hoist which has been idle for period of one month or more but less than one year should be given an inspection conforming with the requirements for Frequent Inspection prior to being placed into service 2 Ahoist which has been idle for a period of more than one year should be given an inspection conforming with the requirements of Periodic Inspection prior to being placed into service 12 Page CALL TOLL FREE 888 844 6113 3 Standby hoist should be inspected at least biannually in accordance with the requirement of Frequent Inspection In abnormal operating conditions hoists should be inspected at shorter intervals Filtration Should the air line filtration not be integrated into the motor housing a proper high capacity filter is required with a 100 micron screening and should were possible include a water separator Do not use tap water screens as they pass particles of betwee
55. n and Maintenance Manuals for additional installation inspection and operation instructions Pneumatic Hoists use oil to prevent excessive heat build up and to prevent wear that could cause sparks Oil Grease levels must be properly maintained X I Check oil level in motor Lubricator daily At the beginning of each shift operate the hoist in both directions without a load Ensure the motor runs free and brake does not drag Check grease level in gearbox every 3 months Keep hoist housings clean of dust and dirt build up which can cause heat build up ARENT A worn or improperly functioning brake may cause excessive heat build up or sparks Operation When lowering loads near the hoist s rated load and at very slow speeds monitor the temperature of the brake housing This load speed combination may result in automatic brake dragging which could cause heat build up Indications that the heat build up on the brake is excessive are a Housing surface temperatures in excess of 120 C b Visible indications of hot paint such as blisters or scorching c The smell of hot oil or burning paint Stop all operations any time a hot brake is detected Ensure load chain piles naturally in chain bucket Load chain that does not pile naturally can chafe excessively leading to sparks ATS 2000 PTY LTD e3 600 2001 004302 07 708 OLD PTA RD TEL 27 011 887 2605 FAX 27 011 440 5382 BRAMELY WYNBURG Email info ats2
56. ng a LUBRICATION section snapping sound Worn or rusted See INSPECTION to determine wear limit Replace if necessary and lubricate frequently Replace worn parts Check load chain is correctly reeved and is not twisted WWW ELEPHANTLIFTING COM Maintenance CALL TOLL FREE 888 844 6113 14 Page For best results use ATS INDU series of hoists parts illustration to follow sequence of stripping and assembly e Disconnect air before maintenance on the hoist while it is supporting a load Shut off air system and depressurize air lines before performing any maintenance Before performing maintenance tag controls to indicate state of unit DANGER DO NOT OPERATE EQUIPMENT BEING REPAIRED e Only allow personnel trained in the operation and service of this hoist to perform maintenance After performing any maintenance on the hoist conduct a proof load and braking test 125 of its rated capacity as well as a dynamic performance test in accordance with SANS1639 2010 before returning the hoist to service Load Chain Care Keep the chain well lubricated as described in the LUBRICATION section Never operate a hoist if the load chain does not run freely and smoothly into and out of the chain guides and load sheave and that the chain splitter is in good condition or when it makes noises indicative or jamming wedging or other malfunctions Chain Replacement Refer to Inspection section
57. nual trolleys PRODUCT DESCRIPTION To traverse loads ATS2000 air hoists can be suspended or built into ATS2000 trolleys The air hoist is suspended with its upper hook in the load bolt or load eye of the trolley Built in means that the hoist is rigidly mounted into the trolley by means of a twist proof load eye ATS2000 lifting gear and low headroom trolleys have this rigid connection only For ultra low UL configurations please see the UL Installation and operation manual ATS2000 trolleys are moved according to their construction e Manual trolleys by pushing or pulling by hand on hooks and or load e Reel chain trolleys by winding or unwinding the reel chain e Motorized trolleys by actuating the control of the traversing motor The operating pressure of the traversing motors is adapted in accordance with the operating pressure of the corresponding hoist see nameplate ATS2000 trolleys are designed in accordance with DIN15018 and correspond to stress group B4 lifting group H2 They are suitable for girders according to DIN 1025 or similar types of girder The track width of the trolleys above 2 tons carrying capacity is adjusted to the girder profile given by the customer in the order sheet Note The track width of some ATS2000 trolleys can be adjusted within a certain range If you wish to operate the trolley on a girder profile different to that originally specified please contact ATS 2000 PTY Ltd ATS2000 tr
58. odes or procedures relevant to the industry in which the hoist is being Used Testing of pneumatically powered chain hoists must only be carried out by the competent person contemplated in SANS 1639 2010 For Hoist used outside of South Africa It is the responsibility of the owner user to install inspect test maintain and operate a hoist in accordance with ANSI ASME B30 16 Safety Standard for Overhead Hoists OSHA regulations If the hoist is installed as part of a total lifting system such as an overhead crane or monorail it is also the responsibility of the owner user to comply with the applicable ANSI ASME B30 volume that addresses that type of equipment It is the responsibility of the owner user to have all personnel that will install inspect test maintain and operate a hoist read the contents of this manual and applicable portions of ANSI ASME B30 16 Safety Standard for Overhead Hoists and OSHA Regulations If the hoist is installed as part of a total lifting system such as an overhead crane the applicable ANSI ASME B30 volume that addresses that type of equipment must also be read by all personnel If the hoist owner user requires additional information or if any information in the manual is not clear contact Harrington or the distributor of the hoist Do not install inspect test maintain or operate this hoist unless this information is fully understood A regular schedule of inspection of the hoist in
59. of movement of the lower hook and the trolley When the buttons are released the control valve shuts off the air supply to the hoist thereby applying the brake and stopping the hoist EMERGENCY STOP All controls are fitted with an emergency stop button The emergency stop button when pressed locks in the down position and halts the motion of the trolley All other pushbuttons are then inoperable The emergency stop can be released once the danger has been eliminated Operation of the trolley using the pushbuttons can only take place after this has been done The control is shown in Figure 5 e In the event of a hazard press down firmly on the red EMERGENCY STOP button e Once the hazard has been removed pull the E stop button to re activate the control Figure 5 4 Button Control with E stop TAKING OUT OF OPERATION SHUTTING DOWN If the hoist is to be taken out of operation for a period of time longer than a regular service interval it must be protected against corrosion and dirt as follows e Coat the chain and hook with a light oil film e Move the load hook out of the lifting area in order to avoid hazardous situations e Do not move against the lifting and lowering limiters buffers emergency end stop devices e Depressurise the air line DISMANTLING ATS2000 Air Hoists must only be dismantled by qualified personnel as described in the SAFETY INFORMATION section Disconnect the air supply hose
60. of the hoist unless for test purposes 3 Never use the load chain as a sling 4 Never operate the hoist with twisted kinked or damaged chain 5 Becertain the load is properly seated in the saddle of the hook 6 Do not use load chains as an earth for welding Do not attach a welding electrode to a hoist or sling chain 7 Do notuse the up and down buffer stops as a means of stopping a hoist The up and down buffer stops are emergency devices only Keep hands and clothing free from the toggle lever 8 Do notleave a load suspended for extended periods 9 Always stand clear of the load path WWW ELEPHANTLIFTING COM 10 Never use the hoist for lifting or lowering people and never stand on or under a suspended load 11 Never lift move or suspend loads over people 12 Before each shift check the hoist for wear or damage Check brakes limit buffer stops etc 13 Periodically inspect the hoist thoroughly and replace worn or damaged parts 14 Follow the lubrication instructions 15 Do not attempt to repair load chain or hooks Replace them when they become worn or damaged 16 Never operate a hoist when the load chain is not centered under the hook Do not pull the load sideways 17 Always rig the hoist properly and carefully 18 Do not apply shock loads to the hoist Take up the slack chain slowly when commencing with lifting operations 19 Keep the load chain clean and well lubricated Do not
61. olleys are fitted with anti climb and anti drop devices These form fitting devices are additional safety measures and prevent the trolley from disengaging from the girder irrespective of the function of the running wheels and from climbing the girder flange The minimum beam curve radius can be seen in the attached technical data sheet Special ATS2000 trolley models can be delivered with e Extra low height for low headroom trolley e Rack and pinion drive for form fitting power transmission Locking device for fixing in a certain position Two travel speeds Infinitely variable travel speed Pneumatic end switches for limiting the movement increased spark protection as described below in case of especially high requirements for explosion protection e Cleaning of the exhaust air by filter silencers e Throttle control for reducing the maximum travel speed INTENDED USE ATS 2000 trolleys in combination with ATS 2000 air hoists are intended to be used exclusively for lifting and lowering loads and for their horizontal movement above floor Any other use or use outside these stipulations is deemed to be impermissible For applications requiring this type of use please consider the ATS 2000 range of winches and the ATS Rigga range of hoists ATS 2000 cannot be held liable for any damage resulting from incorrect usage The entire risk is borne by the operator The following situations among others are regarded as impro
62. ommends two types of inspection 1 The frequent inspection performed by the operator as pre work inspection 2 The periodic inspections performed by personnel trained in the operation and repair of this hoist Careful inspection on a regular basis will reveal potentially dangerous conditions while still in the early stages allowing corrective actions to be taken before the condition becomes dangerous Any deficiency revealed through inspection must be reported to an appointed person A determination must be made as to whether a deficiency constitutes a safety hazard before resuming operation of the hoist RECORDS AND REPORTS An inspection record should be maintained for each hoist listing all points requiring periodic inspection written report should be made monthly on the condition of the critical parts of each hoist These reports should be dated signed by each person who performed the inspection and kept on file where they are readily available to authorized personnel PERIODIC INSPECTION Frequency of periodic inspection depends on the severity of usage 14 Page NORMAL HEAVY Yearly Biannually SERVERE Quarterly Please note the requirements of the Occupational Health and Safety Act of South Africa Act 85 of 1993 Driven Machinery Regulation 18 Lifting Machines and Lifting Tackle regarding the examination and testing of lifting machines and lifting tackle Disassembly may be required for HEAVY or SEVERE
63. omote safety of all persons and equipment in the workplace All equipment manufactured is thoroughly checked packed and inspected before dispatch Any loss or damage which occurs during shipment while en route must be reported to ATS2000 immediately Should any item be delivered to you in apparent good condition but upon opening the container loss or damage has taken place while in transit notify ATS2000 PTY LTD immediately Should any items be delivered back to ATS2000 PTY LTD all transport costs will be for the account of the user These instructions are prepared by ATS2000 PTY LTD for the purpose of maintenance repair and the use of its air hoists No responsibility for failure of equipment due to manufacturing procedure will be assumed if these instructions are not carried out Only original ATS2000 supplied spares are to be used in all repairs WWW ELEPHANTLIFTING COM CALL TOLL FREE 888 844 6113 2 Page Safety Information This manual will refer to existing legal requirements and engineering practices as known when this document was written Should any such legislation or practices change or be enlarged upon then due consideration must be taken Various standards have been used to assist in compiling this document and will be listed where applicable The use of powerful lifting equipment is subject to certain hazards that cannot be overcome by mechanical means but only by the exercise of intelligence care and com
64. onduct all lifting operations in such a manner that if there were an equipment failure no personnel would be injured This means keep out from under a raised load and keep out of the intended path of any load ATS 2000 industrial and mining air hoists are manufactured in accordance with the latest ISO9001 standards The Occupational Safety and Health Act of 1993 section 10 states 1 Any person who designs manufactures imports sells or supplies any article for use at work shall ensure as far as is reasonably practicable that the article is safe and without risks to health when properly used and that it complies with all prescribed requirements Any person who erects or installs any article for use at work on or in any premises shall ensure as far as is reasonably practicable that nothing about the manner in which it is erected or installed makes it unsafe or creates a risk to health when properly used Any person who manufactures imports sells or supplies any substance for use at work shall a ensure as far as is reasonably practicable that the substance is safe and without risks to health when properly used and b take such steps as may be necessary to ensure that information is available with regard to the use of the substance at work the risks to health and safety associated with such substance the conditions necessary to ensure that the substance will by safe and without risks to health when properly used
65. or excessive clearance or damage Ensure they Swivel easily and smoothly Maximum Mini permissible hook PM HOOK RATING opening permissible height dimension a dimension h 0 5 2 Ton 31 25 6 3 Ton 35 7 36 1 6 Ton 46 44 7 10 Ton 50 4 58 9 If safety catch fitted subtract the thickness of the safety catch from the maximum hook opening dim a Hook dimensions and wear limits 3 Hook Travel Buffers The hook travel buffers are securely attached to either end of the load chain When functioning as hook travel limits they operate in conjunction with the load limiter which stops the air motor when pulled against the hoist If the buffers are pulled against the hoist and the hoist stops release the controls and listen for the sound of the load limiter valve resetting as it exhausts a small amount of air 4 Air System Visually inspect all connections fittings hoses and components for indication of air leaks Repair any leaks found 10 Page CALL TOLL FREE 888 844 6113 Controls During operation of the hoist check the response of the hoist to the pendent is smooth and not sticky Ensure that the control handle switches to its maximum position in both directions The control handle must return to neutral when released If hoist responds slowly or movement is unsatisfactory do not operate hoist until all deficiencies have been corrected If fitted with an E Stop button ensure when ac
66. or HEAVY or SEVERE usage Keep accumulative written records of periodic inspections to provide a basis for continuing evaluation Inspect all the items in Frequent Inspection Also inspect the following 1 Fasteners Check cap screws and nuts Replace if missing or tighten if loose 2 All Components Inspect for wear damage distortion deformation and cleanliness If external evidence indicates the need disassemble Check gears shafts bearing load sheaves chain guides springs and covers Replace worn or damaged parts Clean lubricate and reassemble 3 Hooks Inspect hooks carefully for cracks using magnetic particle or other suitable non destructive testing methods Inspect hook swivels Tighten swivel bolts if necessary 11 Page CALL TOLL FREE 888 844 6113 10 11 Load Sheaves Check for damage or excessive wear Replace if necessary Observe the action of the load chain feeding through the hoist Do not operate a hoist unless the load chain feeds through the hoist and undercarriage smoothly and without audible clicking or other evidence of jamming wedging or malfunctioning Motor If performance is poor disassemble the motor and check for wear or damage to bearings vanes cylinder end plates and other parts The parts should be cleaned lubricated and reassembled Replace worn or damaged parts Brake Raise a load equal to the rated capacity of the hoist about 200mm off the floor V
67. per use Exceeding the permitted load carrying capacity Oblique pulling of loads Sliding loads Detaching dragging or pulling of loads Catching of falling loads Carrying people Jog control over longer distances Switching to the opposite direction with load in motion e Operation reaching of the end stop See also RULES FOR THE SAFE OPERATION OF TROLLEYS Page 12 6lPage Intended use also includes observance of the operation manual and compliance with the inspection and maintenance conditions OPERATING CONDITIONS ATS2000 Air Hoists are extremely robust and require little maintenance They are suitable for use in explosion hazardous areas see rating on hoist for details as well as in areas with increased concentrations of soot and dust high humidity and at ambient temperatures of 20 C up to approx 70 C if they are not heated above this level due to external influences The thermal endurance of chains and hooks is 150 C When touching metallic hand controls which are colder than 0 C skin could freeze within a few seconds and at temperatures above 43 C burns may occur s a protective measure please wear suitable gloves For stationary outdoor operation hoists must be protected against weathering and the maintenance intervals must be reduced Depending upon the version ATS2000 Air Hoists must be operated at a system pressure of 4 bar or 6 bar see information on the nameplate If the system pres
68. rate the hoist 3 Subject each hoist to a regular inspection and maintenance as outlined in this manual under the section Inspection 4 Beaware of the hoist capacity and weight of load at all times e Operators must be physically competent e Operators must have no health condition which might affect their ability to act they must have good hearing vision and depth perception e The hoist operator must be carefully instructed in his duties and must understand the operation of the hoist including a study of manufacturer s literature e The operator must thoroughly understand proper methods of hitching loads and should have a good attitude regarding safety e It is the operator s responsibility to refuse to operate the hoist under unsafe conditions MOUNTING THE TROLLEY ATS2000 trolleys must only be installed by qualified personnel Faulty installation can lead to serious accidents The trolley girders for ATS2000 trolleys must be able to safely withstand the expected forces The calculation of the static load and the selection of the girder profile are the responsibility of the operator The carrying capacity of the suspended built in hoist must not be greater than the capacity of the trolley Dynamic tractive forces must be considered ATS2000 trolleys are designed for running girder profiles in accordance with DIN 102 or similar profiles There must be sufficient room for the trolley to move freely along
69. rmal operating conditions hoists should be inspected at shorter intervals FILTRATION Should the airline filtration not be integrated into the motor housing a proper high capacity filter is required with a 100 micron screening and should were possible include a water separator Do not use tap water screens as they pass particles of between 0 25 0 50 mm which will cause excessive wear in the motor TESTING THE BRAKE TROLLEYS Test the brake function daily MOTORISED When the pushbuttons of the controls are released the trolley must not keep running for an unusually long time If the trolley keeps running for an unusually long time after braking the brake must be stripped and inspected by a qualified person TROUBLESHOOTING This section provides the information necessary for troubleshooting the ATS INDU series of hoists The troubleshooting guide provides a general outline of problems which could be experienced with normal use of the hoist It lists the symptom the possible cause and the possible remedy for the trouble being experienced SYMPTOM CAUSE REMEDY Trolley cannot EMERGENCY If there is no danger be moved STOP button release the pressed EMERGENCY STOP button Motor run dry Repair the motor check rotor is stuck the service unit fill with oil remove water or renew grease lubrication Trolley can only Defective Have control device be moved control device repaired slowly
70. rolley do not apply side loads perpendicular to the natural tilt of the hoist 6 Page CALL TOLL FREE 888 844 6113 Installation of the Chain Bag Container 1 The chain container must be able to accommodate the full length of load chain If the load chain will not feed into the chain container due to it being over full a larger container must be fitted 2 Allow the hoist to lower the bottom hook until the lower hook is at its lowest point of travel Do not stall the hoist 3 Attach the chain container to the hoist 4 Now run the hoist so that the hook is lifted The slack side of the chain will feed into the chain container Ensure that the chain container is positioned such that the load chain hook or undercarriage does not come into contact with the chain container e Do not fill the chain container by hand This may cause the chain to twist resulting in jamming of the hoist Air Supply The ATSi INDU series hoists are rated 6 2 bar This pressure must be maintained at entry to the hoist to enable the hoist to operate at rated load as specified under the section SPECIFICATIONS The hoists will however operate at pressures of as low as 4 bar but performance will be affected The air supply to the hoist must be clean free from water and contain lubrication e The hoist must NOT be subjected to air pressures exceeding 7 bar as this may cause excessive dynamic loading of the hoist Air Lines It is recommend
71. se specific greases are not available use an equivalent grease WWW ELEPHANTLIFTING COM Load Chain Failure to maintain motor lubricator will reduce oil lubricating to the load chain no lubrication will result in rapid load chain and load sheave wear that can lead to chain failure resulting in severe injury death or substantial property damage 1 Fill lubricator daily or more frequently depending on severity of service 2 In a corrosive environment lubricate more frequently than normal 3 The exhausting air lubricates each link of the load chain continuously 4 The chain will be cleaned by the exhaust air and blow off any dirt before it reaches the hoist load sheave 5 Use ATS Blue Lube for filling the lubricators or SAE 10W or 27 32 centistoke oil Hook Assemblies 1 Lubricate the hook swivel and hook latch pivot points Hook and latch should swivel pivot freely 2 Use SAE50 to 90 EP oil for hook lubrication 13 Page CALL TOLL FREE 888 844 6113 Troubleshooting This section provides the information necessary for troubleshooting the ATS INDU series of hoists The troubleshooting guide provides a general outline of problems which could be experienced with normal use of the hoist It lists the symptom the possible cause and the possible remedy for the trouble being experienced SYMPTOM CAUSE REMEDY Hoist will not No air supply to Refer to operate hoist or too little SPECIFICATIONS volu
72. sure is too low important functions of the hoist will be impaired e The brake will drag and is thus subject to a high degree of wear An impermissibly high degree of warming could take place e The controls become noticeably less sensitive Warning against excessive system pressures Operating with excessive system pressures results in danger due to overloading Therefore the pressure must be limited to that specified on the nameplate ATS2000 Air Hoists must be operated with a sufficiently clean and dry air supply The air supply must fulfil the following quality requirements e Particle size less than 40 am e Particle density less than 10 mg m Corresponds to Class 7 in accordance with ISO 8573 1 2001 Order to provide adequate compressed air quality operation with a service unit is recommended An oiler is not required in the service unity as the motor is provided with internal permanent lubrication Also see LUBRICATION Page 11 Do not operate ATS2000 Air Hoists with other gases With moist air or at ambient temperatures at or below 0 C there is danger of icing in the motor Icing can be prevented by e The use of an upstream air dryer e Adding anti icing agent to the lubrication oil depending upon moisture content of compressed air 7 Page TRANSPORT AND STORAGE If you wish to transport your ATS2000 Air Hoist to another site please observe the following points e Carefully dismount trolley e Set
73. t Serial No Please enter the Serial No of your ATS trolley here It can be found with the delivery documents or on the nameplate on the motor cover THIS MANUAL MUST BE READ BEFORE USING OR REPAIRING THESE PRODUCTS This manual contains important safety installation operation and maintenance and repair information Make this manual available to all persons responsible for the operation installation maintenance and repair of these products Do not use this hoist for lifting supporting or transporting people or lifting or supporting loads over people Always operate inspect and maintain this hoist in accordance with South African Bureau of Standards Specification number SANS1638 2008 pneumatically powered chain hoists and SANS 1639 2010 Reconditioned pneumatically powered chain hoists and any other safety codes or procedures relevant to the industry in which the hoist is being used Testing of pneumatically powered chain hoists must only be carried out by the competent person contemplated in SANS 1639 2010 For Hoists used outside of South Africa It is the responsibility of the owner user to install inspect test maintain and operate a hoist in accordance with ANSI ASME B30 16 Safety Standard for Overhead Hoists OSHA regulations If the hoist is installed as part ofa total lifting system such as an overhead crane or monorail it is also the responsibility of the owner user to comply with t
74. ted accordingly and sound judgment used in determining their application This manual provides information for all personnel involved with the safe installation operation and proper maintenance of this product Even if you feel you are familiar with this or similar equipment you should read and understand this manual before operating the WWW ELEPHANTLIFTING COM product As certain aspects of this product may be different to what you are accustomed to Danger Warning Caution and Notice Throughout this manual there are steps and procedures which if not followed may result in an injury The following signal words are used to identify the level of potential hazard Danger is used to indicate the presence of hazard which will cause severe injury death or substantial property damage if the warning is ignored Warning is used to indicate the presence of a hazard which can cause severe injury death or substantial property damage if the warning is ignored Caution is used to indicate the presence of a hazard which will or can cause minor injury or property damage if the warning is ignored Notice is used to notify people of installation operation or maintenance information which are important but not hazard related NOTICE Safety Summa e Do not use this hoist or any equipment attached to it for lifting supporting or transporting people or lifting or supporting loads over people e ATS INDU series of air hoists
75. the entire hoist down carefully do not allow it to drop For weights see the technical data sheet supplied with the unit e Lay control and supply hoses together in such a way that they are not kinked e Ensure that the controls are not damaged Risk of malfunction e Reel in the hoist chain in such a way that loops cannot form and the chain cannot become twisted e Secure the chain STORAGE CONDITIONS BREAKS IN OPERATION e Inthe case of longer operational breaks coat the chain and hook with a light oil film e Motor conservation for storage run a small amount of ATS Blue Line oil through the motor to coat the internal components STORAGE e If the hoist is to be stored for a long time spray anti corrosion spray or SAE 10W or 27 32 centistoke oil into the air inlet port and run the hoist slowly for a few seconds This will compensate for the slight delay of the oil coming from the lubricator and stop moisture rusting the bearings Plug hoist air inlet port Always store the hoist in a no load condition Wipe off all dirt and water Oil the load chain hook pins and hook latch Store the hoist in a clean dry environment Before returning the hoist to service follow instructions for hoists not in regular service in the INSPECTION section INITIAL OPERATION The four most important aspects of hoist operation are 1 Follow all safety instructions when operating hoist 2 Allow only suitably trained personnel to ope
76. the whole of the track For example there should be no screw heads clamping plates web plates or other similar items in the way Please bear in mind that the side plates of the trolley could be taller than the girder especially if the girder is particularly small If this is the 8lPage case the girders must be suspended or mounted so that they are self supporting in order to avoid interfering with the movement of the trolley Unhindered movement of the attached energy supply system must be ensured along the trolley s path The control hoses on the motor side leading to the control valve should only be connected after having mounted the trolley in order to avoid damage see section CONNECTING THE CONTROL HOSES MOUNTING Screw the clevis load bar with the end marked with an L left handed thread approx 3 mm into the side plate also marked with L Screw the second side plate rear plate approx 3 mm onto the other end of the clevis load bar as well Following this the clevis load bar is turned further into the side plates until both ends are visible at the outer sides of the side plates MOUNTING TROLLEY WITH CLEVIS LOAD BAR INTO GIRDERS WITH OPEN ENDS By screwing in the clevis load bar both side plates are brought to a distance that is approx 4 8 mm wider than the bottom flange width of the girder See Figure 1 A 1 1 Figure 1 Girder to Wheel Clearance The running gear can now be mounted into th
77. tivated hoist does not operate Hook Safety Latch Make sure the hook safety latch is present and operating properly Replace if necessary Do not use hoist if hook safety latch is missing or damaged Load Chain Examine each of the links for bending cracks in weld areas or shoulders traverse nicks and gouges corrosion pits and chain wear including bearing surfaces between chain links see figure 5 Replace a chain that fails any of the inspections Check chain lubrication and lubricate if necessary Refer to LOAD CHAIN in LUBRICASTION section Weld Wear in these areas The full extent of load chain wear cannot be determined by visual inspection At any indication of load chain wear inspect chain and chain wheel in accordance with instructions in Periodic Inspection WWW ELEPHANTLIFTING COM 8 Load Chain Reeving Ensure welds on upright links are away from driven load sheave Reinstall chain if necessary Make sure chain is not twisted or kinked Adjust as required Periodic Inspection Frequency of periodic inspection depends on the severity of usage NORMAL HEAVY Yearly Biannually Please note the requirements of the Occupational Health and Safety Act of South Africa Act 85 of 1993 Driven Machinery Regulation 18 Lifting Machines and Lifting Tackle regarding the examination and testing of lifting machines and lifting tackle SERVERE Quarterly Disassembly may be required f
78. unning wheels of the front side plate on the bottom flange of the girder 7 Thread on and tighten the rear side plate using washer sets see section Screw retainers and torques page 43 Please pay attention to the position and number of the locking rings and distance washers that fasten the hoist to the middle of the trolley See Figure 3 below LOCK RING WITH HANDLE LOCK RING WITH GRUB SCREW Figure 3 Lock Ring Order 8 Connect the controls see section Connecting the Controls After mounting please check 1 The clearance between the outer edge of the girder flange and the wheel flange It should be between 2 and 3 mm on either side 2 The position of the anti tipping device on the rear plate It should have a clearance of approx 1 mm to the underside of the girder 3 The fit and position of the end stops ADJUSTING THE DRIVE The rack and pinion drive may be moved vertically if the retaining bolts are loosened This feature allows for the adjustment of the flank clearance It also offers the option of releasing the engagement into the rack and pinion This is shown in Figure 4 RACK AND PINION After mounting the trolley with the rack and pinion drive disengaged the flank clearance must be adjusted In case of more than one drive on a running gear one drive must be engaged first as described To engage additional drives the pinion must be brought into a suitable position with respect to the rack
79. ver Do not attempt to adjust load limiter unless certified by ATS2000 and correct weight is available The load limiter function operates on clutches which limits torque input When in the overload condition the load can still lowered to rectify the overload condition The load limiter will be activate during lifting and lowering which will protect the load in over extending of the load chain Since the load limiting clutches operate on torque input this will operated within the allowable 3096 overload limits as prescribed in SANS 1638 2008 at ANY air pressure e Avoid shock loads on the hoist e Do not leave the hoist unattended while any loads are suspended if it is not necessary e Avoid attempting to lower loads longer that the chain that is available 9 Page CALL TOLL FREE 888 844 6113 Inspection ATS2000 recommends two types of inspection a The frequent inspection performed by the operator as pre work inspection b The periodic inspections performed by personnel trained in the operation and repair of this hoist Careful inspection on a regular basis will reveal potentially dangerous conditions while still in the early stages allowing corrective actions to be taken before the condition becomes dangerous Any deficiency revealed through inspection must be reported to an appointed person A determination must be made as to whether a deficiency constitutes a safety hazard before resuming operation of the hoist
80. who designs manufactures imports sells or supplies any article for use at work shall Ensure as far as is reasonably practicable that the article is safe and without risks to health when properly used and that it complies with all prescribed requirements m X Any person who erects or installs any article for use at work on or in any premises shall ensure as far as is reasonably practicable that nothing about the manner in which it is erected or installed makes it unsafe or creates a risk to health when properly used 3 Any person who manufactures imports sells or supplies any substance for use at work shall a ensure as far as is reasonably practicable that the substance is safe and without risks to health when properly used and b take such steps as may be necessary to ensure that information is available with regard to the use of the substance at work WWW ELEPHANTLIFTING COM the risks to health and safety associated with such substance the conditions necessary to ensure that the substance will by safe and without risks to health when properly used and the procedures to be followed in the case of an accident involving such substance 4 Where a person designs manufactures imports sells or supplies an article or substance for or to another person and that other person and that other person undertakes in writing to take specified steps sufficient to ensure as far as is reasona

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