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SX Service Manual for Hoist - R&M Materials Handling equipment

1. Qe A AS A 2 Adjusting nuts for flange width 3 Trolley positioning nuts 4 Frame tube 5 Trolley side plate Remove the temporary transport supports Take the hoist out of the packing and move it to the installation site Lift the hoist using the lifting lugs provided Loosen the tightening nuts for flange width 2 Adjust the distance between the travel wheels A so that it is slightly wider than the beam flange B for installation purposes by turning the screws 3 If necessary open also the screws 4 Lift the hoist onto the beam 111 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC e Adjust the side plate 5 of the trolley inwards by turning the screws 3 until there is a gap of approximately 3 5mm between the flange of the travel wheels and the flange of the beam e Adjust the position of the trolley so that the hook is hanging below the centerline of the beam Lock the position by tighten the nuts 2 W Tighten the nuts 2 and the screws 4 to the correct ti
2. AOOO a lia lard ci a tt Htt cn L OX a jee H H DOWN O AS cS e m NORTH XK lt 4 E ee SOUTH Q n lt AA aA EAST JE ox Q n WEST c_hopb1d O5 e 0 Markings in compliance with FEM and DIN standards Markings in compliance with SEN standard Markings in compliance with SFS standard Markings in compliance with ANSI standard Up Down pushbutton Right Left pushbutton for trolley Forwards Backwards pushbutton for bridge of crane Hoist selection pushbutton only if the pushbutton controls several hoists On pushbutton and warning signal Emergency stop pushbutton released by turning lockable in some models Use the following procedure to start up a hoist that is in standby mode e Release the emergency stop pushbutton 6 by turning it Use a key to release if it is the lockable type e Press the On pushbutton 5 The hoist is now ready for operation 1 If the pushbutton controller includes a selection switch check that the hoist selection switch 4 is in the correct position before using pushbuttons 1 2 and 3 After operating the hoist return it to standby mode as follows e Run the hoist to the correct parking position Stop all hoist motions e When all hoist motions have ceased press the emergency stop pushbutton 6 The pushbutton will lock 10 130 R amp M Materials Handling In
3. 0cceeeeee 74 5 2 Sheave support and rope anchorage support 76 5 27 1 Service R2 and R4 reevings cceccee 76 5 28 Rope anchorage cccseccseecseeseeeeeeeeees 76 9201 SOV VICC siina aide de vane wheane 77 5 28 2 PSSSMDIY vcrmitesidennsnsisntwiansrdencdwatinvsranddaraincilans 78 5 29 Hook block rope reeving and return SIO AV CS oot sate ceca ieee coemenseedeeestastucacteecee 80 5 29 1 Service io s xiccdutdestesand demscsdslocneien desedeneetenciep a hesat 87 9 29 2 Hook block ASSEMDIY cccceeeeeeeeeeeeeeeees 88 5 29 3 Return sheave assembly c cseeeeeeeeeees 92 290 Wire TODS csniestucr2innsndoriteatecidaderoaspinwnveineests 94 5 30 1 Wire rope structure cc cecccecceeeeeeeeeeeeeees 94 5 30 2 Service iawisscancvncessncietnradevesuauderedeandclexseesdstevsuens 95 9 30 3 ASSOMDIY sicciicscacvseavanndiewanavsesesenescienasaiacatean ia 98 5 31 Overload protection ccccceceeee eee eeees 99 SILI SOVICE Se ee 100 5 32 Condition monitoring unit 101 E YA E L Sn en AA ee 102 5 33 Load signal amplifier ccceeeeeees 103 5 33 1 AjUStMeNt ccccccccsseceseseeseseeeneseeeneaees 103 6 Installation wssncceisssncraersncasnccarcesantasncsneetonntes 105 6 1 Prior to installation ccccecceee eee ee ee 105 6 2 Low headroom trolley drum size 6 243 mm 106 6 3 Low headroom trolley ccccceceeeee ee 107 6 3
4. 36 5 12 Manual Crank cccccccesceeeeeceeeeneeeneeenes 36 9 12 1 Assembling the manual crank 0000 3 5 12 2 Operating the manual crank 000c0 3 5 12 3 Before normal operation of the hoist 37 5 12 4 Assembly ccccccccescecseseeseseeeseseeeneeeessneees 37 5 13 Hoisting limit switch Drum size 6 243 mm 38 o S a S E a E E eee ea 38 5 14 Hoisting limit switch new white 39 oh E E ee ee eee 39 514 2 ASSOMDIY rirc a i 40 5 143 PACS UMC ING ccenn E 41 5 14 4 Fine adjustment ccccecseeecseeeeeeeeeeeeeeens 42 5 15 Hoisting limit switch old black 43 S191 GGV euren r 43 5 15 2 Assembly so snneennonnnsennennnsrsrnsrrserresrnrssreesnes 44 DIa Adus UMM saesanacsssensannssventanduensasetoenaaenonenelason 45 5 16 Hook operated upper limit switch 243 mm 47 5 16 1 DOT VIC Ct cheactcsdcnrabcheneunenebackenseddeubendeieeheadtehosncnee 48 5 17 Hook operated control limit switch 303 355 406 608 MM cece ceccecee sees eeeeeeeeeeeeeees 48 5 18 Pushbutton controller ccccseeeeeeeeees 48 wle T GECE eee ee ear 49 5 19 Travelling machinery ccccseceeeee sees 50 AIT DEVIC oner E EA 52 5 20 MFO6 Travelling motor with Compact DC brake 53 5 20 1 Adjustment of Compact brake air gap 53 5 20 2 Removing the Compact brake 000 53 5 20 3 Removing DC brake and in
5. c_dmcs0401a 1 Connectors 2 Signal LEDs 3 Parameter switches 57 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 23 Rope drum Drum size 243 303 355 406 mm 1 Rope drum 2 Bearing strips for rope drum 3 Bearing frame 4 Sealing 5 Connector rods for end flanges of rope drum 6 Rim gear cover and inspection hole 7 Rim gear 8 Drum axial locking part A Lubrication point for drum bearing B Lubrication point for drum bearing 5 23 1 Service drum size o 243 303 355 406 mm e Check the proper rotation of rope drum with and without load Pay attention to running sound of rope drum bearings and check that the rope drum does not touch with machinery end plates e Lower the hook to the ground e Check the grooves of the drum er Healthy grooves are smooth and do not have sharp edges In case of doubt unwind some more rope from the drum and compare the used grooves with unused grooves e Lubricate the drum surface e Check the drum axial locking parts 8 for wear Replace the axial locking part with new one e Lubricate the groove in the drum in which the axial locking part is located e Lubricate the drum bearing 58 13
6. 6 Installation Familiarize yourself with the installation instructions delivered with the hoist before commencing Pay attention to the instructions on safe operation of the hoist 6 1 Prior to installation Check the following basic requirements before commencing installation of the hoist e Adequate personnel resources such as competent fitters and work supervisors have been allocated to the work e Sufficient and appropriate tools and equipment are available such as lifting equipment and a test load e Sufficient time has been reserved for installation and testing e The hoist being installed is suitable for the application and operating environment It is recommended that qualified service personnel authorized by the manufacturer of the hoist do the installation work 105 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 6 2 Low headroom trolley drum size gt 243 mm Clearance between the wheel flange and the main girder flange measure X must be 3 5 mm Ensure that the clearance is equal on both ends of the trolley c_qztrO1c Locking washers Fixing nuts Plain washers Adjusting nuts Lifting mounts Screw rods Se SS e Remove the temporary transpor
7. 5 16 Hook operated upper limit switch 243 mm Hook operated limit switch has 2 steps normal limit switch and extra safety limit switch In first step limit switch trips hoisting movement when hook reaches the adjustable lever Hoisting movement is possible again after tripping as soon as hook has been lowered from the switching area Safety switch is safety switch will cut he main power if normal switch fails In this case hoisting or lowering is not possible until the reason for limit switch failure has been solved C A 8 r 1 Hoist 2 Limit switch inside the electric panel 3 Limit switch lever 4 Hook 47 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 16 1 Service e Check the proper tripping point of upper limit function e Test safety limit switch function manually monthly e Check the wiring for loose connections 5 17 Hook operated control limit switch 303 355 406 608 mm Hook operated limit switch trips hoisting movement when hook reaches the adjustable lever Hook operated limit switch can be automatic reset or manually reset With automatic reset hoisting movement is possible again after tripping as soon as hook has been lowered from the switching ar
8. S1 if S2 is fine tuned Upper limit of hoisting upwards Lower limit of hoisting downwards S1 Supervision limit for phase sequence of hoisting or hoisting safety limit S2 Upper limit of hoisting S3 Slowdown limit switch for hoisting S4 Lower limit of hoisting 42 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 15 Hoisting limit switch old black The rotary hoist limit switch contains four contacts with the below described default functions The rotary limit switch unit for hoisting is located in the connection box on the hoisting gearbox P iisa 83 6 c_holitc 1 Supervision limit for phase sequence of hoisting or hoisting safety limit S2 Upper limit of hoisting S3 Slowdown limit switch for hoisting S4 Lower limit for hoisting 5 Locking screw for adjustment mechanism 5 15 1 Service e Check the proper tripping point of all limiting functions e Check that the locking screw 5 is tight e Check the wiring for loose connections 43 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfie
9. Previous examinations indicated a high rate of wear In case of doubts please contact the manufacturer for advice 5 30 2 2 Discard criterias Maximum number of broken wires in outer strands Examination of the broken wires shall be made at least in the rope area which has the most bendings over the rope sheaves during normal operation and at the rope end near the wedge housing Before the examination of broken wires the examination areas shall be carefully cleaned The wire breaks are better visible if the rope is lightly bended er The internal examination of wire rope shall not be done in the regular maintenance unless the person is trained for that examination ISO4309 Annex D Standard Ropes and Heavy Duty Ropes Rope diam Detected length mm Duty M4 Duty class M5 M6 a 206 D S E 95 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Rotation Resistant Ropes Rope diam Rope Detected length mm construction Duty class M4 Duty class M5 M6 Local reduction of rope diameter Rope diameter can decrease due to external or internal wear or damage When the actual diameter of a standard or heavy duty rope has decreased 7 of the nominal diameter the rope shall be changed In rotation resistant
10. is just activated Test the operation The downward motion must stop at the described distance Raise the hook until the top of the hook block is approx 100mm under the bottom flange of the main girder or other fixed structure Turn the screw S3 until the limit switch S3 is just activated e Test the operation The upward motion must slow down to Low speed at the described distance e Raise the hook until the top of the hook block is approx 50mm under the bottom flange of the main girder or other fixed structure e Turn the screw S2 until the limit switch S2 is just activated e Test the operation The upward motion must stop at the described distance e Raise the hook to the up most position until the motion is stopped by the upper limit switch S2 41 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 HANDLING P 937 328 5100 a FAX 937 325 5319 INC e Turn the screw S1 so that it will activate just after S2 in upwards direction e2 e D LTN c_holiad1b e Close the connection box 5 14 4 Fine adjustment If maximum height of lift is needed fine tune the upper and lower limit of hoisting w Do not the exceed the minimum distances er Notice the right direction of adjusting screw rotation Readjust
11. 3 in place with four M8x25 screws 6 Test the tightness of the rope guide by grabbing it by hand and rotating it around the rope drum and moving it back and forth in the drum s axial direction The rope guide should slide without effort on the rope drum Friction between the rope guide and drum will cause wear on the drum and the guide The rope guide should be allowed to move axially one to three millimetes This way it will be loose enough to not bind on the drum and tight enough to not rise up and jump to wrong drum groove If the rope guide feels too tight on the drum i e no axial movement requires effort to rotate around drum add rim spacers 5 between the rope guide halves until proper tightness is achieved If the rope guide feels too loose on the drum i e over 3 millimeters of axial movement remove rim spacers 5 from between the rope guide halves until proper tightness is achieved Re install the dismounted intermediate shaft Install the rotation support 4 on the rope guide After completing the installation test drive the hoist while observing the rope guide travel through the whole height of lift Test the tightness of the rope guide at both the upper hoisting limit and the lower hoisting limit to make sure there is no binding at either end Adjust if necessary 65 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R am
12. 325 5319 HANDLING 5 14 2 Assembly 1 Hoist limit switch 2 Connection box cover 3 Fixing screws limit switch Disassembly e Switch OFF the power supply to the hoist Remove the connection box cover 2 Remove the wires from the limit switch Remove the fixing screws 3 Extract the limit switch 1 Re assembly e Fit the limit switch carefully in its place so that the pinion fits into the gear rim of the drum e Tighten the fixing screws 3 e Re connect the wires e Switch ON the power supply to the hoist and check the proper functioning of the limit switch w In many cases it is necessary to re adjust the limit switch Be aware of incorrect settings during testing the operation 40 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 14 3 Adjustment mm 7 S1 Measurement for phase sequence supervision limit S2 Measurement for upper limit of hoisting S3 Measurement for slowdown limit of hoisting S4 Measurement for lower limit of hoisting C Minimum distance of hook from bearing surface of hoist travel wheel H Maximum lifting height Lower the hook to approx 100mm above the floor Turn the screw S4 until the limit switch S4
13. 937 325 5319 5 29 1 Service er Check that the sheaves 3 and 4 rotate freely Check the sheaves for wear and damage Check the side plates of the hook block are tight and not damaged Check that the hook rotates freely Check that the safety catch functions properly Check the hook forging for wear burrs deformation and cracks When the safety catch is straight but it is able to flip over the tip of the hook check the hook forging dimensions RSN DIN 15401 and HBC dimensions f1 11 e3 e3 h2 h3 h4 o c_hb1b RSN HBC HBC RSN 10 RSN 16 RSN 20 RSN 25 HBC 1 6 HBC 2 5 HBC 5 a 5 5 e 7 80 90 112 140 160 180 56 63 80 a 40 45 50 56 63 7n 90 12 125 140 45 51 63 as 5 6 72 80 9 101 127 160 180 202 6o 65 84 ob 3 45 5 e 7 100 1235 140 160 46 5 7 T Se SS a oh oboa o a fo o a a a o e e a a a a e os joe e j is es es zat a j eoo f aso ios jrs a ot 31 35 40 45 7 46 88 ee 7a 4o 45 poo 125 4 1 1 18 18 23 3 3 33 14 1 18 Cm 48 s e 0 90 100 125 160 180 200 he 40 48 58 67 75 106 132 150 170 56 65 9 Ca a ee ee ee a ee eee eee eee eee Ce e ee ee a a e e e a e eae a a a a a a e a a 8 9 to 12
14. 4 Double girder trolley 1 Travel wheel 2 Rail e Remove the temporary transport supports Take the hoist out of the packing and move it to the installation site Lift the hoist using the lifting lugs provided Check that the rail centers B on the main beam are suitable for the hoist trolley Check that the groove C in the travel wheel is 15 mm wider than the rail width A Lift the hoist trolley onto the track Check the proper installation and position of the runway end stops Check that the hoist buffers are able to bump into the runway end stops or buffers of other trolley Note that in some hoist models the position of buffers can be changed 6 4 1 Outfitting the hoist e Install the power supply Refer to the section Connecting the to mains network e Adjust the limit switch for hoisting Refer to the section Adjusting hoisting limit switch e Carry out the commissioning inspection and complete the commissioning log Refer to the section Commissioning 109 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 6 5 Normal headroom trolley 6 5 1 Straight beam Cos SD 1 Adjusting bar 2 Adjusting nuts for flan
15. 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 HANDLING INC 11 P 937 328 5100 FAX 937 325 5319 3 Cam wheel 4 Follower roll 6 Roll for limit switch 7 Shaft of detent arm 15 Over speed limit switch 21 Helical spring 24 Disc springs 25 Screw 26 Marking point 27 Only in models with drum diameter 608 mm with 2 hoisting motors Assemble the brake rims 1 together with disc springs 24 10 pcs and screws 25 All the disc springs must be placed so that the concave sides are facing in to the brake rim In the two brake rims model the connection points of the halves of both rims shall not be aligned they must be 90 degrees apart The 90 degrees placement is to reduce the risk of having two bolt connection teeth being contacted by the detent arm when an overspeed braking occurs Adjust the rims so that there is a difference of 5 mm 0 2 between the teeth of the two brake rims The 5 mm difference is to allow one rim to begin the braking before the second rim engages to reduce the dynamic impact Adjust the cam wheel 3 so that when the follower roll 4 is on the highest point of the cam wheel there is a clearance of 3 mm 0 12 between the head of the detent arm and the tooth of the brake rim If the cam wheel is replaced position the cam wheel by turning it until the marking point on the brake rim is aligned with the contact point of the cam wheel halves Adjust the gap between th
16. Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 33 Load signal amplifier The load signal amplifier amplifies the signal coming from the load sensor The amplified signal is fed into the condition monitoring unit The LED s indicate the load in percentage of the rated load of the hoist 0 LED lights up when the lifted load is equal or less then 0 indicating slack rope whereas the 100 LED lights up when the load is equal or bigger then 100 indicating overload 0 C 100 GAIN xe PPLE EEP EPI OV SIGN 10V IN IN c_esd142a 5 33 1 Adjustment Adjustment with no load e Check that there is no load on hook e Adjust the trimmer ZERO to counterclockwise until the light O goes on e Adjust the trimmer ZERO back to clockwise until the light 0 goes off Now the output signal should be about 4 VDC Voltage can be measured between the terminals 1 and 3 Adjustment with nominal load You may have to bypass overload protection on condition monitoring unit when lifting a test load Adjustment with 100 load e Lift up the rated load of the hoist e Adjust the trimmer GAIN clockwise until the light 100 goes on e Adjust the trimmer GAIN counterclockwise until the light 100 goes off Now the output signal should be about 6 VDC Voltage can be measured between the terminals 1 and 3 If a 100 test load is not available adjus
17. Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC C toene na TOAT 2 inspeoton of hoiting machinery and couping a nspecion thong gear 5 nspecton of hoiting morando spect of hoiing im swish 7 Inspection of push buton coneoler B nspecton oftaveting machinery o nspecionffequenycontoler 10 nspecionofropesium ooo 11 nspecionfrope gue ooo 2 pecton fre dongs x prsnom i gt e a E S ee E S 18 rspecionofropesteavebeam o IT ispecionofwierope oooi gt 12 rspecionofoveroad esr a 1o heecon codon momomo fx 2o anuar specion according oealreqrements x O 1 Not all hoist types include this equipment Germany Inspection according to BGV D6 bisherige UVV 8 VBG 9 Tr lt x KK K XI X X X X x 8 3 Calculation of Safe Working Period SWP If the hoist is not provided with a condition monitoring unit the end of the Safe Working Period must be calculated in accordance with standard FEM 9 775 Calculation has to be carried out during each recurring inspection and servicing The end of the Safe Working Period can be calculated as follow 124 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATE
18. M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 27 Sheave support and rope anchorage support 5 27 1 Service R2 and R4 reevings L Locking plate L Locking plate W Locking washer OL Old type locking plate OW Old type washer NL New type locking plate L S Locking plate locking screw W Locking washer L S Locking plate locking screw e Check that the support shaft and the rope anchorage plate or overload device are correctly in their slots e Check that the locking part is in the groove of the shaft in cases which there is no other block against the shaft s axial movement er Replace locking washer OW or locking plate OL with the shaped locking plate NL if possible Or replace locking washer W with the locking plate L if possible e Check that fixing screws are tight e Check that the sheave block and the rope anchorage can freely tilt with rope e Lubricate the load carrying surfaces in the ends of the shaft and the rope anchorage plate with a small amount of grease 5 28 Rope anchorage The free end of the rope is fixed in a suspended rope anchorage The rope clamps ensure that the rope can not accidentally slip through the rope anchorage 76 130 R amp M Materials Handling Inc reserves t
19. P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 11 2 Brake release usage instructions Wy Secure the area under and around the hoist Warn the personnel on the shop floor and the supervisors about the intended action Wy Make sure the area under the hoist is free of obstacles w Beware that the motor rotational speed does not exceed the rated rotational speed w Ensure that the brake s temperature does not increase uncontrolled Lower the load as follow e Pull the lever arm carefully to open the brake and release immediately when motor stars to rotate e Pull and release a few times to study how the rotational speed is growing e Once known how the rotational speed behaves open the brake shortly and close again before the rotational speed reaches the maximum e Let the brake cool down for at least one minute after five times manually opening the brake w When the brake s temperature exceeds 100 C water drop boils let it cool down for a longer period at higher intervals e g after 4 times opening the brake Overheating the brake will damage the friction material and the load may drop e Repeat the procedure until the load is lowered safely to the floor 5 12 Manual crank Manual brake release and manual crank is used to move the load in case of power failure w In hoist models equipped with 2 hoisting motors and thus 2 main brakes both brakes must be manually opened with levers simultaneously and both motors mus
20. R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 9 1 2 Brake c_brda1b Fan cover Fan Brake Inside of the brake Brake disc Friction plate Anchor plate Fixing screws SOI Poh e Lower the hook to the ground Switch OFF the power supply to the hoist e Remove the protective cover of the hoisting machinery e Lock the rope drum with i e a wooden wedge to prevent it from rotating w The weight of the rope may cause the drum to rotate when the gearbox is detached e Remove the fan cover 1 and fan 2 er Do not pull the fan by the fins Place your fingers behind the fan and carefully pull the fan off the shaft Remove the fixing screws for the brake Detach the brake 3 Check the brake type on the rating plate fixed to the brake Measure the thickness of the brake disc 5 Replace the brake disc if the thickness is less then the minimum thickness as according to the below table 33 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 HANDLING P 937 328 5100 aay FAX 937 325 5319 e Check the physical condition of the teeth on the brake disc e Check the wear of the friction plate 6 Replace the fric
21. SWP If the hoist is operated in extremely cold conditions the factory installed grease must be replaced with synthetic transmission grease Refer to the section Lubricants for further instructions Drum size 243 303 355 406 mm c_r1ge1b Breather plug Fixing screws for hoisting machinery Fixing screws for gearbox cover Gearbox cover Cover of connection box Fixing screws for cover of connection box Gearbox plug Inspection hole for gear rim ONOARWND 30 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Drum size gt 608 mm c_r3geboia Breather plug Fixing screws for hoisting motor Fixing screws for gearbox cover Gearbox cover Fixing screws for gearbox Fixing plate for gearbox Gearbox plug Coupling ONOOARWND 5 8 1 Service e Check the gearbox visually for leakage e Incase the gearbox shows signs of excessive leakage find the reason for this and replace the worn part or the complete gearbox e Check the breather plug breaths freely and clean if needed e Check for any excessive vibration and or noise S If the factory installed grease is topped up with a different lubricant ensure that the lubricant is compatible Refer to the secti
22. Wy Keep the instructions in a safe place for future reference 2 2 Symbols The following symbols are used in the instructions WY Warning ce Caution 7 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 3 Safe operation 3 1 Intended use of the hoist and ambient conditions The hoist is intended for lifting and moving goods The hoist may not be used for lifting and moving people The hoist is intended for indoor use or for use in outdoor premises when specially equipped for the purpose The ambient temperature should be 10 40 C 14 104 F with explosive proof hoists 20 40 C 14 104 F or if specially equipped 20 50 C 4 122 F The relative humidity of the ambient should be less than 90 If the hoist is used in exceptional ambient conditions such as in a windy area a corrosive atmosphere or in an area prone to earthquakes or is used to handle dangerous materials such as molten metal any need for special equipment must be determined with the manufacturer or the manufacturer s representative 3 2 Sound intensity level The sound intensity level of the hoist in an operating location will not exceed 70dB A 3 3 Service classification of hoist Safe and effective opera
23. from the drum so that the hook block is free If needed adjust the lower limit switch e Switch OFF the power supply to the crane e Remove the shaft locking parts 5 e Extract the shaft 5 from the support frame 3 WY Be aware the sheaves as well as the sleeves will come loose one by one when extracting the shaft Re assembly e Insert the shaft 5 into the shaft support 3 while inserting the sheaves 4 and sleeves Lock the shaft with the locking screws Tighten all fixing screws to the required torque Switch ON the power supply to the crane Raise the hook block Carefully guide the rope with a gloved hand until the hook block hangs free from the working platform If the lower limit switch has been adjusted re adjust to the correct position e Test the operation of the hoist 5 30 Wire rope The rope of the hoist is a wearing load bearing part In order to ensure safe and efficient operation of the hoist it is essential to follow the safe working principles described in the safety instructions Regular inspection of the rope is a vital safety procedure requirement 5 30 1 Wire rope structure A Rope B Rope core C Strand D Wire L Left hand lay R Right hand lay Standard and heavy duty wire ropes have 8 outer strands and steel core The steel core is covered by plastic in heavy duty rope The lay of the outer strands is left handed in single rope hoists True vertical hoists have two ropes one l
24. it from rotating Wy The weight of the rope may cause the drum to rotate when the gearbox is detached Open the connection box 3 and remove the wires Securely suspend the hoisting motor with i e a chain hoist Remove the fan cover 16 and the fan 15 Remove the fixing screws of the brake 14 and remove the brake 13 brake disc 12 and friction plate 11 Remove the motor fixing screws 10 Extract the motor 9 from the gearbox 7 Remove the coupling 8 Remove the fixing screws for the gearbox 6 and the fixing plate for the gearbox 5 Extract the gearbox 7 from the hoist Re assembly It is advised to change the coupling each time when hoisting machinery is disassembled e Lubricate the inside of the coupling e Place the coupling on the gearbox shaft and assure that it fits tight and correct Wy The groove in the coupling MUST face the gearbox side e Fit the gearbox in it s place Be aware of Guide pins on the bearing house Drive pinion of the gear fits correctly into the gear rim of the drum Rotate the gearbox s shaft to guide the pinion into the gear rim and to check the right fitting Fit the gearbox fixing plate 5 on its place and fasten the fixing bolts 6 Tighten the bolts to the correct torque Place the motor onto the gearbox and guide the wires through the holes into the connection box Make sure that the motor s shaft fits correctly into the splines of the coupling Y
25. limit switch so that there is a minimum of 15mm gap between the rope guides and the rope fixing clamps when the hook is in its lowest position see drawing below Test drive the hoist and re adjust if necessary 64 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice HANDLING INC R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 min 15 mm 0 6 1 Rope fixing clamps 2 Rope 3 Rope guide Assembly Dismount one intermediate shaft from the hoisting unit It is recommended to remove the shaft that is at the top corner opposite to the side where the rope leaves the drum Place the front half of the rope guide 1 on the rope drum so that the grooved side is pointing away from the rope fixing clamps The rope guide should be positioned so that the rope leaving from the drum comes through the slot at the front The rope should be in the middle of the guide to be correct Place the rear half of the rope guide 2 on the rope drum so that the fixing holes align with the front half of the rope guide Fix the rope guide halves together with the M8x60 screws 7 and springs 8 Make sure that there are at least 2 5mm of spacer plates 5 between the rim halves at both ends Tighten the screws until the springs are compressed to a length of 15mm Fix the rope slot locking bar
26. phases in the power supply If travelling motion produces a load noise or strong vibration the trolley is probably incorrectly installed on the track Check the trolley is properly mounted on the track Wy Do not use the hoist before you have identified and eliminated the cause of excessive noise or vibration 7 1 4 Inspection and adjustment of the hoisting limit switch e Adjust the limit switch for hoisting Check the operation of the limit switch by running the hoist to the top and bottom limits Adjustment of the hoisting limit switch is described in the section Hoisting limit switch 119 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC w For safety reasons the hoisting limit switch must always be adjusted before the commissioning tests are continued 7 1 5 Inspection and adjustment of the limit switch for travel not in all models e Adjust the triggering locations of the limit switch Check the operation of the limit switch by running the hoist to the triggering locations w For safety reasons the triggering locations of the limit switch for travel must be adjusted before the commissioning tests are continued 7 1 6 Inspection of hook and operation of rope sheaves e Check that the rope sheaves
27. plate of the hoist when ordering spare parts Always use genuine spare parts and lubricants approved by the manufacturer of the hoist R amp M reserves the right to revoke warranty terms when non original parts are used 14 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 Construction 5 1 Low Headroom Trolley Hoist R amp M Materials Handling Inc The low headroom hoist trolley is a hoist model that is installed on the bottom flange of the main beam The low headroom hoist allows maximum effective use of the available lifting height Drum size 243 mm Hoisting motor and brake Hoisting gear Connection box Rope drum Electric cubicle Hook block Travelling machinery NOOR WD 15 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Drum size p 303 355 mm Hoisting motor and brake Hoisting gear Connection box Rope drum Electric cubicle Hook block Travelling machinery NOORWOND Drum size b 303 mm low profile 4 STA y Up P RFR i Vf l M l P SS
28. rope Check that there is no damage to rope end connection fixing parts e Check the rope guides for damage Check the body of rope guide for deformations Check the guiding surface visually e Change the drum end plate on hoisting machinery side e Check the drum end plate on drum brake side Change drum end plate if any deformations or cracks are found Pay special attention to hoisting unit support plates and to the area near the fixing point of the lower corner of the hoisting unit If any bends or cracks are found the support plates must also be changed e Change the hoisting unit fixing bolts e Change the fixing bolts of intermediate beams 5 26 5 5 Load beam inspection after overspeed e Check the load beam 72 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Replace if deformations cracks broken welding seams etc are found around the hoisting unit fixing places 5 26 5 6 Other components inspection after overspeed e Check the fixing of counterweights No deformations cracks etc are allowed around the fixing places e Check visually the hook block upper sheave block overload device and rope anchorage No deformations allowed change accordingly Inspect the rope Check the overload device
29. ropes the decrease by 3 cause rope discard Local increase of rope diameter Deformations inside the rope can cause increase of rope diameter If the actual rope diameter is increased by 5 the rope shall be changed Basket birdcage deformation Basket deformation is a result of a difference in length between the rope core and outer strands Rope with basket deformation shall be changed immediately 96 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc RETI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Protrusion of rope parts Rope with rise up of core strand or group of wires shall be changed immediately Loose outer strands The outer strands of the ropes shall be tight when the rope is not loaded In standard and heavy duty ropes the outer strands can have small visible gap under load If the gap does not close when the load is released the rope shall be changed Kink Kink or tightened loop is created by a loop in the rope which has been tightened without allowing for rotation about its axis Rope with a kink shall be changed immediately Bends L 10xd _ lt 2xd i e s eee c_rowavi1a Bends and angular deformations are normally caused by external influence Broken wires shall be carefully studied in the ar
30. ror 3 2kg 4 5kg 6 3kg 8 8kg 12 3kg 17 1kg 34kg 66kg 95kg 136kg alan oe law 15 kg 87 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Note Safety latch on HBC forging decreases dimension az about 5 mm and about 15mm on RSN forging Hook forging standard ee HBC DIN 15400 5 29 2 Hook block assembly Hook block 2 fall 1 rope reeving Safety latch set Hook forging Bearing set Thrust bearing Locking set Cover plate Shaft assembly Sheave cover plate 10 Rope sheave 11 Side plate 12 Rope bearing sheave set 13 Hook block fixing bolts and nuts ONDOAN Disassembly e Lower the hook onto a stable working platform Pull with a gloved hand some extra rope down from the drum so that the hook block is free If needed adjust the lower limit switch e Switch OFF the power supply to the crane e Remove the shaft fixing parts 8 88 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice HANDLING INC R amp M Materials Handling Inc RETI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 51
31. rotate freely e Check the general outlook of the coating in case of bronze coated hooks 7 1 7 Inspection of rope e Check that the rope has not been damaged in transport e Check that the rope is correctly reeved e Check the fixing of the rope ends Ensure that the rope is assembled inside the rope anchorage correctly e New wire rope shall be taken in use by a load which is of approx 10 of the nominal load This load shall be lifted to the total lifting height 5 10 times If the hook tries to turn around during the lifting place the hook in the lowest position without load open the rope end wedge housing and rotate the wedge housing until the hook is straight er Note the correct position of the wedge housing see sticker 7 1 8 Inspection of overload protection e Check that the overload protection mechanism operates correctly Check that the rope anchorage and support beam move freely 7 1 9 Inspection of trolley e Check that the wheelbase of the trolley is correctly adjusted e Check the tightening and locking of all screws for trolley adjustment e Run the trolley at least 3 5 times over the whole length of the girder 7 1 10 Inspection of brake operation e Check that the hoisting brake operates correctly in both up and down directions 7 2 Inspections with test load 100 of the rated load of the hoist 7 2 1 Inspection of motor current e Check the motor current in each phase during hoisting motion wit
32. s0 7o o awo 20 o o 10 so 3 o 320 640 1260 2600 2 o wo 320 e o 10 6 160 62 8 a e tw 2 63 15 1 po o o o o o o The table below shows the service intervals for the hoist in SWP periods and in calendar months Items for inspection and servicing refer to the servicing procedures described earlier in these operating instructions The servicing procedure must be carried out latest at the end of a SWP period or by the end of the stated number of calendar months Hoists without a condition monitoring device must follow a servicing procedure guide by calendar months For ensuring the usability of the hoist the servicing intervals can be shortened er Hoists used under harsh conditions may require a shorter servicing interval than stated in the table below Consult with a representative of the manufacturer for a tailored service agreement er If ambient temperature is frequently over 40 C 104 F the servicing interval is half of the interval Stated in the table below W Periodical inspecting and servicing procedure may only be carried out by a serviceman authorized by the hoist manufacturer or service personnel adequately trained by the hoist manufacturer Items for inspection and servicing Interval SWP reduction 80 Hoist classification all M5 M6 M3 M4 Calendar period Years 1 4 8 123 130 R amp M Materials Handling
33. the hoist out of the packing and move it to the installation site Lift the hoist using the lifting lugs 4 e Loosen the locking 1 on frame tubes of the trolley drive side Loosen the lowest fixing screws 2 for the fixing brackets Adjust the distance between the travel wheels A so that it is slightly wider than the beam flange B for installation purposes WY Do not unscrew the fixing screws for the fixing bracket on the hoisting machinery side e Lift the hoist onto the beam Adjust the X measurement until there is a gap of approximately 3 5mm between the flange of the travel wheels and the flange of the beam Use a nylon mallet to adjust the X measurement e Check the wheels of the trolley are correctly aligned 107 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Wy Tighten the lowest fixing screws 2 for the fixing brackets of the trolley on both sides to the correct tightening torque Refer to the section Recommended tightening torques e Tighten the locking screws 1 for trolley adjustment on both sides Drum size 355 406mm and 6 303 for low profile 1 Adjusting bar 2 Locking screws 3 Frame tube 4 Locking screw e Remove the
34. the holding brake limit switch when operating in down direction and verify that hoisting is stopped in the down direction Up direction should continue to operate e Detent arm Check that the arm rotates easily on its shaft 5 26 5 1 Should An Overspeed Occur Service after an emergency braking Should an overspeed braking occur the hoist and overspeed brake shall be inspected repaired and adjusted prior to further use of the hoist Extreme caution must be taken and the load must be removed from the hook of the hoist 5 26 5 2 Overspeed Condition Find Fault e Find the reason for drum brake emergency braking An overspeed occurs because of a failure in the drive transmission system of the hoist Possibilities The hoist brake has worn steel on steel a coupling has sheared a gear in the gearbox has stripped a drive shaft has broken 5 26 5 3 Hoisting unit inspection after overspeed e Check the condition of the hoisting gear s and drum gear rim No abnormal noises when driving Check that the gear rim fitted inside the drum has not slipped e Disassemble motor and check the condition of spline on motor shaft and on gear s primary shaft No deformations or broken teeth allowed e Change the coupling between the motor and gear e Change the motor fixing bolts 5 26 5 4 Hoisting Machinery inspection after overspeed e Check the rope drum Check the rope grooves visually for any markings from the rope guide or wire
35. the joint plate 4 and the lower frame half 2 fix the joint plate and lower frame half together with two M8x25 screws Pass the stainless steel rim 1 around the rope drum and into the groove that travels around the rope drum from the upper frame half 3 to the lower frame half 2 Pass the ends of the rim through both frame halves 66 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC e Pass the ends of the rim 1 through the sleeves 5 and press the sleeves into the sockets in the frame halves e Fix the rim in place with the two M10 Nyloc nuts 6 Follow the adjustment instructions to get the nuts to the proper tightness Rope guide initial adjustment e Tighten the two Nyloc nuts 6 until the rope guide is snug against the rope drum Tighten both nuts evenly so that the rim ends go through the frames in a straight line If either nut is tightened more than the other the rim alignment will change and it might bent in adverse ways e Adjust the nuts so that the guide doesn t rotate around the drum by gravity alone but will rotate if additional force is applied in up or down direction The required additional force should be 20N 30N Rope guide test drive and final adjustment e Test drive the hoist in both
36. to minimize swing WY NOTICE when the pushbutton is returned to neutral an established deceleration or slowdown ramp time is in full control of the motion before STOP WY EMERGENCY STOP WILL STOP MOTION IMMEDIATELY 12 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 4 Hoist manufacturer 4 1 Hoist identification data The type marking and serial number of the hoist are shown on the rating plate attached to the hoist and in the inspection records supplied with the hoist er Always state the serial number of the hoist when ordering spare parts or service 4 2 Directives and standards The hoist and hoist components meet the requirements of the relevant FEM standard The hoist complies with the European legislation and harmonized standards currently in force The hoist and hoist components meet the requirements of the following European Community directives e EC Directive on the safety of machinery 98 37 EC e EC Low voltage directive 73 23 EC e EC EMC directive 89 336 EC The following harmonized standards have been applied to the product e EN 292 1 Safety of machinery Basic concepts and general principles for design Part 1 Basic concepts and methods e EN 292 2 Basic concepts and general principle
37. torque Refer to the section Recommended tightening torques Inadequate or exceeded tightening might cause rope guide to failure in operation 61 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Disassembly e Loosen fixing screws 1 e Remove bearing housing and second half of sleeve on both ends of rope guide e Remove first halves of sleeves e Remove rope guide S gt Note that 1 of 3 screws is longer this should be located closest to the drum Rope guide drum size 303 355 406 mm 1 Rope guide 2 Rope press roll spring 3 Rope press roll axle 4 Rope press roll 5 Connector rod for end flanges of hoisting machinery Pressure roller machinery hoists c_rirq2f 1 Rope press roll 2 Connector rod for end flanges of hoisting machinery 62 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Rope guide drum size 608 mm D c qderogu3a 1 Connector rod for end flanges of hoisting machinery 2 Rope guide 3 Rotation support Rope
38. until the hook block hangs free from the working platform e If the lower limit switch has been adjusted re adjust to the correct position e Test the operation of the hoist 90 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Hook block all other models FSS H J ea 7 Kf WD j EO eee c_hb20as1b_004723 oe aT r Note The actual hook block outlook may vary depending on the size Safety latch set Hook forging Hook bearing set Thrust bearing Locking ring or nut Cover Shaft amp shaft locking screws Sheave cover 10 Rope sheave 11 Side plate amp side plate locking screws 12 Rope sheave bearing set In bigger models the locking ring is replaced by a locking nut Depending on the amount of rope falls there are additional sheave side plates and sheave covers O COND O1 B WD Disassembly e Lower the hook onto a stable working platform Pull with a gloved hand some extra rope down from the drum so that the hook block is free If needed adjust the lower limit switch 91 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice HANDLING INC R amp M Materials Handling Inc REI 4501 Gatewa
39. with a load Check the operation of the hoist upper limit switch Check that the bridge and trolley wheels have not been damaged and are lying on the runway rails Check the fixing of the machinery hoist 5 26 5 7 Drum brake inspection after overspeed e Check the detent arm for any damage The edge should not be deformed out of shape e Check the shaft of the detent arm No deformation cracks etc should be on the shaft e Check the fixing hole for the detent arm No deformation i e oval shape or cracks e Change the brake rim s screws and disc springs e Proceed with all other checks as in normal drum brake service e Adjust the brake Refer to the manufacturer s hoist test report er With every fifth emergency breaking the detent arm and its shaft has to be changed 73 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc RENTI 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 MATERIALS HANDLING INC 5 26 6 Adjusting overspeed brake c_db03a K gt j CAAA oo VAVO 3 f E T J3 c_db02a c_db01a 1 Brake rim 2 Detent arm 74 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI
40. with the hoist Check the rope certificate to determine whether the rope is of the correct diameter and breaking load e Unroll the cable when delivered as a roll or use a cable reel stand when delivered on a drum Follow the principles as set out in standard ISO 4309 e Fasten the rope end to the rope drum with the rope clamps c_rorefita e Switch ON the power supply to the crane e Run the rope onto the rope drum until enough free rope is available for the reeving using the hoisting motor e Thread the rope through the rope sheave or rope sheaves as shown in the rope reeving diagram e Fix the rope in the rope anchorage tighten it and fasten the rope clamp on the free end of the rope Wy Place the rope in the rope anchorage the right way around e Place the rope anchorage in its suspension point Fix the locking pins e Always adjust and check the limit switch for hoisting after replacing the rope See section Hoisting limit switch Adjustment for details 98 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC er In two rope systems True Vertical Lift replace both ropes simultaneously Ensure that both ropes are exactly identical except right left hand lay er In two rope systems Tru
41. 0 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC w Only lubricate the greasing points A OR B but not both During lubrication the drum MUST rotate at least two complete rounds Do not use excessive grease as that may damage the bearings Approximately two pumps of grease will suffice e Lubricate the gear rim 7 through the inspection hole 6 Drum size gt 608 mm c_r3rdia 1 Rope drum 2 Bearing 3 Bearing frame 4 Sealing 5 Cover and inspection hole 6 Rim gear 5 23 2 Service drum size 608 mm e Lower the hook to the ground e Check the grooves of the drum er Healthy grooves are smooth and do not have sharp edges In case of doubt unwind some more rope from the drum and compare the used grooves with unused grooves e Lubricate the drum surface e Lubricate the gear rim 6 through the inspection hole 5 5 23 3 Drum wear inspection Wear shall be defined with help of drum circumference measure a ea T Nominal dimension en aE 59 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FA
42. 00 FAX 937 325 5319 Remove the hook block fixing parts 13 Remove the side plates 11 Remove the sheave cover screws and remove the sheave cover plate 9 Remove the cover plate 7 locking set 8 and thrust bearing 5 Extract the hook 3 from the bearing set 4 Re assembly Lubricate the thrust bearing and the hook shaft Insert the hook 3 into the bearing house 4 and re assemble the thrust bearing 5 and the locking set 6 ia Pa D1 7 LB Lea Roe gt lt D2 i on a c_hobeas1a Re assemble the rope sheave 10 sheave cover plates 9 and the shaft 8 Insert the hook assembly and the sheave assembly into the side plates 11 Tighten the hook block fixing bolts and nuts 13 and the shaft assemble 8 Switch ON the power supply to the crane Raise the hook block Carefully guide the rope with a gloved hand until the hook block hangs free from the working platform If the lower limit switch has been adjusted re adjust to the correct position Test the operation of the hoist Hook block 4 fall 1 rope reeving drum size 303 355 406 mm ee g g N Note The actual hook block outlook may vary slightly depending on the manufacturing date 2 Safety latch set 3 Hook forging 89 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice HANDLING INC R amp M Materials Ha
43. 02 P 937 328 5100 FAX 937 325 5319 HANDLING INC Wy Safety limit switch is not adjustable e Lubricate the pivot joint of the lever mechanism the suspension support of the rope anchorage and the rocker bushings of the support beam with suitable thin oil Regulations in certain countries require that the operating point of overload protection is checked annually by conducting an overload test If local requirements necessitate an overload test conduct the annual inspection as follows e Prepare a test load that is 10 heavier than the operating point for overload protection stated in the written records for the test drive of the hoist Raise the test load a little and only once If the overload protection halts the hoisting of the test load it is operating correctly If the overload protection does not prevent hoisting of the test load the overload protection must be re adjusted Wy Only a service agent authorised by the manufacturer may adjust the overload protection Wy Do not repeat the overload test unnecessarily The overload test is an actual overload The test can only be conducted in carefully prepared and properly supervised conditions 5 32 Condition monitoring unit The electrical cubicle on the hoist contains the condition monitoring unit that supervises the safe operation of the hoist The unit collects data on functions that affect safety and calculates the remaining time in the Safe Working Period SWP duri
44. 1 Outfitting the hoist eeeeeeeeeeeeees 108 6 4 Double girder trolley cccccceeceeeeeee 109 6 4 1 Outfitting the hoist eeeeeeeeeeeee es 109 6 5 Normal headroom trolley c068 110 691 Straight DEAN esasa 110 6 5 2 Curved beam when two trolleys 111 6 5 3 Outfitting the hoist eeeeeeeeeeeeee es 112 6 6 Normal headroom trolley drum diameter GOS a 113 6 6 1 Straight DEAM cecceeeseeeeeeeeeeeeeeaeeeeens 113 3 129 6 6 2 Curved beam cccccceeceeseseeeesesseesseeseeees 115 6 6 3 Outfitting the hoist eeeeeeeeeeeeees 116 6 7 Installing the hoist fixed trolley 116 6 7 1 Outfitting the hoist eeeeeeeeeeeeees 117 6 8 Installing the hoist machinery hoist 117 6 8 1 Outfitting the hoist eeeeeeeeeeeeees 117 6 9 Connecting to the mains network 118 7 COMMISSIONING c ccceseeeeseeeeeeeeeeeeeeees 119 7 1 Inspections without load 06 119 7 1 1 Inspecting the connections of electrical SOQUIOIMC MM asrianiasr in E Ar 119 7 1 2 Inspection of pushbutton controller and directions Of rotation ccccssceccsesseeseeseeeseeseeeees 119 7 1 3 Checking operating sound ccceeeeees 119 7 1 4 Inspection and adjustment of the hoisting limit switch 119 7 1 5 Inspection and adjustment of the limit switch for travel not in all models ce eeeeeeeeeeeeeeeeees 120 7 1 6 Inspection of hook an
45. 201 610 7 924 122 48 194 76 o o B267 B226 120 200 4 7 79 188 5 74 167 66 60 31 B248 B219 331 610 13 24 188 5 7 4 327 129 O O B 2 128 B25 120 200 4 7 7 9 188 5 7 4 168 66 101 4 B 2 49 B 2 1 9 201 330 7 9 13 188 5 7 4 248 98 61 24 B 2 89 B 2 3 5 331 610 13 24 188 5 74 370 146 O 0O B 2 151 B 2 5 9 8 200 330 7 9 13 220 87 248 98 71 28 B 2 89 B 2 3 5 Single Trolley 451 610 17 7 24 220 87 390 154 O O B 2 161 B 2 6 3 8 Bogey Trolley 451 610 17 7 24 220 87 390 154 O O B2161 B263 6 6 1 2 True vertical lift 2 ropes from drum ete a 201 330 7 9 13 232 91 232 91 0 o 8286 B234 331 450 13 17 7 232 9 1 232 91 O O B 2 86 B 2 3 4 451 610 17 7 24 232 9 1 232 91 O O B 2 86 B 2 3 4 331 450 13 17 7 306 12 306 120 O O B 2 123 B 2 4 8 451 610 17 7 24 306 12 306 120 O O B 2 123 B 2 4 8 12or 120 200 4 7 7 9 183 72 168 66 74 29 B 2 49 B 2 1 9 16 331 450 13 17 7 183 7 2 316 124 O O B 2 123 B 2 4 8 451 610 17 7 24 183 7 2 316 124 o O B 2 123 B 2 4 8 114 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevar
46. 325 5319 HANDLING INC Disassembly e Lower the hook onto a stable working platform Pull with a gloved hand some extra rope down from the drum so that the hook block is free If needed adjust the lower limit switch e Switch OFF the power supply to the crane e Remove the shaft locking parts 5 e Extract the shaft 5 and the rope sheave 4 from the shaft support 3 Re assembly e Insert the sheave 4 and the shaft 5 into the shaft support 3 Lock the shaft with the locking screws Tighten all fixing screws to the required torque Switch ON the power supply to the crane Raise the hook block Carefully guide the rope with a gloved hand until the hook block hangs free from the working platform If the lower limit switch has been adjusted re adjust to the correct position e Test the operation of the hoist Return sheave all other models 5 3 2 Se Pet BY c_roshO1c Note The actual outlook may vary depending on the size 2 Support shaft 3 Support frame 4 Rope sheave 5 Sheave shaft sleeves and locking parts 93 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Disassembly e Lower the hook onto a stable working platform Pull with a gloved hand some extra rope down
47. 5 20 MFO06 Travelling motor with Compact DC brake SF c MF06b1 DC DC brake CB Compact brake Fixing screws for travelling gear Travelling motor Friction disc Brake discs Aluminium ring Adjustment nut for brake air gap self locking Motor cover Power supply plug Rectifier DC brake motor 10 Brake DC brake motor 11 Brake disc DC brake motor 12 Friction plate DC brake motor OONOANRWN 5 20 1 Adjustment of Compact brake air gap Ensure there is no danger of live voltage Remove the power supply plug 8 for the travelling machinery Open the motor cover 7 Push the brake disk 4 and measure the air gap between the adjustment nut 6 and aluminium ring 5 The air gap have to be 0 2 0 3 mm If needed adjust the air gap using the adjustment nut 6 Fasten the motor cover 7 and the power supply plug 8 5 20 2 Removing the Compact brake Ensure there is no danger of live voltage Remove the power supply plug 8 for the travelling machinery Open the motor cover 7 93 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R amp M Unscrew the adjustment nut 6 for the brake air gap Extract the brake parts If the thickness of the friction material is
48. A p AC N Wo A 7 o Hoisting motor and brake Hoisting gear Connection box Rope drum Electric cubicle Hook block Travelling machinery NOORWN 16 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Drum size p 406 mm Hoisting motor and brake Hoisting gear Connection box Rope drum Electric cubicle Hook block Travelling machinery NOOR WD 5 2 Double girder Trolley Hoist Double girder trolleys are available in numerous versions where the available height above the main girders determines the construction Double girder trolleys are commonly used in applications where heavy load handling is required 17 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Drum size gt 303 355 mm c_datrieb 1 Hoisting motor and brake 2 Hoisting gear 3 Connection box 4 Rope drum 5 Electric cubicle 6 Hook block 7 Travelling machinery Drum size gt 406 mm c_da
49. Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING Hook operated upper limit switch Rope drum Rope guide Overload protection Installation Low headroom trolley Lubricants Lubricant quantities a controller a guide assembly instruction added drum guide diameter 608 mm Installation curved beam Drawing updated 18 4 2006 KHHUJII Hook block Thrust bearing assembly updated 16 8 2006 KHHJII Construction Wire rope Update on rope assembly True vertical lift 30 8 2006 KHHASI Inspections without load updated assembly drum diameter 243 mm limit switch guide drum diameter 608 mm limit switch protection support service instructions added inspection 6 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 2 Introduction 2 1 Instructions The instructions for safe and effective installation operation and maintenance of the hoist are included in the hoist delivery The hoist itself is also provided with labels and markings The instructions are issued on paper and or on CD ROM The instructions for using digital CD ROMs are printed on the packaging Read the instructions supplied with the hoist before installation and commissioning
50. C Alternative CastolEPLo0 T amo O anon Hoisting gears GEN4 series cae Couplings C Mtematve ShelTess2 Alternative BelRayWireRopeLubrcant O Sd C Mtematve BelRay intFuid PAltemative Briub50SOdYSSSCSC SSC CTTCUd Open transmissions Factory installed Almagard3752_ o v AO ABD Drumrim gear Alternative ShellAlbidaGC zonna 40 4248 C Altemative NesteAvora soms aoo Factory installed lubricant is being used unless otherwise specified by the customer S If the transmission oil has to be topped up make sure that the lubricant being added is compatible If transmission oil has to be replaced flush out the gearbox before filling up If the hoist is operated for long periods in extremely cold conditions colder than 25 C 13 F or extremely hot conditions hotter than 55 C 131 F it is recommended that a synthetic lubricant is used Lubricant Almagard 3752 is manufactured by Lubrication Engineers Inc 128 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 9 2 Lubricant quantities 9 2 1 Lubricant volumes hoisting gears O Dms eariy O Vome SS O 9 2 2 Lubricant volumes travelling gears Hoist trolley type Drum size Gear type i
51. Do NOT tighten the assembling bolts of the motor before the motor fits correctly and straight in the flange of the gearbox There is a risk to damage or misplace the inner circlips of the coupling when using force e Tighten the motor fixing bolts 10 to the correct torque 29 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC e Assemble the friction plate 11 Text REIBSEITE must be against the friction disc 12 if applicable Assemble the brake disc 12 and the brake 13 Tighten the fixing screws 14 for the brake Re assemble the fan 15 and the fan cover 16 Reconnect the motor wires and close the connection box Remove the drum locking device wooden wedge Re assemble the protective cover of the hoisting machinery Test the proper operation of all movements and functions w In many cases it is necessary to re adjust the limit switch Be aware of incorrect settings during testing the operation 5 8 Hoisting gearbox The hoisting gearbox comprises multistage spur gear transmission The lubricant for the hoisting gear is semi fluid grease When used in conformance with the operating group classification of the hoist the gearbox lubricant does not need to be changed during the Safe Working Period
52. English 7 9 2007 SERVICE MANUAL FOR HOIST DOCTNI16 0 0RD RM MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R amp M MATERIALS HANDLING INC w Read the instructions supplied with the product before installation and commissioning S Table of content 1 Major update history only in English 5 2 Introduction saeiceaencsecccensat eee sees eee neeemeceseseee 7 2 1 Instructions 20 0 eee ce cece cece eeeeeeeeeeeeeneeeeees T7 22 MOOG ons eee tees eee see eee T 3 Safe operation cccsistanaatahsnsasecscunessauaancsecewucacary 8 3 1 Intended use of the hoist and ambient CONGOS ae nousacaeranndeeanesssneupopontenteaiades 8 3 2 Sound intensity level ccceeceeeeeeeeeeees 8 3 3 Service classification of hoist 8 OO OAC SOCCWUIM oriee as 8 3 3 2 Average daily operating time cceees 8 3 3 3 Determining the operating group of the hoist 9 3 4 Safe working principles ccceceeeeeeeees 9 3 5 Using the pushbutton controller 9 3 5 1 Using the pushbuttons two steps contactor control 11 3 5 2 Using the pushbuttons EP mode optionally used with Inverter controls ccccsseceeeeseeeeeeaeeeeens 11 3 5 3 Using the pushbuttons two speeds controlled DY INVETIET acire EEE E 12 4 Hoist manufacturer cccccce
53. Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 21 2 Dismounting the travelling motor Ensure there is no danger of live voltage Remove the power supply plug 8 for the travelling machinery Unscrew the fixing screws 3 for the motor Detach the motor from the gearbox Re assemble in the reverse sequence 5 22 Inverter for travel The electrical cubicle on the hoist contains a inverter that controls the speed of rotation of the travelling motor according to the commands given by the operator The inverter has a signal LEDs 2 indicating its operating status and eventual malfunction The parameters of the inverter are pre set at the factory and usually do not require re adjustment In case re adjustment is needed please refer to the Service Manual of the respective inverter for details or contact a representative of the manufacturer All electrical connections to the inverter are made via connector s 1 0 7kW inverter 1 Connectors 2 Signal LEDs 3 Parameter switches 2 2kW inverter c_fc022a 1 Connectors 2 Signal LEDs 3 Parameter switches 96 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 4 kW inverter
54. I 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 6 6 2 1 Standard reeving 1 rope from drum Falling a o H o r ae 6 40 157 146 5 75 6 6 2 2 Standard reeving 2 ps from drum tt serra RTF opes ee ee ee 4 o 0 146 5 75_ 6 6 023 146 5 75 8 12 047 146 5 75 6 6 3 Outfitting the hoist e Install the power supply Refer to the section Connecting the to mains network e Adjust the limit switch for hoisting Refer to the section Adjusting hoisting limit switch e Carry out the commissioning inspection and complete the commissioning log Refer to the section Commissioning 6 7 Installing the hoist fixed trolley e Remove the temporary transport supports Take the hoist out of the packing and move it to the installation site e Check that the fixing holes in the site of location match the fixing holes 1 in the trolley e Lift the trolley into position Fasten the fixing screws 116 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 6 7 1 Outfitting the hoist e Install the power supply Refer to the section Connecting the to mains n
55. RIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 8 3 1 STEP 1 Operating hours per inspection interval T 2 H N T J V x60 H average hoisting height m N number of work cycles per hour cycles h 7 daily working time h V hoisting speed m min J working days during inspection interval days 8 3 2 STEP 2 Actual load spectrum factor per inspection interval Kmi Load spectrum factor can be calculated using following table Load Lifting time Factor k Sum 100 Sum Divide by 100 100 Load spectrum factor o O N ol N Il Load spectrum factor Kmi 8 3 3 STEP 3 Partial duration of service S hours When the load spectrum factor of inspection interval Kmi and the operating hours per inspection interval T are identified the Partial duration of service S can be calculated as follow S 1 2 K 7 8 3 4 STEP 4 Actual duration of service S hours Actual duration of service can be calculated when the earlier partial duration of inspection intervals is known S S 8 58 125 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 8 3 5 STEP 5 SWP and remaining service life SWP and estimated remain
56. X 937 325 5319 HANDLING INC re groove top 301 8 mm 403 2 mm 604 2mm 605 2mm _ 604 2 mm D3 Drum nominal 243mm 303mm 355mm 406mm l406mm 608mm 608mm_ 608 mm diameter Bint ghee 743 mm 933 mm 1090mm 1241mm 1250mm 1863mm 1876mm 1863 mm circumference II x D1 Acceptance criteria OS SONNE l lt 3 0 mm lt 3 7 mm lt 4 3 mm lt 5 0 mm lt 5 0 mm lt 7 4 mm lt 7 4 mm lt 7 4 mm change 0 4 of nominal OOE depth change lt 0 6 mm lt 0 5 mm lt 0 6 mm lt 0 8 mm lt 0 6 mm lt 1 1 mm lt 0 8 mm lt 1 1 mm 20 of nominal Tools needed caliper tape ruler square ruler ruler or flat bar thin steel wire piano wire or 0 8 1 0 mm thickness welding wire First measure reference circumference and groove depth on a drum area which is not worn rope does not usually come out of the drum Then do the same measures in at least 3 points on the drum where grooves are most worn Drum circumference e Place min 55 mm long ruler R or flat bar on the top of 3 grooves on the rope drum unworn area Make sure by square ruler that the ruler is perpendicular to the grooves e Turn piano wire W one round around the rope drum on the bottom of the groove Mark start and end points M on the wire by help of the ruler e Then mark the acceptance criteria A in the wire to distance C mm from the end mark When measuring worn grooves compare the drum circumference to this mark The maximum allowed
57. above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 6 Trolley buffers The hoisting trolley is provided with rubber buffers Some models are equipped with buffer extensions 5 6 1 Service e Check that the buffers and runway end stops are in good condition Replace broken buffers e Check that the hoist buffers bump into the runway end stops or buffers of other trolley 5 Hoisting machinery The main components of the hoisting machinery are the hoisting motor gear and rope drum Power from the motor is transmitted via the rim gear of the transmission to the rope drum One end of the transmission train that is comprised of the hoisting motor gearing and rope drum is fixed to the end flanges of the hoisting machinery 5 7 1 Service e Check and replace the coupling between motor and gearbox Note the exceptional service interval See the sections Service of the individual components for details 5 7 2 Assembly Drum size 303 355 406 mm The motor and gearbox are attached as a complete sub assembly inside the rope drum The motor gearbox subassembly must be extracted from the drum as a whole in case any work on the gearbox motor or coupling is required c_rihmiat 1 Hoisting motor 2 Hoisting
58. aee eon am area 9 2 3 Lubricant volumes drum rim gear 9 243 mm 1 fez imperial 4 303 mm 2 5 foz Imperial 355 mm 100 ml 3 5 fl oz Imperial gt 406 mm 150 ml 5 3 fl oz Imperial b 608 mm 500 ml 17 6 fl oz Imperial 129 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 10Troubleshooting The table below lists some of the faults and malfunctions that may occur in the hoist their causes and the corrective actions needed to eliminate them ce If you are unable to identify and eliminate the fault using this table contact a service agent authorized by the manufacturer Faut Probable cause Corrective action The hoist is not Main supply power is not connected Switch the main power supply on operative Release the Emergency Stop button Press the Start button See section Using the pushbutton controls A fuse has blown Replace the fuses The hoisting motor has overheated Wait for the motor to cool Avoid unnecessary and repetitive short and the temperature sensor is starts preventing operation A motion has reached its limit Drive away from the limit One phase is dead no voltage Repair the power supply See section Connecting to the mains network The ho
59. andard hook with HBC1 6 hook forging nominal load 3200kg 46 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Rope reeving 02 Standard hook with RSN1 hook forging nominal load 2500kg 500 650 Min Cimmj 435 465 500 530 560 sos e25 eso eoo 715 Rope reeving 04 Standard hook with HBC2 5 hook forging nominal load 5000kg Bimm 100 150 200 260 305 350 aoo 450 soo sso eoo feso feso Rope reeving 04 Special hook with HBC2 5 hook forging nominal load 6300kg Bimm Joo 150 200 260 305 a50 aoo Jaso soo sso eoo Jeso feo Min C mm 505 485 465 435s aes 500 sss ses eoo ess ees ess C dimensions for Low Headroom Trolley drum diameter 406 mm Rope reeving 02 Standard hook with HBC2 5 hook forging nominal load 5000kg Bimm 100 Jaso 200 250 290 430 450 500 sso Jeoo Jero Min C mm 630 615 600 585 570 585 615 645 jeso 65 Rope reeving 04 Standard hook with HBC5 hook forging nominal load 10000kg Bimm 100 150 200 250 290 430 450 500 sso Jeoo 610 Rope reeving 04 Special hook with HBC5 hook forging nominal load 12500kg Bimm 100 150 200 250 200 430 450 500 s50 eoo Jero Min C mmi 655 640 e20 eoo 585 eoo ess ess roo 705s
60. c reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 3 5 1 Using the pushbuttons two steps contactor control co w ep ia amp eee c_cots2a A Position of pushbutton 0 1 and 2 B Speed The position of the pushbutton affects the speed as follows e Position 0 Neutral position Motion stops e Position 1 Slow speed e Position 2 High speed Wy A skilled operator always uses the low speed step 1 when starting to hoist Slack is taken out of rigging and the wire rope is subjected to the load in the low speed Be aware of load balance as the load is hoisted from floor level Proceed to high speed step 2 when the load is clear of all obstacles When lowering the load a skilled operator controls the lowering speed from High to Low speed when setting the load Low speed allows time to maneuver load into position Minimal jogging or inching may be required DO NOT JOG FROM NEUTRAL TO HIGH SPEED POSITION OR VICE VERSA 3 5 2 Using the pushbuttons EP mode optionally used with Inverter controls gt gt gt 2 w gt i s gt A Position of pushbutton 0 1 and 2 B Speed Variable speed with 2 step pushbutton Electronic Potentiometer The position of the pushbutton affects the speed as follows e Posit
61. ceseececececeeaeeeceeaeeneaeeees 125 8 3 2 STEP 2 Actual load spectrum factor per INSPECTION interval Kmi cccecesececeeeceeeceeeceeeeeeeeeeeaues 125 8 3 3 STEP 3 Partial duration of service S hours 125 8 3 4 STEP 4 Actual duration of service S hours 125 8 3 5 STEP 5 SWP and remaining service life 126 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R amp M MATERIALS HANDLING INC 8 4 General Overhaul GO 00 eee 126 8 5 Recommended tightening torques 126 9 ID CICAIAUS scriind 128 9 1 Lubricant types sessicceswccenccdcroveten tepsdideed neces 128 9 2 Lubricant quantities cc eeeeeee eee 129 4 130 9 2 1 Lubricant volumes hoisting gears 129 9 2 2 Lubricant volumes travelling gears 129 9 2 3 Lubricant volumes drum rim gear 129 10 Troubleshooting ccccceseceseeeeeeeeeeeeeees 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 1 Major update history only in English Section Description Date Handled by limit
62. d MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 6 6 2 Curved beam a mE z9 _ A C Ha E p 2 Adjusting nuts for flange width 3 Trolley positioning nuts 5 Trolley side plate e Remove the temporary transport supports Take the hoist out of the packing and move it to the installation site Lift the hoist using the lifting points marked on the hoist e Loosen the adjusting nuts for flange width 2 Adjust the distance between the travel wheels A so that it is slightly wider than the beam flange B for installation purposes e Lift the hoist onto the beam e Adjust the side plate 5 of the trolley inwards until there is no gap between the flange of the travel wheels and the flange of the beam Then adjust the other side plate 5 of the trolley inwards until there is a gap of approximately 3 5mm between the flange of the travel wheels and the flange of the beam e Loosen the adjusting screws for trolley positioning 3 ee Adjust the position of the trolley so that the hook is hanging below the centerline of the beam Select L dimensions according to rope reeving from table below Wy Tighten the nuts 2 and the screws 3 to the correct tightening torque Refer to the section Recommended tightening torques 115 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc RE
63. d operation of rope SNGAVOS cee eee ene ee eee eer eer eee 120 7 1 7 Inspection Of rope ccccceecceeeeeeeeeeeeeee ees 120 7 1 8 Inspection of overload protection 120 7 1 9 Inspection of trolley cccecceeeeeeeeeeeeeees 120 7 1 10 Inspection of brake operation 008 120 7 2 Inspections with test load 100 of the rated load of the hoist cccccceececeeeceeeeeeeeseeeeeaees 120 7 2 4 Inspection of motor current cceee 120 7 2 2 Inspection of running temperature 121 7 2 3 Inspection of travelling machinery 121 7 3 Inspections with overload 110 125 of the rated load of the hoist cceeeeeeee eee 121 7 3 1 Inspection of overload protection 121 7 3 2 Inspection of brake operation 00 121 7 3 3 Inspection Of rope ccc cceecceceeeeeeeeeeeeeees 121 7 4 After the inspections cccccceeeeeeees 121 LAA CICAD aaraa REE 121 1 4 2 User TAINING sca saincincdanseaveinsanensenccavaeieyatanavane 121 7 4 3 Hand over document c ccceceeceeeeeeaees 121 8 Maintenance ssiissicesasisintionsiidurrduiawvetouncsuseins 122 8 1 Daily inspections 00n0nnannannennannannnnne 122 8 2 Periodical inspections and servicing 123 8 3 Calculation of Safe Working Period SWP 124 8 3 1 STEP 1 Operating hours per inspection interval j cece ec eececcececcececcececee
64. difference in circumference between reference area and worn area is 0 4 Groove depth _ _ pe e Place min 55 mm long ruler or flat bar on the top of 3 grooves 1 on the rope drum unworn area e Measure groove depth G placing caliper on the ruler e Repeat same measurement on the worn area of the drum 60 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC e The maximum difference in groove depth between reference area and worn area is 20 of the nominal groove depth 5 24 Rope guide The rope guide ensures that the wire rope winds on the drum correctly and prevents the wire rope from jumping into the wrong groove Rope guide drum size 243 mm OGQOOOH c_rirq4D 1 Fixing screws 2 Bearing housing 3 Intermediate beam 4 Sleeve half 5 Rope guide 6 Rope Assembly e Put rope guide 5 on the intermediate beams e Put the first halves of bearing sleeve 4 between rope guide 5 and intermediate beams 3 e Put the second half of bearing to upper intermediate beam and install bearing housing 2 and fixing screws 1 e Do the same to lower bearing w Tighten the fixing screws and fixing nuts on all rope guides to the correct tightening
65. djusted per instructions w After the drum brake has been activated do not jumper any controls to lower the load using the hoist 1 Brake rim 2 Detent arm 3 Cam wheel 4 Follower 15 Micro switch 20 Rope drum 21 Adjustment spring 5 26 5 Service e Check that the drum brake and surrounding surfaces are free from oil grease excessive dust and or other substances that may reduce the effectiveness of the friction material of the drum brake e Helical spring Check visually that there is no corrosion to the spring and the spring is not worn at connection points e Follower roll Check visually that the roll is not corroded Check that the roll is not worn more than 3 mm of its original diameter Test that the roll follows the cam wheel easily and it is fixed firmly to the detent arm e Limit switch Check that the limit is securely fastened 71 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Check that the positioning of the limit switch is correct and will be contacted by the follower roll The gap between the follower roll and limit switch is to be 0 5 mm measured on the cam wheel s highest point Refer to the Drum Brake Adjusting instructions Manually activate
66. e Vertical Lift ensure that both rope are of equal length A small variation in length may cause the hook block and the balancing beam to tilt Adjust the rope length by pulling one of the ropes further through the wedge housing until the hook block hangs as straight as possible maximum 5 degrees tilt allowed e New wire rope shall be taken in use by a load which is of approx 10 of the nominal load This load shall be lifted to the total lifting height 5 10 times If the hook tries to turn around during the lifting place the hook in the lowest position without load open the rope end wedge housing and rotate the wedge housing until the hook is straight Note the correct position of the wedge housing see sticker e Append the rope certificate for the new rope to the documentation for the hoist 5 31 Overload protection The overload protection prevents hoisting motion when there is an excessive load The operating point of overload protection is stated in the written records for the test drive of the hoist Overload protection is achieved by either a mechanical switch or an electronic load sensor The mechanical switch is connected to the hoisting circuitry and controls the hoisting contactor The load sensor is connected to a separate condition monitoring unit The condition monitoring unit prevents hoisting motion when there is an excessive load The overload protectors with a load sensor are equipped with an additional safety li
67. e fan cover 1 Remove the fan 2 Raise the hoisting motor at the brake end and extract the machinery from the rope drum Use lifting aid such as a chainhoist for the bigger heavier models Lower the machinery to rest on the gearbox with the motor facing upwards 26 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC w Handle the motor gearbox subassembly with care Avoid damaging the inner dust ring and the rim gear cover e Remove the fixing screws of the brake and remove the brake 3 brake disc 4 and friction plate 6 Carefully guide the connection wires and plug through the hole in the gearbox e Remove the fixing screws for the motor e Extract the motor from the gearbox Carefully guide the power feed wires and plug through the hole in the gearbox e Remove the coupling Re assembly It is advised to change the coupling each time when hoisting machinery is disassembled e Lubricate the inside of the coupling e Place the coupling on the gearbox shaft and assure that it fits tight and correct w The groove in the coupling MUST face the gearbox side e Make sure that the motor s shaft fits correctly into the splines of the coupling w Do NOT tighten the assembling bolts of the moto
68. e is able to stop the motion adequately 7 3 3 Inspection of rope e Ensure that the rope has not slipped in the rope anchorage by comparing the measures with the stated measures in the table See section Rope anchorage 7 4 After the inspections 7 4 1 Cleaning e Check that all tools and materials used during installation are removed from the hoist and track 7 4 2 User training e Ensure that the hoist operator and supervision personnel are aware of the need for user training er The authorized service organization of the hoist manufacturer can arrange user training by separate agreement 17 4 3 Hand over documents e Check the documents delivered with the hoist Ensure that entries in the documents are properly recorded and that the reference data in the documentation matches that on the type rating plates er Compile a commissioning log for the hoist and keep it with the other documentation for the hoist 121 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 8 Maintenance The lifetime of the hoist is divided into Safe Working Periods SWPs At the beginning of the Safe Working Period a new hoist has an SWP of 100 A Safe Working Period ends when the SWP of the hoist is zero When a Safe Working P
69. e limit switch 15 and the roll 6 to 0 5 mm 0 02 Make this adjustment when the follower roll is on the highest level of the cam wheel Adjust the length M of the helical spring 21 to the value recorded on the Q drum brake report included in the delivered hoist documentation The follower roll must be at the highest point on the cam wheel when the length of the spring is measured Be aware that the spring must not be damaged If damaged replace the spring Verify the spring type from the Q drum brake report Verify that the brake rim screws are loose allowing the brake rims to slide freely on the drum during the following test Test that the overspeed drum brake does not actuate when lowering the nominal load with full speed If the drum brake activates increase the M dimension to increase the follower roll tension on the cam wheel preventing premature drum braking action Before repeating test verify that all rim and cam wheel positioning marks are correct according to steps 3 4 and 5 After successful testing tighten the brake rim screws 25 to a torque of 60 Nm 44 ft Ib Check with the caliber that the gap between the brake rim halves is the same on both connections This is to ensure the even tooth to tooth distances over the brake rim connection Manually activate the limit switch when operating in down direction and verify that hoisting is stopped in the down direction Up direction should continue to operate 75 130 R amp
70. e the floor Loosen the locking screw 5 Turn the screw S4 until the limit switch S4 is just activated Tighten the locking screw and test the operation The downwards motion must stop at the described distance Repeat step 1 4 until the correct setting is achieved e Raise the hook until the top of the hook block is approx 100mm under the bottom flange of the main girder or other fixed structure e Loosen the locking screw 5 e Turn the screw S3 until the limit switch S3 is just activated e Tighten the locking screw and test the operation The upwards motion must slow down to Low speed at the described distance e Repeat step 6 9 until the correct setting is achieved e Raise the hook until the top of the hook block is approx 50mm under the bottom flange of the main girder or other fixed structure e Loosen the locking screw 5 e Turn the screw S2 until the limit switch S2 is just activated e Tighten the locking screw and test the operation The upwards motion must stop at the described distance e Repeat step 11 14 until the correct setting is achieved 45 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC e Raise the hook to the upmost position until the motio
71. ea Hook operated limit switch with automatic reset can be used as a working limit before standard upper limit tripping height With manual reset hoisting movement is not possible before limit switch has been manually re activated Hook operated limit switch with manual reset can be used as a back up switch for the standard upper limit When manual reset limit is used as back up switch and switch stops the hoisting movement function of rotating limit switch have to be checked and corrected before using the hoist again Hook operated limit switch increases hook approach hook rail distance c_holsia 1 Hoist 2 Limit switch 3 Limit switch lever 4 Hook 5 18 Pushbutton controller Operating instructions for pushbutton controller are described in section Using the pushbutton controller 48 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC or c_hopbnw1b 1 Movement pushbuttons 2 Hoist selection pushbutton only if pushbutton controls several hoists 3 On pushbutton and warning signal 4 Emergency stop pushbutton 5 Display optional Or 4 c_hopbolta 1 Movement pushbuttons 2 Hoist selection p
72. ea of bends Discard criteria for a bend is e lt 2 x d over a length of 10 x d A milder bend can often be removed by carefully bending the rope by hand in the opposite curve Rope with sharp bend shall be changed immediately 97 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 30 3 Assembly Disassembly e Adjust or by pass the lower limit switch so that the rope can be fully unwound from the drum e Lower the hook onto a stable working platform e Remove the rope guide see section Rope guide Assembly for details e Pull with a gloved hand the rope down from the drum until the last turn e Switch OFF the power supply to the crane e Extract the rope anchorage from the overload device see section Rope anchorage Assembly for details and remove the rope from the anchorage Pull the rope out from the hook block and return sheaves e Remove the rope clamps from the drum and remove the rope er In some cases it can be possible to pull the new rope on to the hoist by using the old rope and a cable sock Pay special care when using this practice Make sure there is no risk for personal injuries and assure the new rope does not get damaged Re assembly e Check that the new rope is compatible
73. ed acceleration or speed up ramp time will minimize the motion from achieving full speed instantly minimizing load swing Position 2 is the High speed command but the ramping time to full speed allows the operator to hold any speed between Low and High by returning to the first position commanding HOLD SPEED w NOTICE when the pushbutton is returned to neutral an established deceleration or slowdown ramp time is in full control of the motion before STOP A skilled operator can use this ramp time to his advantage by pushing in position 1 to command HOLD SPEED The motion will hold the speed the motion has slowed down to Wy EMERGENCY STOP WILL ALWAYS STOP MOTION IMMEDIATELY 3 5 3 Using the pushbuttons two speeds controlled by Inverter la p mp E ZA A 7 E A 0 papapa c_coms2a A Position of pushbutton 0 1 and 2 B Speed Two step pushbutton Low and High Speed with Soft Starting and Soft Stopping The position of the pushbutton affects the speed as follows e Position 0 Neutral Position Controls motion to slowdown and stop e Position 1 Accelerate to low speed e Position 2 Accelerate to High speed Wy Frequency Inverter Drives provide state of the art control in the hoist bridge and trolley motions of industrial cranes This simple control has two speeds Low and High but with the advantage of speeding up smoothly to minimize swing When returning to Low Speed or Stop a smooth slowing down occurs
74. eeeeeeeeeeeeees 13 4 1 Hoist identification data cceeeeeeees 13 4 2 Directives and standards 00006 13 4 3 Manufacturer s contact details R amp M 13 4 3 1 Spare parts oo nnonnnaannnannoennnnnnenannnenennnnnnnnnne 14 5 Construction cccsccsseceeeeeeeeeeeeeeeeeeeeeenees 15 5 1 Low Headroom Trolley Hoist 15 5 2 Double girder Trolley Hoist 0 17 5 3 Normal Headroom Trolley Hoist 20 5 4 Fixed HOISt ccccecceeeceeeeeeeeeeeteeeeeeenaes 21 5 5 Machinery Hoist cccccccecceceseeeeeeeeees 24 5 6 Trolley buffers cccccecceeeceeeeeeeeeeeeees 25 DO SORVICC eaea dvaennnncusaws 25 5 7 Hoisting machinery cccecceeeceeee scene es 25 Del HOSE VICC acicaecctecinsc cep R 25 5 7 2 Assembly cccccceeeeeeeeceeeeeeeeeeeseeeeeseeeeeseeeees 25 5 8 Hoisting GEALDOX c ccc ceecceeeceeeceeeeeeeeees 30 D81 SEVICE ce 31 5 8 2 Assembly ccccceecesseeeeeeeeeceeeeeseeeeeseeeeesneens 31 5 9 Hoisting motor and brake 0c00 32 2 129 Keep the instructions in a safe place for future reference S91 DENCE es E 32 5 10 Second brake cccccccsseecceseessseeseeeeees 34 5 11 Manual brake release for hoisting motor for brake type NM387 ou cccecceeeeceeeeeeeeeeeeeee 35 5 11 1 Assembling the manual brake release 35 9 11 2 Brake release usage instructions
75. eft hand lay another right hand lay 94 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Rotation resistant ropes have more outer strands than standard ropes Outer strands have left hand lay while inner strands are in right hand lay 5 30 2 Service e Inspect the rope Regular rope inspection and maintenance shall be carried out according to the guideline instructions below and according to international standard ISO 4309 2004 e Lubricate the rope with suitable lubrication Lubricant for wire rope shall be water resistant non adhesive transparent thin oil which is able to penetrate in the rope w The rope shall be changed before the limits have been reached Change the rope if there is a risk that limits are reached before the next examination 5 30 2 1 Periodical examinations Visual deformations and damages in the rope shall be inspected daily by the user Wire ropes shall be inspected by authorized service personnel at least every 12 months or 10 SWP The inspection intervals should be shortened when The hoist is used in heavy duty or process use e g duty class M6 or higher papermill cranes etc The hoist is used under harsh conditions e g extreme temperatures excessive dirt dust or outdoors
76. eriod ends a General Overhaul GO must be conducted after which the hoist is assigned a new Safe Working Period refer to the section General Overhaul GO During the SWP the safe and efficient operation of the hoist is contingent on regular servicing W For the safety carry out the inspection and servicing procedures for the hoist in accordance with the table below Y To avoid any risk of spark with explosive proof hoists due to the friction of two mechanical parts it is important to follow strictly the maintenance intervals The safety of the equipment could be compromised if not 8 1 Daily inspections Wy Carry out following daily inspection on start of each work shift Do not use the hoist unless it is in proper condition Contact a service agent authorized by the manufacturer immediately in case of doubts The usage of a defective hoist can result in serious damages injuries or death Inspection of the wire rope Check the wire rope visually for kinking crushing corrosion broken wires and broken strands Check visually that the rope lays in the grooves of the drum and in the rope sheaves Inspection of the hook block Check that the hook moves freely in every allowed direction Check the presence of the safety latch and it s functioning Check the free and smooth rotation of the rope sheaves Inspection of the hoist limit switch Verify that the upper limit switches operate properly Verify that the lower limit switch operates prope
77. etwork e Adjust the limit switch for hoisting Refer to the section Adjusting hoisting limit switch e Carry out the commissioning inspection and complete the commissioning log Refer to the section Commissioning 6 8 Installing the hoist machinery hoist G Yt D tt e Remove the temporary transport supports Take the hoist out of the packing and move it to the installation site e Check that the fixing holes in the site of location match the fixing holes 1 in the hoist e Change electric cubicle position if needed All fixing directions A B C and D are possible Move the fixing parts 2 to correct fixing corners e Lift the hoist into position Fasten the fixing screws e Instal rope reeving w Instal rope direction s according to manufacturer s instruction Be in contact with authorised hoist service 6 8 1 Outfitting the hoist e Install the power supply Refer to the section Connecting the to mains network e Adjust the limit switch for hoisting Refer to the section Adjusting hoisting limit switch e Carry out the commissioning inspection and complete the commissioning log Refer to the section Commissioning 117 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfie
78. ge width 3 Trolley positioning nuts 4 Frame tube 5 Trolley side plate e Remove the temporary transport supports Take the hoist out of the packing and move it to the installation site Lift the hoist using the lifting lugs provided e Loosen the adjusting nuts for flange width 2 Adjust the distance between the travel wheels A so that it is slightly wider than the beam flange B for installation purposes e Lift the hoist onto the beam e Adjust the side plate 5 of the trolley inwards until there is a gap of approximately 3 5mm between the flange of the travel wheels and the flange of the beam Tighten the nut 2 to the sideplate 5 On the other side of the sideplate leave 0 1 0 2 mm clearance between the nut 2 and the sideplate Lock the nuts 2 to place by the extra nuts 6 e Loosen the adjusting nuts for trolley positioning 3 Adjust the position of the trolley so that the hook is hanging below the centerline of the beam 110 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice 6 5 2 FAX 937 325 5319 INC R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 HANDLING P 937 328 5100 Recommended tightening torques Tighten the nuts 2 6 and 3 to the correct tightening torque Refer to the section c_nab2b
79. gearbox 3 Cover of connection box 4 Hoisting limit switch 25 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice HANDLING INC R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 5 Cover of rim gear 6 Rim gear 7 End flanges of hoisting machinery A B C D Fixing screws for hoisting machinery Disassembly Lower the hook to the ground Switch OFF the power supply to the hoist Remove the protective cover of the hoisting machinery Lock the rope drum with i e a wooden wedge to prevent it from rotating Wy The weight of the rope may cause the drum to rotate when the gearbox is detached er S Open the cover of the connection box on the gearbox 3 Extract the power feed connector for the hoisting motor Remove the brake wires from the connector Detach the rotating limit switch 4 Loosen the cable entry and remove the cable and rotating limit switch from the connection box In some models you must remove the wires from the limit switch and the terminal strip Remove the fixing screws A and C from the hoisting machinery and replace them with thread bars Drum size 303 355 mm M8x600 Drum size 406 mm M12x 800 Remove the fixing screws B and D 1 Fan cover 2 Fan 3 Brake 4 Brake disc 5 Fixing screws for motor 6 Friction plate Remove th
80. ghtening torque Refer to the section Recommended tightening torques 6 5 3 Outfitting the hoist e Install the power supply Refer to the section Connecting the to mains network e Adjust the limit switch for hoisting Refer to the section Adjusting hoisting limit switch e Carry out the commissioning inspection and complete the commissioning log Refer to the section Commissioning 112 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 6 6 Normal headroom trolley drum diameter 608 mm 6 6 1 Straight beam oe J i o foe T S U l NY U 1 7 7 L4 a 3 E S 2 L3 L1 sL J c_nab3a Ko 1 Adjusting bar for trolley position 2 Adjusting nuts for flange width 3 Trolley positioning nuts 4 Frame tube 5 Trolley side plate 6 Adjusting bar for flange width e Remove the temporary transport supports Take the hoist out of the packing and
81. guide assembly drum size 608 mm Rim front half Rim rear half Rope slot locking bar Rotation support Rim spacer Locking bar fixing screws Rim fixing screws Springs ONOONRWNH w Fully disassemble the rope guide before installation 63 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Replacing an old style rope guide with a heavy duty rope guide When replacing an old style rope guide with a new style rope guide in true vertial lift hoist or machinery hoist the hoisting limit switch setting for the hook s lower position may need re adjusting to ensure safe operation See the drawing below to identify the type of rope guide you have on the hoisting unit c_qderogu5 lt A Old style rope guide B New style rope guide 1 Stainless steel rim at the bottom of the drum groove 2 Plastic support element 3 Straight front face plate 4 60mm wide cast iron rim around the rope drum 5 Spring loaded rim joint 6 Roller bearing support assembly The heavy duty rope guide cannot travel as close to the rope fixing clamps on the rope drum as the old style rope guide It takes approximately 10mm more space in that direction After installing the heavy duty rope guides adjust the hoisting
82. h rated load 120 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC The current should be in balance in all phases and may not exceed the ratings for the motor Check the current at both hoisting speeds 7 2 2 Inspection of running temperature If the thermal protection halts hoisting prematurely identify the reason for overheating before continuing the commissioning tests 7 2 3 Inspection of travelling machinery e Check that the acceleration and braking motions operate smoothly e Run the trolley at least 3 5 times over the whole length of the girder Remove the paint coming loose from the runway of the trolley 7 3 Inspections with overload 110 125 of the rated load of the hoist 7 3 1 Inspection of overload protection e Check that the overload protection mechanism operates with an overload The overload protection must prevent hoisting motion when the load exceeds the trigger load for the overload protection mechanism that is stated in the test drive If the hoist is provided with a condition monitoring unit refer to the separate operating instructions for commissioning the condition monitoring unit 7 3 2 Inspection of brake operation e Lower the load in slow speed and stop Ensure that the brak
83. he manual brake release is allowed to use only in case of emergency Potential energy of load will heat up the brake rapidly Follow the instructions for usage carefully Faulty usage of the manual brake release can cause uncontrolled lowering of the load It is recommended to contact a service agency authorised by the manufacturer Especially trained personnel are able to ensure safe lowering of the load In hoists models equipped with a second brake optional the second brake must be detached before installing brake release fork to the main brake E In hoist models equipped with 2 hoisting motors and thus 2 main brakes both brakes must be manually opened with levers simultaneously This action requires 2 persons to carry out c_mobrib 1 fork lever assembled to hoisting motor brake 2 lever arm 3 brake frame A gap gt 1 8 mm 5 11 1 Assembling the manual brake release e Ensure that the fork lever 1 can move freely Gap A between fork the lever 1 and brake frame 3 must be at least 1 8 mm e Screw the lever arm 2 into fork lever 1 In hoists with drum 406mm and drum length H 1250mm or J 1600 mm the brake is installed in the end of gearbox 35 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502
84. he right to alter or amend the above information without notice R amp M MATERIALS R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC K RX C_rowh2b YS za XS R 1 Rope 2 Rope anchorage 3 Wedge 4 Rope clamp A Rope drum o 243 mm 5 28 1 Service gt 04 2004 01 2005 gt c_rowh3c 1 Rope drum p 243 mm DLA minimum L2minimum L4 H Thread Torque Imm fmm fmm mm mm tN p15 15 4 mM 8 8 amp 9 11 12 77 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice HANDLING INC R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 13 14 15 16 Check that the rope clamp nuts are tight Ensure that the rope has not slipped in the rope anchorage by comparing the measures with the stated measures in the table Make sure the rope end protrudes from the rope anchorage as specified on table Check the condition of the rope at point A Ensure that the rope is assembled inside the rope anchorage correctly 5 28 2 Assembly c_roan01_d000491c 1 Rope 2 Rope anchorage 3 Wedge 4 Rope clamp 5 Split pin 6 Washer 7 Shaft Disassembly Lower the hook onto a stable platform Pul
85. ice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 Drum size gt 608 mm 1 Hoisting motor and brake 2 Hoisting gear 3 Connection box 4 Rope drum 5 Electric cubicle 6 Hook block Drum size gt 608 mm two motors 1 Hoisting motor and brake 2 Hoisting gear 3 Connection box 4 Rope drum 5 Electric cubicle 6 Hook block 23 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 5 Machinery Hoist A machinery hoist does not include a hook or travelling machinery Machinery hoists are used in applications where only lifting or pulling is required Machinery hoists can be mounted in different positions according to the required lifting or pulling angle Drum size o 303 355 406 mm DOG 1 Hoisting motor and brake 2 Hoisting gear 3 Connection box 4 Rope drum 5 Electric cubicle Drum size gt 608 mm c_qdhm1b_d001536 1 Hoisting motor and brake 2 Hoisting gear 3 Connection box 4 Rope drum 5 Electric cubicle 24 130 R amp M Materials Handling Inc reserves the right to alter or amend the
86. ing drum size p 303 355 406 mm c_hbresh02v1a 1 Hook forging 2 Safety catch 3 Rope sheave 80 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 2 fall 1 rope reeving drum size bp 608 mm rr 1 Hook forging 2 Safety catch 3 Rope sheave 4 fall 1 rope reeving drum size p 303 355 406 mm c_hbreshO4via 1 Hook forging 2 Safety catch 3 Rope sheave 4 Return sheave 5 Return sheave shaft 6 Support frame 7 Support frame shaft 81 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 4 fall 1 rope reeving drum size bp 608 mm Hook forging Safety catch Rope sheave Return sheave Return sheave shaft Support frame Support frame shaft NOORWOND 6 fall 1 rope reeving drum size gt 355 406 608 mm Pe Hook forging Safety catch Rope sheave Return sheave Return sheave shaft Support frame Support frame shaft NORWOOD 82 130 R amp M Materials Handling Inc reserves the right to alter
87. ing service life can be obtained from table below Hoist operating group marked on hoist s rating plate Estimated remaining 1Am 2m 3m 4m years Actual duration of service S h o f o o oo g o o s eo o o o 0o s 6o o n s aw o o0 o O o a oo m 22 on 6 s o s0 so 5 o o 120 s90 40 o 4 s mo 240 mo s gt eo a0 260 5040 2 2 z ao 280 so 1 1 mo s20 6o o o When SWP is zero a General Overhaul GO must be conducted Refer to section General Overhaul GO 8 4 General Overhaul GO Once the SWP of the hoist reaches zero the hoist has exhausted its theoretical lifetime The probability of a defect in the hoist is therefore higher and operating safety is jeopardized When the theoretical lifetime is exhausted a General Overhaul GO of the hoist must be conducted Only the hoist manufacturer or a service organization authorized by the hoist manufacturer may conduct a GO The components in the hoist that have an impact on hoist lifetime are inspected in a GO and critical components are replaced A new theoretical SWP is given to the hoist after completion of a GO Wy When the Safe Working Period SWP of the hoist is exhausted the hoist may only be used after a GO has been conducted If the hoist is not provided with a condition monitoring unit the end of the Safe Working Period must be calc
88. ion 0 Neutral Position Controls motion to slowdown and stop e Position 1 Start in low speed and Hold speed Command When starting the movement in first step go to low speed is initiated When speeding up pushing step 2 accelerate to high speed and a desired speed is reached return to position 1 the Inverter control will hold the speed the motion has reached A quick back and forth movement between position 1 amp 2 can provide the crane operator variable speeds for safer and more productive operation When slowing down release button to neutral and returning to position 1 the Inverter control will hold the speed the motion has attained A quick back and forth movement between position 0 amp 1 again provides 11 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC the crane operator variable speeds to minimize swing reducing the slowdown ramp time to stop providing safer and productive operation e Position 2 Accelerate to high maximum speed w Inverter Drives provide state of the art control in the hoist bridge and trolley motions of industrial cranes A skilled operator can benefit from this type of control system Note an establish
89. ions of electrical devices comply with the wiring diagrams and meet local requirements In particular check connections that affect safety and control of the hoist e Check the cableways for electrical wiring Make sure that wires do not snag on structures when the hoist and trolley are in motion 7 1 2 Inspection of pushbutton controller and directions of rotation e Check that the pushbutton controller and pendant cable are in good condition Check that the pushbutton controller is at the correct height e Press the direction buttons on the pushbutton controller and check that the resultant motions occur in the correct direction w Check the resultant motion by pressing first the UP direction button even though the hook is near the upper limit e fthere is an error in the direction of all movements it can be corrected by changing the sequence of two phases of the power supply Change the phase sequence of the input power leads to the hoist e Check the operation of the emergency stop button Wy Do not depress the emergency stop button unnecessarily 7 1 3 Checking operating sound e Listen to the sound made when travelling and hoisting and assess whether the sound indicates an installation error e Check the vibration made when travelling and hoisting by feeling the hoist with your hand If the hoisting motor makes a loud intermittent noise and the hoist vibrates strongly the problem may be in the power supply Check and correct all
90. ist is operative The hook is holding an overload Check that the load on the hook does not exceed the maximum but does not hoist the permitted load load The load slips The hoisting brake is worn Contact a service agent authorized by the manufacturer See downwards section Hoisting motor Hoist motions are in the The phases of the power supply are Interchange the sequence of 2 phases of the power supply Check wrong direction connected wrongly the directions of motion See section Connecting to the mains network Travel motion is not There are obstructions on the track Clear the track ee or makes a Travel control is malfunctioning See section Inverter for travel oad noise 130 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice
91. ithout notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC w The drum brake must always be kept clean The braking torque reduces strongly if any grease or oil penetrates to the friction surfaces 5 26 1 Holding Brake The holding brake acts as a second brake and mechanically locks the drum when the hoisting or lowering motion has stopped When the operator starts hoisting or lowering the holding brake will be released and driving upwards or downwards is possible However in case the main brake has slipped during standstill the cam 2 may be locked against the brake rim 1 and the electromagnet 3 is not able to release the cam In this case it is necessary to drive the hoist in upwards direction prior to powering in order to release the drum brake Wy Do not drive the hoist in the upper stop limit switch when handling heavy loads Stop lifting as soon as the hoist enters the upper slow down limit In case the holding brake locks frequently it may indicate wear of the main brake c_db04a c_db02a 1 Brake rim 2 Cam 3 Electromagnet 16 Solenoid 24 Disc springs 25 Screw 5 26 2 Service e Check that the drum brake and surrounding surfaces are free from oil grease excessive dust and or other substances that may reduce the effectiveness of the friction material
92. l some more rope off the drum with a gloved hand Switch OFF the power supply to the hoist Remove the split pin 5 Remove the washers 6 and the shaft 7 while holding the rope anchorage 2 Slide the rope anchorage out of the overload device Remove the rope clamps 4 Tap the wedge 3 out of the rope anchorage and remove the rope 1 78 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Re assembly e Insert the rope into the rope anchorage Wy Make sure the rope enters the anchorage in the correct direction See section Rope Anchorage Service for details e Insert the wedge into the rope anchorage making sure that a length of at least six times the rope diameter protrudes from the anchorage e Pull the rope firmly into the rope anchorage so that the shaft easily fits into the suspension hole e Place the rope anchorage into the overload device and insert the shaft with the washers Wy It is important that the rope anchorage is correctly mounted in the overload device See the below table for details Drum o 243 Drum 6 303 and p 355 Drum o 406 Drum o 406 Drum o 608 Drum o 608 Drum o 608 e Assemble the rope clamps on the protruding end of the rope and insert the split
93. ld Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING 9 15 2 Assembly 1 Hoist limit switch 2 Connection box cover 3 Fixing screws limit switch Disassembly e Switch OFF the power supply to the hoist Remove the connection box cover 2 Remove the wires from the limit switch Remove the fixing screws 3 Extract the limit switch 1 Re assembly e Fit the limit switch carefully in its place so that the pinion fits into the gear rim of the drum e Tighten the fixing screws 3 e Re connect the wires e Switch ON the power supply to the hoist and check the proper functioning of the limit switch Wy In many cases it is necessary to re adjust the limit switch Be aware of incorrect settings during testing the operation 44 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 15 3 Adjustment 22 gt 50 mm ye mm 7 S1 Measurement for phase sequence supervision limit S2 Measurement for upper limit of hoisting S3 Measurement for slowdown limit of hoisting S4 Measurement for lower limit of hoisting C Minimum distance of hook from bearing surface of hoist travel wheel H Maximum lifting height Lower the hook to approx 100mm abov
94. ld Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 6 9 Connecting to the mains network An electrical wiring diagram is delivered with the hoist Carry out the following procedures before connecting the hoist to the mains network e Check that the rated voltages correspond to the main voltage The voltages and frequencies marked on the rating plate of motors driven by inverter can deviate from the values on the rating plate for the hoist e Ifthe hoist has been in storage for a long time or has been transported by sea check that the motors are dry and measure their insulation resistance e Ensure that the power supply to the hoist is protected with fuses of the correct size e Check that the phase sequence is correct e Carefully check all connections 118 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 7 Commissioning Before handing over the hoist at least the inspections and adjustments listed below should be carried out In some cases it is appropriate to carry out a more thorough inspection The scope of the inspection depends on the operating range and application 7 1 Inspections without load 7 1 1 Inspecting the connections of electrical equipment e Check that the connect
95. less than 5 mm replace all the brake parts Re assemble in the reverse sequence Adjust the brake air gap Refer to the section Adjustment of Compact brake air gap 5 20 3 Removing DC brake and inspection of brake friction disc ZLZLLLLLLLLLLLLLLZZL N ae O ZSSS Beg saan IZZZA gt N N IY I INIZIO Ha gij CT S ISS SSS c_trmobr3b 1 Power supply plug 2 Motor cover 3 Brake fixing screws 4 Brake friction disc S Thickness of brake friction disc Ensure there is no danger of live voltage Remove the power supply plug 1 for the travelling machinery Open the motor cover 2 Unscrew the brake fixing screws 3 Check the brake type on the rating plate fixed to the brake Measure the thickness of the brake disc 4 Replace the brake disc if it has worn thin Brake type and size Min thickness of Tightening torque for brake disc brake fixing screws NM38710NR 2 Nm 2 5 Nm 1 8 Ibf ft NM38711NR 4 Nm 2 5 Nm 1 8 Ibf ft Re assemble in the reverse sequence w Tighten the fixing screws of the brake to the correct tightening torque 5 20 4 Dismounting the travelling motor Ensure there is no danger of live voltage Remove the power supply plug 8 for the travelling machinery Unscrew the fixing screw
96. mit switch Overload device mechanical switch drum size 243 mm 1 Rope anchorage 2 Lever mechanism 3 Set of plate springs 4 Mechanical limit switch 5 Adjustment screw for mechanical limit switch 6 Lever movement limiter 99 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Overload protection mechanical switch c_odme1b 1 Rope anchorage 2 Lever mechanism 3 Set of plate springs 4 Mechanical limit switch 5 Adjustment screw for mechanical limit switch Overload protection load sensor 1 Rope anchorage 2 Lever mechanism 3 Load sensor 4 Safety limit switch w Safety limit switch 4 is designed for overload mechanism supervision not for overload protection Safety limit switch 4 does not measure load and it is no substitute for load sensor 3 5 31 1 Service e Check the good condition of the overload protection mechanism and the mechanical limit switch Clean if needed e Test the safety limit switch 4 operation by pressing the switch manually 100 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 455
97. move it to the installation site Lift the hoist using the lifting points marked on the hoist e Loosen the adjusting nuts for flange width 2 Adjust the distance between the travel wheels A so that it is slightly wider than the beam flange B for installation purposes e Lift the hoist onto the beam e Adjust the side plate 5 of the trolley inwards until there is no gap between the flange of the travel wheels and the flange of the beam Then adjust the other side plate 5 of the trolley inwards until there is a gap of approximately 3 5mm between the flange of the travel wheels and the flange of the beam e Loosen the adjusting nuts for trolley positioning 3 113 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC er Adjust the position of the trolley so that the hook is hanging below the centerline of the beam Select L dimensions according to rope reeving and beam flange from table below Wy Tighten the nuts 2 and 3 to the correct tightening torque Refer to the section Recommended tightening torques 6 6 1 1 Standard reeving 1 rope from drum i opes mm Inch mm Inch mm Inch mm Inch mm Inch 100 200 3 9 7 9 122 48 120 47 37 15 B 2 30 B 2 1 2
98. n is stopped by the upper limit switch S2 e Loosen the locking screw 5 e Turn the screw S1 so that it will activate just after S2 in upwards direction s2 St c_holiad1b e Tighten the locking screw and close the connection box Wy In Low Headroom models the C dimension depends on the wheel gauge of the trolley When the B dimension increases the fleet angle of the ropes with the hook in the upmost position changes accordingly To avoid overloading the ropes overload device return sheaves and other structures the minimum C dimension may not be smaller than the dimensions as below c_holiad2a C dimensions for Low Headroom Trolley drum diameter 303 mm Rope reeving 02 Standard hook with RSN1 hook forging nominal load 1600kg Bimm 80 230 250 soo aso 400 aso soo sso eoo Jeso feo Min Cmm 875 390 a20 aso aso s10 s40 s70 eos ess eeo Rope reeving 04 Standard hook with HBC 1 6 hook forging load 2880kg 90 nominal load Bimm so 100 130 320 350 400 aso 500 eso eoo Jeso Jeo Rope reeving 04 Standard hook with HBC 1 6 hook forging nominal load 3200kg Bimm so ioo 130 240 300 aso aoo 450 soo sso eoo feso Jeo Minc mmi as0 340 328 368 400 fass aro s00 sss 570 eoo eso C dimensions for Low Headroom Trolley drum diameter 355 mm Rope reeving A2 Standard hook with RSN1 hook forging nominal load 1600kg Rope reeving A4 St
99. ndling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 4 Hook bearing set 5 Thrust bearing 6 Locking ring 7 Bearing housing 8 Side plate 9 Sheave bearing set 10 Rope sheave 12 Shaft locking 13 Rope sheave set 15 Sleeve Disassembly Lower the hook onto a stable working platform Pull with a gloved hand some extra rope down from the drum so that the hook block is free If needed adjust the lower limit switch e Switch OFF the power supply to the crane e Remove the shaft locking parts 12 e Extract the rope sheave set 13 from the shaft e Remove the sheave cover screws and remove the side plates 8 e Remove bearing housing fixing screws 7 e Remove the locking ring 6 and thrust bearing 5 e Extract the hook 3 from the bearing set 4 Re assembly e Lubricate the thrust bearing and the hook shaft e Insert the hook 3 into the bearing house 4 and re assemble the thrust bearing 5 and the locking ring 6 K a See ESA AZAY iw e Insert the hook assembly into the bearing housing 7 and tighten the fixing screws hand tight e Re assemble the side plates 8 the rope sheaves 10 and the shaft locking parts 12 e Ensure that the sheaves rotate freely before tightening the bearing housing fixing screws to the required torque e Switch ON the power supply to the crane e Raise the hook block Carefully guide the rope with a gloved hand
100. ng drum size 406 608 mm NOJAAN Hook forging Safety catch Rope sheave Return sheave Return sheave shaft Support frame Support frame shaft AS ANa resh24v1b 6 fall 2 rope reeving drum size 406 608 mm 85 130 NOOR WN c_hbresh26vic Hook forging Safety catch Rope sheave Return sheave Return sheave shaft Support frame Support frame shaft R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 8 fall 2 rope reeving drum size 406 608 mm c_hbresh28v1b Hook forging Safety catch Rope sheave Return sheave Return sheave shaft Support frame Support frame shaft NOOR WD 10 fall 2 rope reeving drum size 608 mm c_hbresh20v1b Hook forging Safety catch Rope sheave Return sheave Return sheave shaft Support frame Support frame shaft NOOR WD 86 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice HANDLING INC R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX
101. ng which the hoist can operate safely Separate operating and servicing instructions for the condition monitoring unit are delivered with the hoist Wy Only qualified personnel authorized by the manufacturer of the hoist may do the programming of the condition monitoring unit CU1 4 OVERLOADS S T EMP c_hocu2a 1 Digital display 2 Indicator LEDs 3 Programming buttons 101 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC O N l an 1 O Re O 8 O o 8 8 D O i 2 O O a lan O o O S 9 H jA 6 8 ie 0 o Ie h 9 3 oF J g c_SWM01a 1 Digital display 2 Indicator LEDs 3 Programming buttons Condition monitoring unit c_cid01a 1 Digital display 2 Indicator LEDs 3 Programming buttons 5 32 1 Service Consult with the service manual of the respective condition monitoring unit for details e Check that non of the fault indicating LEDs are lit up and that the display does not show an error message e Write down the primary monitoring values and keep a log of these 102 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway
102. of the drum brake e Check that the solenoid works properly and the cam closes against the brake rim e Manually activate the holding brake limit switch when operating in down direction and verify that hoisting is stopped in the down direction Up direction should continue to operate 69 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 9 26 3 Adjusting holding brake 1 Brake rim 2 Detent arm 4 Shaft of the detent arm 15 Holding brake limit switch 16 Solenoid 1 Assemble the brake rims 1 together with disc springs 24 10 pcs and screws 25 All the disc springs must be placed so that the concave sides are facing in to the brake rim 2 In the two brake rims model the connection points of the halves of both rims shall not be aligned they must be 90 degrees apart The 90 degrees placement is to reduce the risk of having two bolt connection teeth being contacted simultaneously by the detent arm 3 Adjust the rims so that there is a difference of 5 mm 0 2 between the teeth of the two brake rims The 5 mm difference is to allow one rim to begin the braking before the second rim engages to reduce the dynamic impact 4 Tighten the brake rim screws 25 to a torque of 60 Nm 44 ft Ib 5 Check wi
103. on Lubricants for further instructions 5 8 2 Assembly See section Hoisting machinery Assembly for details 31 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 9 Hoisting motor and brake Standard hoists are equipped with two speed squirrel cage motors which are especially designed and manufactured for hoisting duty The motors incorporate a cylindrical rotor and class F insulation and are conform to the protection standard IP54 DIN40050 Optionally the hoist can be equipped with a inverter and specially designed motors for this duty These are one speed squirrel cage motors with increased insulation of the windings In addition these motors are equipped with a speed sensor as a standard The hoisting brake is an electromagnetic safety brake that is closed by spring force Fan cover Fan Brake Brake disc Fixing screws for motor Friction plate OORWN 5 9 1 Service 5 9 1 1 Hoisting motor e Check that the hoisting motor operates properly when loaded e Check for any excessive noise vibration and or heat e Clean the cooling ribs surface when needed 32 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice
104. or amend the above information without notice R amp M MATERIALS HANDLING INC P 937 328 5100 R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 FAX 937 325 5319 8 fall 1 rope reeving drum size o 355 406 608 mm 10 fall 1 rope reeving drum size b 608 mm NOORWOND 83 130 NOORWND Hook forging Safety catch Rope sheave Return sheave Return sheave shaft Support frame Support frame shaft c_hbresh10v1a Hook forging Safety catch Rope sheave Return sheave Return sheave shaft Support frame Support frame shaft R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 1 fall 2 rope reeving drum size b 355 mm c_hbresh21v1a 1 Hook forging 2 Safety catch 2 fall 2 rope reeving drum size 406 608 mm c_hbresh22v1a 1 Hook forging 2 Safety catch 3 Rope sheave 84 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M MATERIALS HANDLING INC R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 4 fall 2 rope reevi
105. ormation without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 25 Rope clamps The rope is fixed to the rope drum with rope clamps The number of rope clamps varies with the type of hoist er In addition to the clamps on the rope ends there must always be at least two full turns of rope on 1 Rope 2 Rope drum 3 Rope clamps 4 Friction turns 5 25 1 Service e Check that the rope clamp bolts are tight e Ensure there are at least two friction turns when the hook is at the lowest position e Make sure the rope end protrudes from the last clamp a distance of 5xd 5 26 Drum Brake The drum brake has been designed as an extra safety device to the hoist To obtain the maximum safety it operates mechanically and applies directly to the rope drum Drum brake has three different configurations i e holding brake overspeed brake and a construction with both holding and overspeed brake functions Wy Drum brakes are tested and adjusted by the hoist manufacturer prior to delivery Only qualified personnel authorised by the manufacturer may install adjust and service the drum brake w Service and maintenance of the drum brake must be done at regular intervals as recommended by the manufacturer 68 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information w
106. p M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Disassembly e Remove the rotation support 4 on the rope guide e Remove one intermediate shaft from the hoisting unit It is recommended to remove the shaft that is at the top corner opposite to the side where the rope leaves the drum Remove the rope slot locking bar 3 and screws 6 Remove the rope guide rim fixing screws 7 When the screws are off remove the springs 8 and the rim spacers 5 Remove the rear half of rope guide 2 Remove the first half of rope guide 1 Rope guide assembly drum size 608 mm 02 2005 12 2006 10 2004 02 2005 A Rope leaves the rope drum B Rope fixing clamp side Fix the joint plate 4 to the guide frame upper half 3 with two M8x25 screws The edge that has the rounding should point towards the rope fixing clamps Place the upper frame half 3 against the drum groove The correct groove is the first empty groove next to the rope Place the plastic guide element 7 over the 50 mm diameter hoist intermediate shaft and fix it to the guide frame upper half 3 with two M8x35 screws The plastic part should be on the side of the rope fixing clamps Pass the rope through the joint plate 4 and place the lower frame half 2 against the drum groove The correct groove is the one from which the rope leaves the drum A With the rope passing through both
107. pin Bend the split pin open er Insert NEW cotter pin DO NOT reuse a removed cotter pin 79 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC e Switch ON the power supply to the hoist e Raise the hook carefully to the upmost position Constantly watch the rope on the drum and make sure that the movement stops before the rope guide reaches the end of the drum e Adjust the hoist limit switch when needed See section Hoisting limit switch Assembly Adjustment for details 5 29 Hook block rope reeving and return sheaves The hook block consists of the hook forging hook forging suspension and rope sheave s The hook forging is supplied with a safety catch The hook forging rotates in a pressure bearing Optionally in some models the hook block can be supplied with a rams horn forging a locking device to prevent the forging from rotating hook forging insulation or non standard forging dimensions A trolley with a hoist that has four or more rope falls is equipped with a rope sheave beam including one or more return sheaves The reeving depends on the type of hoist the amount of ropes on the drum and the amount of rope falls The reeving scheme is shown in the picture 2 fall 1 rope reev
108. quately trained in the safe operation of handling loads w The hoist operator the hoist serviceman and personnel in charge of hoist operation and servicing shall be familiar with and comply with the safe working principles described in the instructions Wy Read all safety instructions supplied with products WY Study meaning of stickers on products 3 5 Using the pushbutton controller The hoisting and travel motions of the hoist as well as crane travel motions are controlled with the pushbutton controller or by remote control Some pushbutton controllers and remote control units are provided with a selector switch that allows the same controller unit to be used to control several hoists and or cranes If the hoist has remote control infrared or radio control separate operating instructions for the remote controller are provided with the hoist The direction symbols on the pushbutton controller conform to local requirements 9 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC A B C D 1 2 3 4 5 6
109. r before the motor fits correctly and straight in the flange of the gearbox There is a risk to damage or misplace the inner circlips of the coupling when using force e Rotate the motor shaft by hand Make sure the shaft rotates freely and that the drive pinion of the gearbox rotates simultaneously e Tighten the motor fixing bolts to the correct torque e Assemble the friction plate 6 Text REIBSEITE must be against the friction disc 4 if applicable e Assemble the brake disk and the brake Do not tighten the brake fixing bolts yet the shaft should be able to rotate freely e Insert the motor gearbox subassembly into the drum Use lifting aid such as a chainhoist for the bigger neavier models w Handle the motor gearbox subassembly with care Avoid damaging the inner dust ring and the rim gear cover e Be aware of Guide pins on the bearing rim flange 27 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Drive pinion of the gear fits correctly into the gear rim of the drum Rotate the motor s shaft on the brake end side to guide the pinion into the gear rim and to check the right fitting Fasten the bolts B amp D Remove the thread bars and fasten the bolts A amp C Tighten the bolts to
110. rating group is obtained from the table below Load spectrum Average daily operating time hours per day a lt 05 lt 1 ps4 lt lt 16 I w a ee vow som tam om m an rm tam am om am m m m m an HEAVY VERY HEAVY 3 4 Safe working principles Carefully following safe working principles is one of the most effective ways of preventing damage to property and injury to personnel The operator serviceman and work manager for the hoist should be familiar with the safe working principles for the hoist A service organization authorized by the manufacturer can provide training for operating the hoist and any maintenance services needed under a separate agreement Misuse of the hoist or improper servicing may result in an accident that cannot be prevented by the safety equipment Crane Operator operation and safety training will introduce the operator to the essential safe handling of loads with the hoist equipment and safety procedures to follow Service training can also provide the preventive maintenance requirements of the hoist to prevent equipment failure effecting production and or safety Work management has an important role in implementing the principles for using the hoist safely Work management must ensure that the hoist and its accessories are fit for the intended purpose and that servicing and maintenance of the equipment is carried out as scheduled Management must also ensure that personnel are ade
111. rd MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 19 1 Service 5 19 1 1 Traveling motor e Check that the traveling motor operates properly when loaded e Check for any excessive noise vibration and or heat e Clean the cooling ribs surface when needed 5 19 1 2 Traveling gearbox e Check the gearbox visually for leakage e Incase the gearbox shows signs of excessive leakage find the reason for this and replace the worn part or the complete gearbox e Check the breather plug if applicable breaths freely and clean if needed e Check for any excessive vibration and or noise er If the factory installed grease is topped up with a different lubricant ensure that the lubricant is compatible Refer to the section Lubricants for further instructions 5 19 1 3 Traveling brake e Remove the end cap of the motor e Check the air gap of the brake WA If the air gap is greater than 0 2 0 3 mm the brake disc may be worn out Check the thickness of the brake disc e Adjust the air gap when needed e Remove dust and dirt from the brake e Close the end cap and check the proper functioning 92 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice HANDLING R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 INC
112. rly Inspection of the pushbutton controller Check the pushbutton controller for cracks or other signs of wear in the housing and for loose or broken buttons Verify that all pushbuttons and switches correspond to their intended functions and directions Check the operation of the emergency button Do not depress the emergency button while the hoist is running during this test Instead depress the emergency button and verify that no movement can be activated with the pushbuttons 122 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 8 2 Periodical inspections and servicing The servicing intervals for the hoist are defined as SWP periods The actual operation of the hoist is taken into account in SWP If the hoist is provided with a condition monitoring unit the SWP value can be read from the SWP data counter display of the unit Refer to the more detailed instructions given in the separate operating instructions for the condition monitoring unit The SWP corresponding to the SWP value can be found from the table below Check the rating plate fixed to the hoist for classification of the hoist s operating group SWP value in relation to the SWP Operating group of the hoist ISO FEM SWP 0 o 1920
113. s 1 for the motor 54 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC e Detach the motor from the gearbox e Re assemble in the reverse sequence 5 21 MF07 and MF10 Travelling motor Fan cover Fan Flywheel Fixing screws for motor Brake Brake disc Friction plate Rectifier Power supply plug ONOOARWN 5 21 1 Removing DC brake and inspection of brake friction disc Ensure there is no danger of live voltage Remove the power supply plug 8 for the travelling machinery Open the motor cover 1 Remove the fan 2 Unscrew the brake fixing screws Check the brake type on the rating plate fixed to the brake Measure the thickness of the brake disc 5 Replace the brake disc if it has worn thin Brake type and size Min thickness of Tightening torque for brake disc brake fixing screws NM38770NR 16 Nm 5 Nm 3 7 Ibf ft NM38771NR 8 Nm 5 Nm 3 7 Ibf ft NM38720NR 21 Nm 9 Nm 6 6 Ibf ft e Re assemble in the reverse sequence Wy Tighten the fixing screws of the brake to the correct tightening torque 55 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501
114. s for design Part 2 Technical principles and specifications e EN 1050 Safety of machinery Principles for risk assessment e EN 60204 32 Safety of machinery Electrical equipment for machinery Part 1 General requirements The quality standard applied by the manufacturer is e EN 29001 ISO9001 Quality Systems The following international technical standards have been applied to the product e FEM 1 001 Section 4 Rules for the design of hoisting appliances Checking for fatigue and choice of mechanism components e FEM 9 901 Design of serial lifting equipment 4 3 Manufacturer s contact details R amp M Contact details for the manufacturer of the hoist Manufacturer s name and R amp M Materials Handling Inc address 4501 Gateway Boulevard Springfield OH 45502 USA Telephone number 1 937 328 5100 Fax number 1 937 325 5319 For further information about the product operational training and servicing please contact the manufacturer s representative located closest to you 13 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 4 3 1 Spare parts Spare parts for the hoist are specified in the separate spare parts catalogue delivered with the hoist Always state the serial number marked on the rating
115. smission running in grease lubrication When used in conformance with the operating group classification of the hoist the gearbox lubricant does not need to be changed during the Safe Working Period SWP If the hoist is operated in extremely cold conditions the factory installed grease must be replaced with synthetic transmission grease Refer to the section Lubricants for further instructions Low Headroom amp Normal Headroom trolleys 1 Gear 2 Motor 3 Gearbox fixing screws 4 Junction box 5 Junction box fixing screws 6 Motor fixing screws 90 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Double girder trolleys drum size o 303 355 406 mm fo SY c_tmqde2a Gear Motor Gearbox fixing screws Junction box Junction box fixing screws Motor fixing screws Securing nuts Coupling ONONKRWNH Double girder trolleys drum size 608 mm c_tmqdeta 1 Gear 2 Motor 3 Gearbox fixing screws 4 Junction box 5 Junction box fixing screws 6 Motor fixing screws 91 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Bouleva
116. spection of brake friction CISC swiss sissnaszciciceonsis Sesiensciseasdnawedsncebascceonetacedoanndaue 54 9 20 4 Dismounting the travelling motor 54 5 21 MFO7 and MF10 Travelling motor 55 5 21 1 Removing DC brake and inspection of brake IPN WGI ONS o EAE EEE E 55 9 21 2 Dismounting the travelling motor 56 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc 4501 Gateway Boulevard Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 R amp M MATERIALS HANDLING INC 5 22 Inverter for travel cccccccsecesseeeeeeeeeeees 56 5 23 Rope drUM ccccccecceceeeeceeeeeeeeeceeeseeeseees 58 5 23 1 Service drum size p 243 303 355 406 mm 58 5 23 2 Service drum size 608 MM cceccee 59 5 23 3 Drum wear inspection cccceeceeeeeeeeeeeeeees 59 5 24 Rope guide eesdctneccnecdsneespcadaceudedetcgetutessncence 61 9 20 RODS ClAIMDS sisiccssnsndovinaasavcndeencacenaqeineinieccs 68 S VE e E 68 5 26 Drum Brake cccccccceccceecceeeceeeseeeeeeeeees 68 5 26 1 Holding Brake cccccceeceeseeeeceeeeseeeeeseeeens 69 5 20 2 SGNV CE iseanan eenn niea an EATE 69 5 26 3 Adjusting holding brake cccseeeeeeeeeees 70 5 26 4 Overspeed Brake ccccceecceseeeeeeeeeseeeeees 70 OZ ONC Eee A 71 5 26 6 Adjusting overspeed brake
117. switch added release and manual crank added Lubricant volumes travel Lubricant volumes for larger trolley gears added 11 1 2005 KHTJPU gears Wire rope Rope inspection criterions changed minimum 13 1 2005 KHHASI wire brakes headroom trolley trolley added Drum size 608 mm ee ee of trolley buffers during installation girder trolley added a of free rotation Replacement of axial locking part Drum size 303 355 406 mm tightening torques Maintenance interval Inspection interval of hoisting machinery and 10 5 2005 KHHJII oe alpino changed Inspection interval for drum eed W brake added service Trolley buffers Trolley buffer inspection instructions added 10 5 2005 KHHJII Wedge housing Replacement of split pin 18 5 2005 KHHJII assembly Lubricants Lubricant type for couplings changed 25 5 2005 KHTJPU Commissioning Inspection of rope anchorage 13 9 2005 KHHJII ee type and volumes for hoisting gears 21 9 2005 KHTJPU GEN4 changed Rope anchorage Drawingsupdated 29 9 2005 na hl and return sheaves coreg eases SR headroom trolley instructions added guide Construction New hoist size added drum diameter 243 mm 13 1 2006 KHHJII Low Headroom Trolley Hoist Hoisting limit switch Drum size 243 mm 5 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway
118. t be equiped with a crank This action requires 2 persons to carry out SSE a ON NI IN f Y e jee a 3 Aaa 7 rt a J S p ae 4 Sa ff Ty A m fo SA vA intl y a ae pest E4 My ees c_mbmc01a 36 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 9 12 1 Assembling the manual crank Switch OFF the power supply to the hoist Remove fan cover 1 Remove retainer ring and fan 2 Install the crank 4 onto shaft gearing and tighten with bolt 3 to the shaft s centre thread screw the lever arm 5 into fork lever Hoist with 406 mm drum diameter and drum length H 1250mm and J 1600 mm the brake is installed in the end of gearbox Fork lever and crank should be assembled here 5 12 2 Operating the manual crank S It is preferred to use the manual crank only for lifting the load or lowering very small loads Lowering heavy loads should be done by the manual brake release only without the crank e Take strong hold to the crank by one hand e Pull releasing lever 5 carefully with your another hand e Move load by rotating manual crank Y Do not pull the lever too much and too abrupt but open the brake with care Sudden uns
119. t supports Take the hoist out of the packing and move it to the installation site Lift the hoist using the lifting mounts 5 w Do not unscrew the fixing nuts on the hoisting machinery side e Lift the hoist onto the beam Adjust the X measurement until there is a gap of approximately 3 5mm between the flange of the travel wheels and the flange of the beam e Check the wheels of the trolley are correctly aligned Wy Tighten the adjusting nuts 4 on both sides to the correct tightening torque Refer to the section Recommended tightening torques 106 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REY 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 6 3 Low headroom trolley When installing a low headroom trolley the wheel gauge has to be adjusted properly Clearance between the wheel flange and the main girder flange measure X must be 3 5 mm Ensure that the clearance is equal on both ends of the trolley c_labib Drum size p 303mm c_bmlata 1 Locking screw and nut 2 Fixing screws for fixing bracket 3 Fixing bracket 4 Lifting lugs for raising the hoist 5 Frame tube e Remove the temporary transport supports Take
120. temporary transport supports Take the hoist out of the packing and move it to the installation site Lift the hoist using slings around the frame tube e Loosen the locking 2 of adjusting bar 1 Adjust the distance between the travel wheels A so that it is slightly wider than the beam flange B for installation purposes UY Do not loosen the fixing parts on the drum side of the trolley e Lift the hoist onto the beam Adjust the X measurement until there is a gap of approximately 3 5mm between the flange of the travel wheels and the flange of the beam Use a nylon mallet to adjust the X measurement e Check the wheels of the trolley are correctly aligned Wy Tighten the locking screw 2 and 4 of the adjusting bar on both sides to the correct tightening torque Refer to the section Recommended tightening torques 6 3 1 Outfitting the hoist e Install the power supply Refer to the section Connecting the to mains network e Adjust the limit switch for hoisting Refer to the section Adjusting hoisting limit switch e Carry out the commissioning inspection and complete the commissioning log Refer to the section Commissioning 108 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 6
121. th the caliber that the gap between the brake rim halves is the same on both sides This is to ensure the even tooth to tooth distances over the brake rim connection 6 Adjust the holding brake limit switch 15 to be mechanically activated by the cam of the detent arm when the solenoid de energized 7 Check that the detent arm 2 is touching the brake rim when the hoist is idle When the solenoid is activated check that there is a clearance between teeth and detent arm 8 Manually activate the holding brake limit switch when operating in down direction and verify that hoisting is stopped in the down direction Up direction should continue to operate 5 26 4 Overspeed Brake Overspeed brake prevents the rope drum from an overspeed condition Overspeed can occur when a component in the transmission or drive train fails and the load on the hook is heavy enough to cause an overspeeding of the drum WY In case the drum brake activates due to overspeed always contact a representative of the hoist manufacturer The hoist must not be used before the cause for an overspeed has been 70 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC found and repaired The drum brake components must be checked for wear and damage and then a
122. the correct torque Re assemble the hoist limit switch Insert the brake wires into the plug and re connect the power feed connector Tighten the brake fixing screws Remove the drum locking device wooden wedge Re assemble the protective cover of the hoisting machinery Test the proper operation of all movements and functions Wy In many cases it is necessary to re adjust the limit switch Be aware of incorrect settings during testing the operation Drum size 608 mm In the models with drum size 608mm the motor s can be extracted from the gearbox separately c_r3hmic Hoisting limit switch Cover hoisting limit switch Connection box Drum bearing house Fixing plate for gearbox Fixing screws for gearbox Hoisting gearbox Coupling CONDOR WNDN 28 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 9 Hoisting motor 10 Fixing screws for motor 11 Friction plate 12 Brake disc 13 Hoisting brake 14 Fixing screws for hoisting brake 15 Fan 16 Fan cover Disassembly e Lower the hook to the ground Switch OFF the power supply to the hoist e Remove the protective cover of the hoisting machinery e Lock the rope drum with i e a wooden wedge to prevent
123. tion disc if it has worn thin e Clean the inside of the brake 4 e Remove the fixing screws 8 e Remove the anchor plate 7 e Clean the anchor plate and brake armature e Re assemble the brake e Clean the brake disc 5 and the friction plate 6 e Re assemble in the reverse order Assemble the friction plate 6 text REIBSEITE against the friction disc 5 if applicable 5 10 Second brake The second brake is an electromagnetic safety brake which is closed by spring force The second brake operates as holding brake when the motion has stopped and the main brake has closed The second brake closes with a small delay and opens simultaneously with the main brake The second brake is attached to the primary shaft of the hoisting gear whereas the hoisting motor with the main brake is attached to the other end of the shaft ZZZLZZZI TTT N 7A Cs e p il u LLALL E FINS fe VY CW ee Ke Y x b R a OnE ll Y 1G Wa N Z a LLLL ETZ 7 ii Vy LLLLL O o a hs 1 Brake 2 Hoisting gear 3 Hoisting motor 34 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING 5 11 Manual brake release for hoisting motor for brake type NM387 T
124. tion of the hoist is dependent on correct classification of the hoist s operating group According to FEM9 511 standard the hoist s operating group can be determined from its load spectrum average daily operating time 3 3 1 Load spectrum The load spectrum can be determined from the table below LIGHT MEDIUM HEAVY VERY HEAVY Occasional full load Occasional full load Repetitive full load Usually almost full load Usually light load Usually light load Usually average load Very heavy fixed load Small fixed load Average fixed load Heavy fixed load Load Load Load Load 100 100 100 100 80 50 50 90 10 Operating time Operating time Operating time Operating time 3 3 2 Average daily operating time The average daily operating time of the hoist can be calculated from the running time of the hoisting machinery hours day 2 H N T V 60 H average hoisting height m N number of work cycles per hour cycles h T daily working time h V hoisting speed m min 8 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 3 3 3 Determining the operating group of the hoist When the load spectrum and the average daily operating time of the hoist are identified the hoist s ope
125. tment can be done with any known load in between 50 110 of the rated load In that case the output voltage with the respective test load has to be calculated as follows oli x2 4 L Usut Output voltage L Test load L Rated load Adjustment with 50 110 load e Lift up the known test load e Connect a Voltmeter between terminals 1 and 3 e Adjust the trimmer GAIN clockwise until the voltmeter shows the correct respective voltage 103 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC w Setup the condition monitoring unit always after load sensor amplifier adjustment Refer to separate service manual for condition monitoring unit Terminal Sga o O O oooO 2 JovVDC Load sensor Exc 3 simal Condition monitoring unit 3S 4 soma Notcomectea SSCS 5 hove Condition monitoring unit 4S 6 A0VDC Load sensor Exc IN Load sensor Out o smD Loadsensor shiel 104 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC
126. tric cubicle 6 Hook block 7 Travelling machinery 20 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Drum size p 406 mm c_qcntr_e000760 Hoisting motor and brake Hoisting gear Connection box Rope drum Electric cubicle Hook block Travelling machinery NOOR WD 5 4 Fixed Hoist Fixed hoists do not have any trolley and are used in applications where horizontal movement is not needed 21 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Drum size gt 303 355 mm 1 Hoisting motor and brake 2 Hoisting gear 3 Connection box 4 Rope drum 5 Electric cubicle 6 Hook block Drum size gt 406 mm z g 7 Z K 4 r FD L NE o pD gt L c_qcfldlelflg_d000610 CY A Fi J 1 Hoisting motor and brake 2 Hoisting gear 3 Connection box 4 Rope drum 5 Electric cubicle 6 Hook block 22 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without not
127. trieb 1 Hoisting motor and brake 2 Hoisting gear 3 Connection box 4 Rope drum 5 Electric cubicle 6 Hook block 7 Travelling machinery 18 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Drum size gt 608 mm Hoisting motor and brake Hoisting gear Connection box Rope drum Electric cubicle Hook block Travelling machinery NOOR WD Drum size p 608 mm two hoisting motors Hoisting motor and brake Hoisting gear Connection box Rope drum Electric cubicle Hook block Travelling machinery NOOR WD 19 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 5 3 Normal Headroom Trolley Hoist The normal headroom trolley hoist hangs under a single beam Normal headroom trolleys can be used with straight or curved beams Drum size p 303 355 mm c_rinatrid 1 Hoisting motor and brake 2 Hoisting gear 3 Connection box 4 Rope drum 5 Elec
128. ulated in accordance with standard FEM 9 775 refer to section Calculation of the Safe Working Period 8 5 Recommended tightening torques Recommended tightening torques for screws and nuts in the hoist Tightening torque Size Strength 8 8 Strength 10 9 126 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC er It is recommended that the self locking nut Nyloc nut is replaced always when removed Self locking nut can be reused max 5 times 127 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 9 Lubricants 9 1 Lubricant types WY Use of a low grade or incompatible lubricant can damage the gearing or bearings Use only the original lubricants recommended by the manufacturer temperature C temperature F Hoisting gears Factoryinstalled MobiuxEP 004 som 224248 GEN1 GEN2and Atematve ShellAvaniaGC Asos sam GEN3 series Atematve Shell AvaniaEPoo asos mone Travelling gears Alternative Neste Center Grease 006P 35 4100 31 4212
129. up and down direction To pass the test drive the rope guides must be able to travel through the whole height of lift without evidence of strong vibrations or excessive wear on the drum e Ifthe rope guides vibrate strongly it is likely that they are too tight against the drum Loosen the upper Nyloc nut 6 by a quarter turn and retry If the guides are still too tight loosen the lower Nyloc nut by a quarter turn and retry Continue loosening the nuts in turns until the vibrations disappear e Ifthe rope guides become too loose against the drum they will begin to rotate around the drum by gravity As a result there will be an audible clanking noise each time the hoist is stopped after ascending load motion This is a result of gravity pulling the loose guides against the intermediate shaft If this occurs tighten the Nyloc nuts in turns until the guides no longer rotate around the drum by gravity Pressure roller drum size p 608 mm gt 10 2004 1 Pressure roll 2 Gap adjustment screw X 1mm gap between roller and rope 3 Limit switch adjustment screw 4 Limit switch Assembly e The height of the pressure roll must be adjusted 2 so that there is always 1 mm gap between the rope and the roll e The limit switch triggering point must be adjusted 3 so that the limit switch is activated before the rope is climbed out of the groove 67 130 R amp M Materials Handling Inc reserves the right to alter or amend the above inf
130. ushbutton only if pushbutton controls several hoists 3 On pushbutton and warning signal 4 Emergency stop pushbutton 5 18 1 Service e Switch OFF the power supply to the hoist e Open the pushbutton controller 49 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC e Check the wires for loose connection e Check that the switch elements are in good condition and not loose e Check the pushbutton rubbers emergency stop button and other eventual selector switches are in good condition Check the cable entry and the plug if applicable are tight and in good condition Close the pushbutton controller Check the buttons move freely and do not stick Switch ON the power supply to the hoist and check all functions Check the display readings if applicable 5 19 Travelling machinery The travelling machinery provides the cross travelling motion of the trolley The traveling machinery consists of a squirrel cage motor and a gearbox The motor can be either a 2 speed motor controlled by contactors or a 1 speed motor controlled by an inverter The 1 speed motors have a built in compact brake whereas the 2 speed motors are equipped with an external electro mechanical brake The gearbox comprises multistage spur gear tran
131. uspected rotation of the crank can cause serious injury WY Do not let the motor gain too high speed Release the lever immediately closing the brake in case the motor and thus the crank starts rotating too fast or when the force to the crank becomes too big for you too hold under control WY Do not let go of the crank before the brake is closed 5 12 3 Before normal operation of the hoist Remove manual crank 4 Remove the lever arm 5 from the lever Install fan and retainer ring 2 Install fan cover 1 Switch ON the power supply to the hoist 9 12 4 Assembly For assembly instructions of the hoisting motor refer to the section Hoisting machinery assembly and follow the instructions for removing and re assembling the brake er In those models where the motor is located inside the drum it is not possible to remove the brake wires without extracting the complete motor gearbox subassembly from the drum In this case it is advised to cut the brake wires near the brake and re connect the wires to the new brake with a proper screw or shrink connector Do not use a plug connection 37 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC 9 13 Hoisting limit switch Drum size 9 243 mm The roller le
132. ve the floor e Loosen the fixing screws 3 e Move limit switch along the fixing plate until the limit roller lever switch is just activated e Tighten the fixing screws and test the operation The downwards motion must stop at the described distance e Repeat step 1 4 until the correct setting is achieved e Re assemble drum cover and close the connection box w Make sure that there is at least 5 turns of the rope left on the drum when the hook is at the lowest position Otherwise rope guide and rope clamp could interfere and damage 5 14 Hoisting limit switch new white The rotary hoist limit switch contains four contacts with the below described default functions The rotary limit switch unit for hoisting is located in the connection box on the hoisting gearbox c_holite 1 Supervision limit for phase sequence of hoisting or hoisting safety limit S2 Upper limit of hoisting S3 Slowdown limit switch for hoisting S4 Lower limit for hoisting 1 NC contact 2 NO contact 3 Common contact er Notice the right direction of adjusting screw rotation 5 14 1 Service e Check the proper tripping point of all limiting functions e Check the wiring for loose connections 39 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc RETI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937
133. ver limit switch unit for hoisting is located under the drum cover on the limit switch fixing plate 5 13 1 Service e Check the proper tripping point of lower limit function e Check that the locking screws 3 are tight e Check the wiring for loose connections Assembly c_zlowli01c 1 Hoist limit switch 2 Connection box cover 3 Fixing screws for limit switch 4 Fixing nut Disassembly e Switch OFF the power supply to the hoist Remove the connection box cover 2 Remove the wires from the limit switch connector in the connection box Remove the fixing screws 3 Extract the limit switch 1 Re assembly e Fit the limit switch carefully in its place so that the roller lever is in correct position and in front of the limit switch fixing plate e Tighten the fixing screws 3 e Re connect the wires e Switch ON the power supply to the hoist and check the proper functioning of the limit switch w In many cases it is necessary to re adjust the limit switch Be aware of incorrect settings during testing the operation 38 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc R amp M 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 HANDLING INC Adjustment e Lower the hook to approx 100mm abo
134. y Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937 325 5319 e Switch OFF the power supply to the crane e Remove the shaft locking parts 8 e Remove the side plate fixing parts 11 e Extract the rope sheaves 10 sheave covers 9 and side plates 11 e Remove the cover plate 7 e Remove the locking ring or nut 6 and thrust bearing 5 e Extract the hook 3 from the bearing set 4 Re assembly e Lubricate the thrust bearing and the hook shaft e Insert the hook 3 into the bearing house 4 and re assemble the thrust bearing 5 and the locking ring or nut 6 el BPSK e Re assemble the side oaa 11 the rope sheaves 10 sheave cover 9 and shaft 8 e Tighten all fixing screws to the required torque e Switch ON the power supply to the crane e Raise the hook block Carefully guide the rope with a gloved hand until the hook block hangs free from the working platform If the lower limit switch has been adjusted re adjust to the correct position Test the operation of the hoist 5 29 3 Return sheave assembly Return sheave 4 fall 1 rope reeving drum size p 303 355 406 mm 2 Shaft 3 Sheave support 4 Rope sheave 5 Shaft set 92 130 R amp M Materials Handling Inc reserves the right to alter or amend the above information without notice R amp M Materials Handling Inc REI 4501 Gateway Boulevard MATERIALS Springfield Ohio 45502 P 937 328 5100 FAX 937

SX Service Manual for Hoist - R&M Materials Handling equipment

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SX Service Manual for Hoist - R&amp;M Materials Handling equipment

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SX Service Manual for Hoist - R&M Materials Handling equipment