Installation, Operation and Mantenance Instructions

ZX6&ZX8

ELECTRICWIREROPEHOIST

INSTALLATION,OPERATIONAND

MAINTENANCEINSTRUCTIONS

56565656defgh StreetCraneCompanyLimitedreservestherighttoalteroramendthedetailsgiveninthispublicationwithoutpriornotification.

StreetCraneCompanyLimited2012DocumentRef:D2840rev.F

defgh Street Crane Co Ltd

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INTRODUCTIONThismanualhasbeencarefullypreparedtoassistyou inthe installation,maintenanceandsafeoperationoftheStreetCraneequipmentasdescribedinthemanual.Itisintheinterestofallpartiesinvolvedwiththeuseofthisequipmenttoensurethatproceduresarefollowedefficientlyandsafely.Before installing,usingorstartinganymaintenanceworkon thehoiststudy thismanualcarefully. Obtainacompleteunderstandingofthehoistanditscontrolsinordertoensurethesafeandefficientuseofthehoist.Ensurethatallpersonsinvolvedintheoperationaresuitablyqualifiedandtrainedinitssafeoperation.Provided that the recommendedoperation,maintenance and lubricationprocedures are followed, youwillmaximisetheHoistslifeexpectancyandhavetroublefreeservice.Anyoneworkingwithoron theequipmentshouldalsobeawareof their relevant responsibilitiesunder theFactoriesAct,theHealthandSafetyatWorkAct1974andLiftingOperationsandLiftingEquipmentRegulations(LOLER) 1998. The user has the responsibility for ensuring that the equipment is properly inspected andmaintainedandissafetouse.NOTE:Othernationalregulationsmayapplyforothercountries.InGreat Britain codes of practice exist for the SafeUse of Cranes. This standard, BS 7121, also coversinspection,testingandexamination.Theusershouldbefamiliarwithitscontentsanditisadvisabletohaveacopyofthisstandardkeptalongsidethismanual.BS7121coversthefollowingsubjects:

Safesystemsofwork Managementoftheliftingoperation Planningoftheliftingoperation,riskassessmentsandmethodstatements Selectionanddutiesofpersonnelandtheirminimumattributes Maintenanceofcranes Inspection,TestingandExamination

In addition,management and supervisionhave an initial role toplay in any safetyprogrammebyensuringthat:

Theequipmentissuitableforthejobintended Theequipmenthasbeenthoroughlyexaminedandissafetouse Asafetyprocedureisadoptedforemergencysituationsi.e.powerfailure Asafesystemofworkisadoptedformaintenancepersonnel

Itshouldbeemphasisedthatthesafetyadviceandmaintenancedetails included inthisdocumentshouldbemadeavailablewhere theycanbemosteffective. It isyour responsibility toensure that this information ismadeavailableatTHEPLACEOFWORK.


IV

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CONTENTS1. GENERALSAFETYINSTRUCTIONS ........................................................................................................10

1.1 SYMBOLS............................................................................................................................................ 10 1.2 PERSONNELDefinitionsandAttributes ........................................................................................... 10 1.3 MAINTENANCESAFETYPROCEDURE ................................................................................................. 10 1.4 MAINTENANCEANDINSPECTIONACCESS ......................................................................................... 11 1.5 WARRANTY/REPLACEMENTPARTS .................................................................................................. 11 1.6 PERIODICTESTS.................................................................................................................................. 11 1.7 STORAGE ............................................................................................................................................ 11 1.8 TRAININGANDAFTERSALESSERVICE ............................................................................................... 11

2 DESCRIPTIONOFEQUIPMENT.............................................................................................................12 2.1 HOISTNAMEPLATE ............................................................................................................................ 14 2.2 LIMITINGDEVICES.............................................................................................................................. 14

2.2.1 Hoistingandloweringlimits.......................................................................................................... 14 2.2.2 Ratedcapacitylimiter(RCL) .......................................................................................................... 15 2.2.3 Travel/Traverselimits(optional) ................................................................................................. 15

3 INSTALLATIONANDCOMMISSIONINGINSTRUCTIONS ........................................................................16 3.1 TRAVERSEENDSTOPS........................................................................................................................ 16 3.2 RUNNING&MOUNTINGSURFACETOLERANCESANDFINISHES....................................................... 17

3.2.1 TolerancesontheInclinationoftheRunningSurface .................................................................. 17 3.2.2 TolerancesonCrabRailGauge&RailHeight................................................................................ 17 3.2.3 TolerancesonSingleGirderRunwayFlangeWidth ...................................................................... 18 3.2.4 TolerancesonMountingSurfaceforFootMountedHoists.......................................................... 18 3.2.5 Toleranceonmisalignmentofrailjoints,wheelrunningsurfacesandguidancesurfaces........... 19

3.3 HOISTWEIGHTSANDLIFTINGPOINTS............................................................................................... 19 3.3.1 LowHeadroom.............................................................................................................................. 19 3.3.2 DoubleGirderCrab ....................................................................................................................... 20 3.3.3 FootMounted ............................................................................................................................... 21

3.4 INSTALLATIONOFLOWHEAD2&4FALLSINGLEGIRDERHOIST........................................................ 22 3.4.1 SettingtheReactionRoller............................................................................................................ 24

3.5 INSTALLATIONOFLOWHEAD6&8FALLSINGLEGIRDERHOIST...................................................... 25 3.5.1 AdjustingtheCTandNonCTtrolleywidthsrunwaywidth300700mm..................................... 25 3.5.2 Installingthehoistontotherunway ............................................................................................. 28

3.6 INSTALLATIONOFFOOTMOUNTEDHOIST........................................................................................ 30 3.7 SETTINGTHEUPPERANDLOWERLIMITSWITCHESStandardEnvironment .................................. 31

3.7.1 Settingthelowerlimit................................................................................................................... 31 3.7.2 Settingtheupperlimit .................................................................................................................. 32

3.8 SETTINGTHEUPPERANDLOWERLIMITSWITCHESGalvanising/AggressiveEnvironments .......... 33 3.8.1 Settingthelowerlimit................................................................................................................... 33 3.8.2 Settingtheupperlimit .................................................................................................................. 33

3.9 ULTIMATEUPPERLIMITSWITCHROTARY(OPTIONAL) ................................................................... 34 3.9.1 Settingtheultimateupperlimit.................................................................................................... 34

3.10 ULTIMATEUPPERLIMITSWITCHHOOKBLOCKOPERATED(OPTIONAL)........................................ 36 3.10.1 Settingtheultimateupperlimit ............................................................................................... 36

3.11 LOWHEADROOMHIGHESTHOOKPOSITION2FALL&4FALL ......................................................... 37 3.12 LOWHEADROOMHIGHESTHOOKPOSITIONZX86FALL&8FALL .................................................. 38 3.13 FOOTMOUNTHIGHESTHOOKPOSITIONZX6&ZX8......................................................................... 38


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3.14 DOUBLEGIRDERPARALLELCRABHIGHESTHOOKPOSITIONZX6&ZX8.......................................... 39 3.15 DOUBLEGIRDERPERPENDICULARCRABHIGHESTHOOKPOSITIONZX8 ......................................... 39 3.16 CHECKING/ADJUSTINGTHERATEDCAPACITYLIMITER ................................................................... 40

3.16.1 AdjustingtheRatedCapacityLimiterforProofLoading .......................................................... 40 3.17 TRAVERSELIMITS(OPTIONAL) ........................................................................................................... 41

3.17.1 Settingtraverselimits............................................................................................................... 41 3.18 CONNECTINGTHEPOWERSUPPLY .................................................................................................... 43

3.18.1 Supplycables/fuses ................................................................................................................ 43 3.18.2 Mainisolatorsupplyswitch(byothers) ................................................................................ 43 3.18.3 Connectingtothemainssupply ............................................................................................... 43 3.18.4 Electromagneticcompatibility.................................................................................................. 45 3.18.5 ConnectingthePendantcontrollerLowHeadroom.............................................................. 45

3.19 COMMISSIONINGPROCEDURE .......................................................................................................... 46 3.20 DISMANTLING/REMOVALOFTHEHOIST ......................................................................................... 46

4 OPERATINGINSTRUCTIONS ................................................................................................................47 4.1 INTENDEDUSE ................................................................................................................................... 47 4.2 DUTIESOFTHEOPERATOR/SAFEHOISTINGPRACTICES .................................................................. 47 4.3 REMOTECONTROLLEDCRANES/HOISTS.......................................................................................... 49 4.4 CONTROLSTATIONOPERATINGINSTRUCTIONS................................................................................ 50

4.4.1 LegendNomenclature................................................................................................................... 50 4.4.2 SwitchON...................................................................................................................................... 50 4.4.3 Pushbuttonoperation .................................................................................................................. 50 4.4.4 Joystickoperation ......................................................................................................................... 51 4.4.5 EmergencyStop ............................................................................................................................ 51

4.5 LEAVINGTHECRANE/HOISTUNATTENDED ..................................................................................... 52 4.6 POWERFAILURE................................................................................................................................. 52

5 INSPECTIONANDMAINTENANCEINSTRUCTIONS................................................................................53 5.1 REPORTINGOFDEFECTSANDINCIDENTS.......................................................................................... 53 5.2 SPECIALKNOWLEDGE ........................................................................................................................ 53 5.3 KEEPINGOFRECORDS........................................................................................................................ 53 5.4 DAILYPREUSEINSPECTIONS(atthestartofeachday/shift)............................................................ 53 5.5 HOISTSTHATHAVEBEENUNUSEDFORANEXTENDEDPERIOD ....................................................... 54 5.6 INSPECTIONANDMAINTENANCEINTERVALS ................................................................................... 55 5.7 LUBRICATION ..................................................................................................................................... 58

5.7.1 LubricationSchedule..................................................................................................................... 60 5.8 INSPECTIONANDMAINTENANCEWIREROPE................................................................................ 62

5.8.1 OffloadingandStorage ................................................................................................................. 62 5.8.2 ReplacingtheWireRope............................................................................................................... 62 5.8.3 FittingtheRopeGuide .................................................................................................................. 67 5.8.4 WedgeandSocketTermination.................................................................................................... 70

5.9 INSPECTIONANDMAINTENANCEHOIST/CRABFRAME ................................................................. 71 5.9.1 Sheaves ......................................................................................................................................... 71 5.9.2 SingleGirderWheels ..................................................................................................................... 72 5.9.3 DoubleGirderCrabWheels(DoubleFlange) ................................................................................ 72

5.10 INSPECTIONANDMAINTENANCEHOISTBRAKE............................................................................. 73 5.10.1 HoistBrakeComponents.......................................................................................................... 73 5.10.2 HoistBrakeData....................................................................................................................... 74


VII

5.10.3 BrakeDisc(Rotor)Spline .......................................................................................................... 74 5.10.4 Checking/AdjustingtheAirGap.............................................................................................. 74 5.10.5 ChangingtheBrakeDisc(brakerotor)/Inspectingthebrakehub .......................................... 75 5.10.6 FittingtheHandRelease .......................................................................................................... 76 5.10.7 Fittingthebrakesealkit(optional) .......................................................................................... 77 5.10.8 Brakerectifier ........................................................................................................................... 77

5.11 INSPECTIONANDMAINTENANCETRAVERSEBRAKE ...................................................................... 78 5.11.1 TraverseBrakeComponents .................................................................................................... 78 5.11.2 Checking/AdjustingtheAirGap.............................................................................................. 79 5.11.3 ChangingtheBrakeDisc(brakerotor)/Inspectingthebrakehub .......................................... 79 5.11.4 FittingtheTraverseDriveHandRelease .................................................................................. 80 5.11.5 Fittingthebrakesealkit(optional) .......................................................................................... 81

5.12 INSPECTIONANDMAINTENANCEHOOKBLOCK............................................................................. 82 5.13 INSPECTIONANDMAINTENANCEHOISTDRIVECOUPLING............................................................ 84

6 FAULTFINDING ..................................................................................................................................85 6.1 GENERAL ............................................................................................................................................ 85 6.2 BRAKES............................................................................................................................................... 86 6.3 MOTORUNITS.................................................................................................................................... 87 6.4 GEARBOXES........................................................................................................................................ 88

7 TECHNICALDATA................................................................................................................................89 7.1 CONDITIONSOFUSE .......................................................................................................................... 89 7.2 PROCEDUREFORESTIMATINGREMAININGSERVICELIFE................................................................. 89 7.3 HOISTMODELCODE .......................................................................................................................... 90 7.4 NOISELEVELS ..................................................................................................................................... 93 7.5 HOISTMOTORDATA.......................................................................................................................... 94

7.5.1 ZX06HoistMotorData3:1SPEEDRATIO400V,3Ph,50Hz...................................................... 94 7.5.2 ZX08HoistMotorData4:1SPEEDRATIO400V,3Ph,50Hz...................................................... 94 7.5.3 ZX06HoistMotorData3:1SPEEDRATIO460V,3Ph,60Hz..................................................... 95 7.5.4 ZX08HoistMotorData4:1SPEEDRATIO460V,3Ph,60Hz...................................................... 95 7.5.5 ZX06HoistMotorData3:1SPEEDRATIO575V,3Ph,60Hz...................................................... 96 7.5.6 ZX08HoistMotorData4:1SPEEDRATIO575V,3Ph,60Hz...................................................... 96 7.5.7 ZX06HoistMotorData3:1SPEEDRATIO380(10%)V,3Ph,60Hz......................................... 97 7.5.8 ZX08HoistMotorData4:1SPEEDRATIO380(10%)V,3Ph,60Hz......................................... 97 7.5.9 ZXDualWoundWUTypeTraverseMotorData400V50Hz ...................................................... 98 7.5.10 ZXDualWoundWUTypeTraverseMotorData460V60Hz ................................................. 99 7.5.11 ZXDualWoundWUTypeTraverseMotorData575V60Hz ............................................... 100 7.5.12 ZXDualWoundWUTypeTraverseMotorData380V60Hz ............................................... 101 7.5.13 ZXTraverseMotorDataforusewithFrequencyInverter...................................................... 102

7.6 CABLECROSSSECTIONANDLENGTHOFSUPPLYCABLE ................................................................. 104 7.7 RESULTSOFPERIODICTESTS............................................................................................................ 105 7.8 RECORDOFREPLACEMENTPARTS(ropes,brakes,sheavesetc.) .................................................... 106

FIGURESFigure1HoistNameplateLocation.................................................................................................................... 14 Figure2SingleGirder2&4FallTraverseEndStops.......................................................................................... 16 Figure3SingleGirder6&8FallTraverseEndStops.......................................................................................... 16


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Figure4DoubleGirderTraverseEndStops ....................................................................................................... 17 Figure5SingleGirderRunwayTolerances......................................................................................................... 19 Figure6DoubleGirderRunwayTolerances....................................................................................................... 19 Figure7LowHeadroom2&4FallLiftingPoints ................................................................................................. 19 Figure8LowHeadroom6&8FallLiftingPoints ................................................................................................. 19 Figure9DoubleGirderCrabLiftingPoints2&4fallunits............................................................................. 20 Figure10DoubleGirderCrabLiftingPoints6&8fallunits........................................................................... 20 Figure11RemovingHoistCoveron6&8fallDoubleGirderCrabs .................................................................. 20 Figure12Lifting6&8fallDoubleGirderCrabs................................................................................................. 20 Figure13FootMountedLiftingPoints............................................................................................................... 21 Figure14InstallingtheLowHeadroomTrolley ................................................................................................. 22 Figure15WithdrawingtheReactionRoller ....................................................................................................... 22 Figure16LowHeadroomRunwayClearance .................................................................................................... 23 Figure17SettingtheLowHeadroomLegs......................................................................................................... 23 Figure18LowHeadroomHoistTransportationFeet......................................................................................... 24 Figure19ReactionRoller ................................................................................................................................... 24 Figure20CTTrolleyPlateAssemblyElectricalPanelside................................................................................. 25 Figure21CTTrolleyPlateAssemblyHoistPanelside........................................................................................ 26 Figure22TrolleyPlateAssemblyfittedfor700mmrunway.............................................................................. 26 Figure23Runwaywidthspacerpositions.......................................................................................................... 26 Figure24SafetyBarPosition ............................................................................................................................. 27 Figure25Endcaprefitted................................................................................................................................... 27 Figure26Endcapreversedandrefitted............................................................................................................. 28 Figure27Liftingthehoisttotherunway........................................................................................................... 28 Figure28Settingthetensioningscrew.............................................................................................................. 29 Figure29InstallationofFootMountedHoist .................................................................................................... 30 Figure30HoistLimitSwitchesStandardEnvironment ................................................................................... 31 Figure31HoistLimitSwitchesStandardEnvironmentRv1(seehoistnameplateforrevision) .................... 31 Figure32HoistLimitSwitchesGalvanising/AggressiveEnvironment............................................................. 33 Figure33UltimateUpperLimitSwitchRotaryType ....................................................................................... 34 Figure34SettingtheUltimateUpperLimitSwitchRotaryType................................................................... 35 Figure35UltimateUpperLimitSwitchHookBlockType................................................................................ 36 Figure36RatedCapacityLimiter ....................................................................................................................... 40 Figure37SettingtheTraverseLimitSingleGirderArrangement .................................................................... 41 Figure38TraverseLimitDoubleGirderarrangement ....................................................................................... 42 Figure39HoistElectricalConnections............................................................................................................... 43 Figure40DelayTimers....................................................................................................................................... 44 Figure41PhaseFailureRelay............................................................................................................................. 44 Figure42ControlTransformerConnections...................................................................................................... 45 Figure43StrainerWireConnections ................................................................................................................. 45 Figure44Clearancestoconsiderwhenlifting ................................................................................................... 48 Figure45RecommendedHandSignals............................................................................................................... 49 Figure46ControlPendantLegends ................................................................................................................... 50 Figure47ZX6Gearboxoilfill&levelpluglocations .......................................................................................... 58 Figure48ZX8Gearboxoilfill&levelpluglocations .......................................................................................... 59 Figure49CorrectUncoilingofWireRopes ........................................................................................................ 63 Figure50IncorrectUncoilingofWireRopes ...................................................................................................... 63 Figure51Windingofnewwireropes ................................................................................................................ 63


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Figure52Fleetangle........................................................................................................................................... 64 Figure53ReevingDiagramsforZX6&ZX82&4FallLowHead&CrabHoists .................................................. 64 Figure54ReevingDiagramsforFootMountHoists:ZX082FTM/ZX084FTM ................................................ 65 Figure55ReevingDiagramsforFootMountHoists:ZX062FTM/ZX064FTM ................................................ 65 Figure56ReevingDiagramsforZX86&8FallLowHead&CrabHoists:.......................................................... 65 Figure57ReevingDiagramsforFootMountHoists:ZX086FTM/ZX088FTM................................................ 66 Figure58FittingTopandBottomHalvesofRopeGuideInnerBand ................................................................. 67 Figure59RopeGuideInnerBandSpringandSleeveArrangement................................................................... 67 Figure60RopeGuideInnerBandFitted ............................................................................................................ 68 Figure61FittingRopeGuideOuterBand .......................................................................................................... 68 Figure62FittingRopeGuidePlateStandardEnvironments ........................................................................... 69 Figure63FittingRopeGuideRetainerStandardEnvironmentsRv1(seehoistnameplateforrevision) ...... 69 Figure64FittingRopeGuidePlateGalvanising/AggressiveEnvironments .................................................... 69 Figure65WedgeandSocketTermination ......................................................................................................... 70 Figure66Sheavecharacteristics......................................................................................................................... 71 Figure67Sheaveandbarrelgrooveinspection.................................................................................................. 72 Figure68HoistBrakeComponents.................................................................................................................... 73 Figure69CheckingHoistBrakeAirGap............................................................................................................. 74 Figure70AdjustingtheHoistBrakeAirGap...................................................................................................... 75 Figure71InspectingtheBrakeDisc ................................................................................................................... 75 Figure72HoistBrakeHandRelease .................................................................................................................. 76 Figure73BrakeSeal ........................................................................................................................................... 77 Figure74TraverseBrakeComponents .............................................................................................................. 78 Figure75CheckingTraverseBrakeAirGap ....................................................................................................... 79 Figure76AdjustingtheTraverseBrakeAirGap ................................................................................................ 79 Figure77TraverseDriveBrakeHandRelease ................................................................................................... 80 Figure78TraverseDriveBrakeSeal................................................................................................................... 81 Figure79HookThroatAdmittance.................................................................................................................... 82 Figure804FallBottomBlock,HookNut,Grubscrew,Greasenipple................................................................ 83 Figure812,6&8FallBottomBlock,HookNut,Grubscrew,Greasenipple ..................................................... 83 Figure82SoundPressureLevels........................................................................................................................ 93

defgh StreetCraneCoLtd

Page10of112 Ref:D2840rev.F

1. GENERALSAFETYINSTRUCTIONS

1.1 SYMBOLS

1 WARNINGThissymboldrawsattentiontothepossibleinjuryorriskoflife.

2 WARNINGOFELECTRICALPOTENTIALThissymbolisfoundonelectricalenclosures.Theseshouldonlybeopenedbyqualifiedpersonsorsuitablyinstructedpersonnel.

3 WARNINGOFSUSPENDEDLOADThissymbolwarnsoftherisktolifeandlimbfromstandingunderasuspendedload.

1.2 PERSONNELDefinitionsandAttributesTheusershouldensure that thepersoncarryingoutany taskhassuchappropriatepracticaland theoreticalknowledgeandexperienceof theequipment inquestionaswillenable them toperform the tasksafelyandrecogniseanyhazardsassociatedwiththework.TheyshouldbephysicallyandmentallyfitandtrainedinSafeHoistingPracticesandtheuseofsafetyandaccessequipment. Noworkofanykindshouldbeauthorisedtopersonswhoareunder the influenceofnarcotics,alcoholormedication,whichaffects theirability to react.Hazardscanonlybeminimisedbycare,commonsenseandbeingalertatalltimes.Variouspersonnelcanbeinvolvedintheliftingoperation,installationandinspectionandmaintenanceoftheequipment,supervisors,coordinators,operators,slingers,signallers,erectorsandmaintenancepersonnel.ThedutiesofthesepersonnelandtheirminimumattributesaredefinedinBS71211:2006.Also,ISO15513givescompetencyrequirements forcranedrivers (operators),slingers,signallersandassessors. In the textof thismanualthefollowingdefinitionsapply:

Userpersonororganisationthathascontrolofboththeliftingoperationandthecraneoperatorandhasthe responsibility to ensure the equipment is properly maintained and thoroughly examined by acompetentperson.CompetentPersonpersonwhohassuchpracticalandtheoreticalknowledgeandmechanicaland/orelectricalexperienceofthecrane/hoistandtheequipmentused inthe liftingoperationwhichenablesthem to detect defects or weaknesses and to assess their importance in relation to the safety andcontinueduseoftheliftingequipment.Operatortrainedpersonwhoisoperatingthecrane/hoistforthepurposeofpositioningloads.

1.3 MAINTENANCESAFETYPROCEDUREWhenpersonnelare required toworkon the crane /hoist for inspection,maintenanceorother reasons,asystemshouldbe inoperation toensure that theyarenotendangeredbymovementof theequipmentandthat a secure working place is provided. Personnel should follow such a procedure. Where no formalprocedureexists,StreetCranerecommendsthefollowing:Oncommencinganymaintenanceworkonthecraneorhoist:

1. Obtainthenecessaryauthorisation/permittowork.2. Parkthecraneorhoistinadesignatedmaintenanceposition,clearofanypersonnel.3. Followtheappropriatehealthandsafetyregulationsandprocedures.4. Remove any loads or attachments from the hook and ensure that the bottom block is suitably

supportedtopreventaccidentalrunaway.


Ref:D2840rev.F Page11of112

5. Disconnectthemainsswitchandsafeguardagainstunauthorisedpoweringup,byplacinglocksandwarningnoticesintheappropriatepositions.

1 Somemaintenanceproceduresaremoreeffectivelyperformedwithpowertotheequipment.Ifworkhastobecarriedoutonliveparts,anadditionalcompetentpersonmustbeavailabletoactuatethepowerisolatingswitchinanemergency.Ensurethatthereisaneffectivemannerofcommunicationbetweenpersonnel.

6. Toavoidinjuries,useonlyinsulatedtoolsandequipment.7. Oncompletionofanymaintenancework,ensureall fixings,guards,covers,drip trays,etc.

arereplaced.1.4 MAINTENANCEANDINSPECTIONACCESSThe equipment itselfmayhavenoprovision formaintenance accessor itmaybe fittedwith fullorpartialmaintenanceaccessplatforms.Wherenooronlypartialaccesshasbeenprovidedontheequipment,separateor additional access equipmentwill be required to service some of the components. These componentsshould be accessed via a secure, mobile or temporary structure e.g. tower scaffold, selfstanding stairplatforms, scissorliftor cherrypicker. Allaccessequipment shouldbeassembledandoperatedby trainedpersonnel in accordance with the manufacturers instructions following the appropriate health and safetyregulationsandprocedures.The following should be considered when choosing the most appropriate type of maintenance accessequipment. Floorspaceavailablefortheaccessequipment. Workingheightabovefloorlevel. Numberofpersonnelwhorequireaccessathighlevel. Totalweightofanypartstoberemoved/replaced. Provisionofsafetyharnessanchorpoints

1.5 WARRANTY/REPLACEMENTPARTSThewarrantywillbecome invalid if the instructions for installation,operationandmaintenance instructionscontainedinthismanualarenotfollowed.WherereplacementcomponentsarerequireduseonlygenuineStreetCraneparts.Modificationstothecraneoranyof itsmechanismsshouldnotbecarriedoutwithout theapprovalofStreetCraneCompanyLimited.Failuretoadopttheserecommendationswillinvalidatethewarrantyandcouldresultinanunsafecondition.Pleasedisposeofelectricalandelectronicequipmentinanapprovedandenvironmentallyfriendlymanner.1.6 PERIODICTESTSThehoistmustbeinspectedbyacompetentpersonatleastonceayear.Thecompetentpersonmayconsidershorterperiodstobemoreappropriatedependingonthedutyofthehoist.Arecordoftheresultsofthetestshouldbekept inthehoist logbook,section7.7. Aspartoftheannualtesttheremainingservice lifeofthehoistshouldbeestablished,seesection7.2.1.7 STORAGEIfthehoististobeplacedinstorageforanyperiodoftimeensurethat: Thehoistiscoveredandstoredindoorsinaheatedbuilding. Packthehoistclearofthefloor.Raisethebottomblocktoitstoppositionandensurethatthereareno

kinksinthewirerope. EnsureallelectricalswitchesareturnedtotheOFFposition. Alwaysfullyinspectthehoistbeforeinstallingandputtingintoservice.

1.8 TRAININGANDAFTERSALESSERVICEIf required,StreetCraneCompanyareable toprovide trainedservice technicians toassist in inspectionandmaintenanceproceduresandprovideoperatortraining.



2 DESCRIPTIONOFEQUIPMENT

The ZX series hoist is of the electrically driven wire rope type. The hoist has a maximum load that it ispermittedtolift.ThisisreferredtoastheRatedCapacityorSafeWorkingLoad(SWL).Theratedcapacityisclearlymarkedonthehoistnameplateandthebottomblock.

1.Hoistmotor 6.Controlpanel 11.Upperlevellimitswitch2.Hoistbrake 7.Traveldrive 12.Lowerlevellimitswitch3.Wirerope 8.Reactionroller(LHonly) 13.Ropeguide4.Bottomblock 9.Travelwheels 14.Ropeclamps5.Hoistgearbox 10.Ratedcapacitylimiter 15.Sheaveassembly



2.1 HOISTNAMEPLATEThehoistnameplateislocatedonthehoistendframeandcontainsthefollowinginformation: Thehoistmodelcode. Themanufacturersname. Theserialnumber. Theyearofmanufacture. Hoistclassification. Mechanismclassifications.

The information on this nameplate will be required when ordering replacement parts and whenassessingtheremainingservicelifeofthehoist.Furtherinformationonthehoistmodelcodecanbefoundinsection7.3.

Figure1HoistNameplateLocation

2.2 LIMITINGDEVICESEachhoistisfittedwithupperandlowerlimitsandaratedcapacitylimiter(RCL).Theseareessentialitemsforthe safe operation of thehoist. Additional limiting devicesmaybe fitted ifdeemed necessaryby the riskassessment.2.2.1 HoistingandloweringlimitsHoisting and lowering limit switches are fitted to all hoists to prevent the hook from going too high anddamagingthehoistandfromgoingtoolowsoastoallowtheropestogoslack.ThesearesafetydevicesandshouldNOTbeusedasanormalmethodofstoppingthehoist. Movement intheoppositedirection,atthespeedselectedbytheoperator(sloworfast)isstillpossibleafterthenormallimithasbeentriggered.



1 Certaincraneconfigurationsallowtheupperhookpositiontobesetatahigherlevelthantheundersideof thebridgegirders (doublegirder cranes). In such instances theoperatormusttakeextremecarewhen liftingtoensurethatadequateclearance ismaintainedbetweentheloadorliftingattachmentandthehoistorcranestructure.

Anoptionalsecondhoistupperlimitorultimatelimitmayalsobefittedifdeemednecessarybytheuserriskassessment.Theultimatelimitisanemergencylimitemployedonlyifthenormalupperlimitfails.Oncetripped,thelimitmustbemanuallyresetbyserviceormaintenancepersonnelandwillrequirethehookblocktobe loweredmanuallyandthelimitreset.Ifthesecondhoistupperlimitoperates,thehoistshouldbetakenoutofserviceuntilthereasonforthenormalupperlimitswitchfailurehasbeeninvestigated.Thefailureshouldberectifiedbeforeputtingthehoistbackintoservice.Thesecondhoistupperlimit,whentripped,willpreventmovementfromallhoistandtraversemotions.Thetravelmotion(longtravel)willremainfullyoperable.Aredwarninglightonthebaseofthecontrolpanelwillilluminatetoindicatewhenthesecondultimatelimithasbeenactivated.2.2.2 Ratedcapacitylimiter(RCL)Allhoistunitsarefittedwitharatedcapacitylimiter(RCL)topreventtheliftingofloadsbeyondthecapacityofthehoist/crane.IftheRCListrippedthehoistmotionwillstopanditwillthenonlybepossibletomoveinthelowerdirection.2.2.3 Travel/Traverselimits(optional)Limitswitchesattheextremesoflongandcrosstravelareoptionalbasedontheusersriskassessment.Therearethreetypes:

1. Onreachingthelimitthecraneorhoisttravelmotionwillstopaltogether.2. On reaching the limit the craneorhoistwill change from fast to slow speedandproceedat slow

speeduntiltheendstopisreached.3. Ifa twostage limit is fitted,on reaching the firststage themotionwill reduce toslowspeed. On

reachingthesecondstagethemotionwillstop.Operationofthelimitdoesnothaveanyeffectonothercranemotions.Movementintheoppositedirection,atthespeedselectedbytheoperator(sloworfast)isstillpossibleafterthelimithasbeentriggered.



3 INSTALLATIONANDCOMMISSIONINGINSTRUCTIONS

Installationandcommissioningof thehoistmustbecarriedoutbyacompetentperson(s). We recommendthatinstallationandcommissioningarecarriedoutbyStreetCraneCompanyortheirapprovedagents.Immediately reportanydamagewhichmayhaveoccurredduring transit. Consultwith themanufacturer /supplierandrepairtheequipmentbefore installation. Donot installdamagedequipment. UseonlyoriginalStreetCranesparepartsforrepairs.Donotcarryoutanyalterationsormodificationstothehoisteitherpriortoorduringinstallation.Ifthehoistislocatedoutdoorswerecommendthatasmallcover(roof)isfittedtotherunwaybeamtoprotectthehoistatitsparkingposition.

3.1 TRAVERSEENDSTOPSSinglegirder2&4 fall lowheadhoists requireend stops tobemountedoneitherendof the runwayandincluderubberbuffersasshown.WeldonendstopscanbeprovidedbyStreetCrane.(PartNo.27031).

Figure2SingleGirder2&4FallTraverseEndStops

Singlegirder6&8fall lowheadhoistsaresuppliedfittedwithrubberbuffers. Suitableendstopsshouldbepositionedateitherend,centralontheundersideoftherunway.WeldonendstopscanbeprovidedbyStreetCrane.(PartNo.2720061).

Figure3SingleGirder6&8FallTraverseEndStops



Doublegirdercrabunitsaresupplied fittedwithrubberbuffers. Suitableendstopsshouldbepositionedateitherendofthecrabrails.WeldonendstopscanbeprovidedbyStreetCrane.(PartNo.2720061).

Figure4DoubleGirderTraverseEndStops

3.2 RUNNING&MOUNTINGSURFACETOLERANCESANDFINISHES

3.2.1 TolerancesontheInclinationoftheRunningSurfaceTheangleofinclinationoftherunningsurfaceforthehoistshouldnotexceedthevaluesshown.

3.2.2 TolerancesonCrabRailGauge&RailHeightThegaugeshallnotdeviatefromthenominalbymorethan3mm.Thedifferenceinrailheightshallnotexceed3mmforgaugesuptoandincluding2000mmor5mmforgaugesgreaterthan2000mm.Railheightshouldbeaminimumof30mm.



3.2.3 TolerancesonSingleGirderRunwayFlangeWidthThe variation in thewidthof a single girder runway flange shouldbeno greater than3mmover its entirelength.

3.2.4 TolerancesonMountingSurfaceforFootMountedHoistsTheverticalmisalignmentbetweenallmountingholesshallnotexceed1mm.



3.2.5 Toleranceonmisalignmentofrailjoints,wheelrunningsurfacesandguidancesurfacesThe running surface for the hoist wheels and guide rollers (single girder hoist only) should be free fromobstructionsandleftunpainted.Thesesurfacesshouldalsobefreefromdamage,pitting,weldbeadsorothersurfacedefects.Surfacesshouldbealignedtoprovideasmoothtransitionpathforthewheelsbetweentracksections. Gapsinanyjoints(J)shouldbenogreaterthan2mm. Thereshouldbenostepintherunningorguidancesurface(h)greaterthan0.5mm. Lateralmisalignmentindoublegirderrailjoints(L1)shouldnotexceed1mm.

NOTE: Runway joint splice plates on the bottom flange are not possiblewith ZX6& ZX8 single girder lowheadroomhoistsbecauseofthehoistreactionroller.

Figure5SingleGirderRunwayTolerances Figure6DoubleGirderRunwayTolerances

3.3 HOISTWEIGHTSANDLIFTINGPOINTS

3.3.1 LowHeadroom

Figure7LowHeadroom2&4FallLiftingPoints Figure8LowHeadroom6&8FallLiftingPoints

3.3.1.1 TableofweightsLowHeadHoists 2Fall 4Fall 6Fall 8Fall NB LB ELB VLB NB LB ELB VLB NB LB ELB LB ELB

ZX6 329 362 410 350 386 439 ZX8 861 983 1255 1385 928 1011 1190 1376 1867 2104 2328 2244 2453

Weightsshownforeachmodelinkgdonotincludeanyoptionalextras

1 TheliftinglugsfittedtothehoistunitaredesignedforliftingthemassofthehoistunitONLY(includinganytransportationfeet).



3.3.2 DoubleGirderCrab

Figure9DoubleGirderCrabLiftingPoints2&4fallunits

Figure10DoubleGirderCrabLiftingPoints6&8fallunits

Doublegirdercrabunitshaving2or4fallsshouldbeliftedusingtheliftingpointsfittedtothehoistendframeseeFigure9. Crabunitswith6or8fallsshouldbe liftedusingtheeyeboltsfittedtoeachcornerofthecrabframeseeFigure10.Beforethe6and8fallunitscanbelifted,thetopsectionofthehoistcovershouldberemovedtoallowliftingchainstoaccesstotheeyebolt.RemovethefourM8setscrewsandwashersseeFigure11.

Figure11RemovingHoistCoveron6&8fallDoubleGirderCrabs

LegofliftingchaincannowpassthroughapertureinendframesideplateseeFigure12

Figure12Lifting6&8fallDoubleGirderCrabs

Afterliftingiscompleted,refitthehoistcovertopsectionandtightensetscrewsto15Nm.



3.3.2.1 TableofweightsDoubleGirderCrab 2Fall 4Fall 6Fall 8Fall NB LB ELB NB LB ELB NB LB ELB NB LB ELB

ZX6 423 477 566 446 502 596

ZX8 PARALLELARRANGEMENT(CRB)1400GAUGE 1002 1104 1329 1078 1185 1419 1292 1410 1669 1496 1753

ZX8 PERPENDICULARARRANGEMENT(CRE)1400GAUGE 1002 1078 1219

2000GAUGE 1039 1123 1398 1116 1204 1398 1234 1300 1406

2600GAUGE 1076 1161 1346 1153 1241 1436 1284 1350 1494 1555 1665

Weightsshownforeachmodelinkgdonotincludeanyoptionalextras3.3.3 FootMounted

Figure13FootMountedLiftingPoints

3.3.3.1 TableofweightsFootMounted

2Fall 4Fall 6Fall 8Fall NB LB ELB NB LB ELB LB ELB LB ELB

ZX6 267 304 355 289 327 384 ZX8 637 716 889 722 809 998 889 1063 941 1114

Weightsshownforeachmodelinkgdonotincludeanyoptionalextras

1 TheliftinglugsfittedtothehoistunitaredesignedforliftingthemassofthehoistunitONLY.



3.4 INSTALLATIONOFLOWHEAD2&4FALLSINGLEGIRDERHOIST Measuretherunwayflangewidth. Whilstthehoist isonthefloorandstoodonthepackingfeet,slackenthe4M12 lockinggrubscrews

thatsecurethepanelsidetrolleyframetothelegs(donotreleaseanyfixingsonthehoistbarrelside). Openthetrolleyframeuntilthegapbetweentheendsofthewheelaxlesisatleast20mmwiderthan

thewidthoftherunwayflange(seeFigure14).Donotremovethecirclipsontheendsofthelegs.

Figure14InstallingtheLowHeadroomTrolley

Disconnect the reaction roller assembly from thewheel support castingby removing the circlip andwasherontheendofthepin.

Withdrawthereactionrollerassemblyfromthewheelsupportcasting(seeFigure15).

Figure15WithdrawingtheReactionRoller

Raisethehoisttorunwaylevel,usetheliftinglugsprovidedseeFigure7. Pushthebarrelsidetrolleyontotherunwayflangeuntilthehoistsideguiderollerstouchthetoeofthe

runway. Secure thebarrel side frameagainstmoving. Ensure that the reaction roller isheld in thecorrectorientationwiththespringpointingoutwards,horizontally.

Pushthepanelsidetrolleyontotherunway(tapwithrubber/nylonmalletasnecessary)untilthegapbetweenguiderollerandtoeofflangeisbetween3and5mm(seeFigure16).Checkthatthegapisthesameatbothends.



Figure16LowHeadroomRunwayClearance

Lower the hoist unit so that the wheels are touching the beam flange ensuring that the 35mmclearancegapismaintained.

1 Donotremovethehoistliftingtackleuntilthehoistisfullysecuredontherunway. RemoveeachofthefourM12lockinggrubscrewsfromthepanelsidetrolleycastings. Usingthesingleconepointsetscrew,screwintoeachholeinturnandtightenuntilacentrepopindent

ismadeinthehoistlegs. Usinga10mmdiameterdrill,drilla fullconeof10mmdiameter intoboth legsat fourpositions (see

Figure17). Removeanyswarffromtheholesusingamagnet. Replaceconepointsetscrewinitsstorageposition,securingwiththelocknut.

Figure17SettingtheLowHeadroomLegs

ReplaceeachofthefourM12 lockinggrubscrewsandtightento40Nm. Secureeachgrubscrewwithlocknuttightenedto40Nm.

Replacethereactionrollerassemblyonthewheelsupportcasting.Setthereactionrolleraspersection3.4.1.

Removethefourbluetransportationfeetfromthehoistlegs(Figure18).



Figure18LowHeadroomHoistTransportationFeet

3.4.1 SettingtheReactionRollerBefore setting the reaction rollerensure that the sideguide rollerson thepanel side trolley frame, i.e. theguiderollersonthesamesideasthereactionrollerassembly,areincontactwiththetoeoftherunwaybeamflange.Forthesettingoperationtheclearancebetweenthesideguiderollersandtherunwayflangemustbeonthebarrelside(notethisisontheoppositesidetothatshowninFigure16).Thereactionrollerfittedtolowheadroomhoistunitsrunsontheundersideoftherunwaybeamdirectlybelowthetraversedrivewheel.Iftherollerassemblyhasnotbeenreplaced,rotatetheassemblyuntilthelocationpinalignswiththeholeinthebodycasting(redadjustingspringfacinghorizontallyoutwards).Pushthepinintotheholeandattachthewasherandcirclip,thewashersitsdirectlybehindthecirclip.

Figure19ReactionRoller

Ensure that the travel drive wheel is in contact with the runway flange. Turn the reaction roller

adjustingnutuntiltherollerjusttouchestheundersideoftherunway. Turntheadjustingnutanadditionalfive(5)fullturnsandthenlockinpositionusingthelocknut.Hold

theadjustingnutandtightenthelocknutto81Nm.

1 Fivefullturnsoftheadjustingnutisimportanttoachievecorrectcompressiononthereactionrollerspring.



3.5 INSTALLATIONOFLOWHEAD6&8FALLSINGLEGIRDERHOIST3.5.1 AdjustingtheCTandNonCTtrolleywidthsrunwaywidth300700mm3.5.1.1 DisassemblyoftheCT&NonCTTrolleyPlateAssemblies

Measuretherunwayflangewidth. Iftherunwayis300mm,adjustmentoftheTrolleyPlateAssembliesisnotrequired,see3.5.2. Whilstthehoist isonthe floorandstoodon itsdelivery feet, identifyM16Hexscrews (3)andM20

SocketCapscrew(1)(viewthroughaccesshole),onCTtrolleyandnonCTtrolleysonElectricalPanelSideonly(seeFigure20).

Usinga17mmAFAllenkeyensureM20SocketCapscrew (1) is fullyscrewed in,turningthescrewclockwise.

Figure20CTTrolleyPlateAssemblyElectricalPanelside

1 To adjust the CT andNon CT trolley assemblies for 350700mm runways removal of the CTmotorsandTrolleyPlateassembliesisrequired,suitableliftingequipmentisnecessary.

RemovebothCTmotors,loosenandremoveM8FlangedHexscrews(4).Placeasideontoasuitablesurface,takingcarenottostraintheelectricalcable.

RemovetheEndcapElectricalPanelSide,loosenandremoveM16Hexscrews(3),seeFigure20. Removethe50mmspacers(3)and25mmspacers(2)fromtheaxleandplaceaside. Remove/slidetheTrolleyPlateAssemblyofffromtheaxle,seeFigure20.

UsetheDshackleholestoattachsuitableliftingequipment(70kg),placeaside. Remove/slidethecompleteTrolleyPlateAssemblyHoistSide,SeeFigure21,includingtheaxleand

spacersfromthehoist.Placeasideontoasuitablesurface.UsetheDshackleholesforsuitableliftingequipment(150kg),placeaside.

1 It is important that the Hoist Side M16 Hex screws(3) are NOT adjusted or loosened,See Figure 21, this ensures correct assembly when the Trolley Plate Assemblies are reassembled.

M20SocketCapscrew(1)(inside end cap viewthroughaccesshole)

EndCap(ElectricalPanelSide)

(300mmRunwayshown)50mmSpacers(3) 25mmSpacers(2)

Axle

M16Hexscrews(3)

M8 Flanged Hex screws(4)

DShacklehole

TrolleyPlateAssembly



Figure21CTTrolleyPlateAssemblyHoistPanelside

3.5.1.2 AdjustingtheTrolleyplate,spacerandsafetybarspositions

Figure22TrolleyPlateAssemblyfittedfor700mmrunway

HoldingtheTrolleyPlateAssemblyHoistside,pushtheaxlethroughandremovethe50mm(3)and

25mm(2)spacers,seeFigure21. Iftherunwayis700mmrefittheTrolleyPlateAssemblyuptotheendcap,andfitthespacersonthe

inside,seeFigure22. ForotherrunwaywidthsseethebelowtableforpositionsofthespacersFigure23.

RunwayWidth(mm) SpacersuptoEndcap Spacersontheinside300 50mm(3)25mm(2) None350 50mm(3)25mm(1) 25mm(1)400 50mm(3) 25mm(2)450 50mm(2)25mm(1) 50mm(1)25mm(1)500 50mm(2) 50mm(1)25mm(2)550 50mm(1)25mm(1) 50mm(2)25mm(1)600 50mm(1) 50mm(2)25mm(2)650 25mm(1) 50mm(3)25mm(1)700 None 50mm(3)25mm(2)

Figure23Runwaywidthspacerpositions

M16Hexscrews(3)DONOTADJUSTORLOOSEN

TrolleyPlateAssembly50mmspacers(3)25mmspacers(2)

Axle

Endcap

For700mmrunwayTrolleyplateisfitteduptotheendcap,allspacers50mm(3)and25mm(2)arefiitedontheinside.

M16Hexscrews(3)HoistSideDONOTADJUST

DShacklehole



AdjustallthetrolleysafetybarsfortherunwayflangewidthasFigure24below.ThesafetybaristogivesupporttotheTrolleyPlateAssemblyuponfittingtothehoist.

Figure24SafetyBarPosition

3.5.1.3 RefittingtheTrolleyPlateAssembliestothehoist

RefitthecompleteTrolleyPlateAssemblyHoistSideincludingtheaxleandspacers(seeFigure22)intothehoistbeam,useDshackleholeforsuitableliftingequipment(Weight150kg).

Ensurethesafetybars(seeFigure25)areincontactwiththetopofthebeamandrelease. Refit the Trolley Plate Assembly Electrical Panel Side and spacers onto the axle, mirroring the

positionsonthehoistside,refertoFigure23forthecorrectpositions.

1 Itisveryimportantthatthepositionsofthetrolleyplateassembliesandspacersaremirroredexactly,ensuringthebeamiscentral,seeFigure25.

RefittheEndcapElectricalPanelSide,fitandtightenM16HexScrews(3)to20Nm.RefittheCTmotors,andtightenM8FlangedHexscrews(4)to24Nm,seeFigure25.

(700mmshown)

Figure25Endcaprefitted

RunwayWidth(mm)

DimX(mm)

300400 140450550 90600700 30

Refitendcap

RefitCTmotor RefitCTmotor

DimX

M16Hexnuts



3.5.2 Installingthehoistontotherunway3.5.2.1 Liftingthehoisttotherunway

RemovetheEndcapElectricalPanelSide,loosenandremovetheM16Hexscrews(3) RefittheEndcapbutinreverse,seeFigure26below,tightentheM16Hexscrews(3),torque20Nm.

ThisgivesspaceontheaxletoallowtheTrolleyPlatestobepositionedwiderthanthebeamflange.

1 ItisveryimportantthattheHoistSideM16Hexscrews(3)areNOTadjustedorloosened.

Figure26Endcapreversedandrefitted

SeeFigure27fitsuitableliftingchainhooktoliftingpointholes.1 Fit suitable liftingequipment to the liftingpointholesensuring that the includedanglebetween chainsdoesnotexceed60andliftthehoistuptotherunwaylevel,ensuringthewidthofthetrolleys issufficienttoclearthebeamrunwaywidth.

3.5.2.2 SettingtheTrolleyPlatesandwheelsontotherunway

Position thehoistensuring theTrolleyPlateAssembly Hoist side and trolleywheels areover therunwayandthatthesiderollersareincontactwiththesideofthebeamflange.

Figure27Liftingthehoisttotherunway

1 For6Fallhoists toallow the fittingof thehoistcover, rotate midspan liftingstrapby90andsecurewith1offM16fastener(the2ndM16fasteneristoberetainedintheunusedholeforfutureliftingrequirements)Figure27.

EndcapReversedElectricalPanelSide

M16Hexscrews(3)HoistsideDONOTADJUST



Supporting theTrolleyPlateAssembly Hoistside,push theTrolleyPlateAssembly Electricalpanelsidetrolleysovertherunwayflange.Ensurethetrolleyplate is incontactwiththe insidespacersandthatthesiderollersare incontactwiththesideofthebeamflange.

RemovethereversedEndcapElectricalPanelSide,loosentheM16Hexscrews(3). Replace any removed spacers and refit the Endcap Electrical Panel Side, tighten the M16 Hex

screws(3)to20Nm. ToallowtheTrolleyPlateAssembliestopivot,thetensioningscrewrequiresadjustment,

seeFigure28.Usinga17mmAFAllenkeyunscrewtheM20SocketCaphead(counterclockwise)untilitmakescontactwiththeendcap.

Usingasuitabletorquewrenchwitha17mmAFAllenkeySocketapply100Nmoftorque(counterclockwise)totheM20SocketCaphead,seeFigure28.

Testthepivotofthetrolleyassembliesusinghandforceonly.

Figure28Settingthetensioningscrew

Lowerthehoistontorunwayflanges,ensuringthatallthewheelsareincontactwiththebeam. Remove thesafetybars (8) fromboth trolleyplateassemblies, releaseM16nutsandunscrew,see

Figure24. Removethetransportationfeetfromthehoist. For6Fallhoiststheliftingstrapsrequireremovalandfittingintothestorageposition,seeFigure27,

toallowthefittingofthehoisttopcover,refitthehoistcover.

M20SocketCapscrewtensioningscrew.Adjustbyturningcounterclockwiseto100Nm.

Endcap



3.6 INSTALLATIONOFFOOTMOUNTEDHOIST

1 TheZX6&ZX8footmountedhoistunitsaredesignedformountinghorizontallywiththefeetatthebottomoftheunit.Thehoistsarenotsuitableformountingsuspendedupsidedownorinanyotherorientationotherthanasshown.

Figure29InstallationofFootMountedHoist

Footmountedhoistunitsaresuppliedwithfourmountingfeet.On2&4fallunitseachfoothasasingle18mmdiameterhole.TheyshouldbesecuredtoasuitablesupportingstructureusingfourM16fixingswithminimumgradeof8.8.On6&8fallunitseachfoothasasingle22mmdiameterhole.TheyshouldbesecuredtoasuitablesupportingstructureusingfourM20fixingswithminimumgradeof8.8.

1 Thesupportingstructureshouldbesuitablydesignedtosupportboththemassofthehoistunittogetherwith its rated capacity plus dynamic effects. Tolerances on themounting surfaceshouldbeinaccordancewith3.2.4.



3.7 SETTINGTHEUPPERANDLOWERLIMITSWITCHESStandardEnvironmentEachhoistisfittedwithanupperandlowerlevelhoistlimitswitch.Thelimitswitchesareactivatedbycontactwiththetravellingropeguidebush/retainer.Thesearesafetyswitchesandshouldnotbeusedasthenormalmethod forstopping thehoist. Whenactivated,eachswitchwillonlyallow travel in theoppositedirection.Removethehoistcovertogainaccesstothelimitswitches.NOTE:Thelimitspacertubesaredesignedtopreventtheswitchesfrombeingplacedoutsidethenormalrangeofoperation.Donotremoveormodifythesetubes.

1 Incorrect settingof the limit switchesmay cause seriousaccidentsanddamage to thehoistunit.

Figure30HoistLimitSwitchesStandardEnvironment

Figure31HoistLimitSwitchesStandardEnvironmentRv1(seehoistnameplateforrevision)

3.7.1 Settingthelowerlimit Releasethegrubscrewsthatsecuretheholdingarmtothelimitbarsandslidetheswitchtowardsthe

endofthehoist. Lowerthehooktothedesiredlowestoperatingposition.Donotletthehooktouchthefloorsuchthat

itwouldcausetheropestogoslack.



NOTE:Theclearancebetweentheropeguideandtheropeclampsshouldnotbelessthan10mmwhenthehookisatitslowestposition.

Slidethelimitswitchuptotheropeguidebush/retaineruntiltheswitchisactivated.Tightenthegrubscrewsholdingthearmtothelimitbar.

Test that the limit operates satisfactorily firstly at slow speed and then at fast speed. Readjust ifnecessary.Whentheadjustmentsarecomplete,replacethehoistcover.

3.7.2 Settingtheupperlimit Releasethegrubscrewsthatsecuretheholdingarmtothelimitbarsandslidetheswitchtowardsthe

endofthehoist. Raisethehooktothecorrectoperatingposition.

1 Theupperhook levelfor lowheadroomhoistsvarywiththerunwayflangewidth. Thehoistwillbeseriouslydamagedifthehookissethigherthanthevaluesindicatedinsection3.11.

Slidethelimitswitchuptotheropeguidebush/retaineruntiltheswitchisactivated.Tightenthegrubscrewsholdingthearmtothelimitbar.

Test that the limitoperatessatisfactorily firstlyatslowspeedand thenat fastspeed,stoppingat thecorrectdistance fromtheundersideofthebeam. Readjust ifnecessary. Whentheadjustmentsarecomplete,replacethehoistcover.



3.8 SETTINGTHEUPPERANDLOWERLIMITSWITCHESGalvanising/AggressiveEnvironmentsEachhoistisfittedwithanupperandlowerlevelhoistlimitswitch.Thelimitswitchesareactivatedbycontactwith the travelling rope guide follower. These are safety switches and shouldnotbeused as thenormalmethod forstopping thehoist. Whenactivated,eachswitchwillonlyallow travel in theoppositedirection.Removethehoistcovertogainaccesstothelimitswitches.NOTE:Theguiderailhasastop tabateachendwhichensures that the limitswitchbracketsarenotplacedoutsidethenormalrangeofoperationoftheswitchesDonotremoveormodifythesestoptabs.

1 Incorrect settingof the limit switchesmay cause seriousaccidentsanddamage to thehoistunit.

Figure32HoistLimitSwitchesGalvanising/AggressiveEnvironment

3.8.1 Settingthelowerlimit RemovetheM6fastenersthatsecurethelimitswitchbrackettotheguiderailandpositiontheswitch

towardstheendofthehoist. Lowerthehooktothedesiredlowestoperatingposition.Donotletthehooktouchthefloorsuchthat

itwouldcausetheropestogoslack. NOTE:Theclearancebetweentheropeguideandtheropeclampsshouldnotbelessthan10mmwhen

thehookisatitslowestposition. Positionthelimitswitchbracketsuchthatthelimitswitchisactivatedbytheropeguidefollower.Refit

andtightentheM6fastenerssecuringthebrackettotheguiderail. Test that the limit operates satisfactorily firstly at slow speed and then at fast speed. Readjust if

necessary.Whentheadjustmentsarecomplete,replacethehoistcover.3.8.2 Settingtheupperlimit RemovetheM6fastenersthatsecurethelimitswitchbrackettotheguiderailandpositiontheswitch

towardstheendofthehoist. Raisethehooktothecorrectoperatingposition.


PositionthelimitswitchbracketsuchthatthelimitswitchisactivatedbytheropeguidefollowerRefitandtightentheM6fastenerssecuringthebrackettotheguiderail..

Test that the limitoperatessatisfactorily firstlyatslowspeedand thenat fastspeed,stoppingat thecorrectdistance fromtheundersideofthebeam. Readjust ifnecessary. Whentheadjustmentsarecomplete,replacethehoistcover.



3.9 ULTIMATEUPPERLIMITSWITCHROTARY(OPTIONAL)When specified, anultimateupper limitmaybe fitted to thehoistunit toprevent thebottomblock fromdamagingthehoistshouldthenormalupper limitswitch fail. Itshouldbesettoactivateattheupper levelgiven in section3.11. Thenormal limit should thenbe set toactivateapproximately75100mmbelow theultimatelimit.Aredwarninglightonthebaseofthecontrolpanelwillilluminatetoindicatewhenthesecondultimatelimithasbeenactivated.

Figure33UltimateUpperLimitSwitchRotaryType

3.9.1 Settingtheultimateupperlimit

1 Extremecaremustbeexercisedwhentestingtheultimatelimitswitchasitisnecessarytobypassthenormalupperlimit.

Repositionthenormalupperlimitsuchthattheultimatelimitisthefirsttooperate. Raise the hook to the desired operating position at slow speedwith no load attached allowing an

additional50mmforafastspeedapproach.


Removethelidfromthesecondupperlimitandloosenthecentralclampscrew(seeFigure34). Turncamno.2adjustmentscrewuntilcamno.2ispositionedjustbeforeitoperatesthemicroswitch. Retightenthecentralclampscrew. Test the operating position in slow speed at first repeating the test in fast speed adjusting the trip

positionwherenecessary.Replacelimitswitchlid. Checkthattheredwarninglightinthebaseofthecontrolpanelilluminates. Setthenormalupperlimitsothatitoperatesapproximately75100mmbelowtheultimateupperlimit

(see3.7.2/3.8.2).



Figure34SettingtheUltimateUpperLimitSwitchRotaryType



3.10 ULTIMATEUPPERLIMITSWITCHHOOKBLOCKOPERATED(OPTIONAL)When specified, anultimateupper limitmaybe fitted to thehoistunit toprevent thebottomblock fromdamagingthehoistshouldthenormalupper limitswitch fail. Itshouldbesettoactivateattheupper levelgiven in section3.11. Thenormal limit should thenbe set toactivateapproximately75100mmbelow theultimatelimit.Aredwarninglightonthebaseofthecontrolpanelwillilluminatetoindicatewhenthesecondultimatelimithasbeenactivated.

Figure35UltimateUpperLimitSwitchHookBlockType

3.10.1 Settingtheultimateupperlimit

1 Extremecaremustbeexercisedwhentestingtheultimate limitswitchas itnecessarytobypassthenormalupperlimit.

Repositionthenormalupperlimitsuchthattheultimatelimitisthefirsttooperate. Raise the hook to the desired operating position at slow speedwith no load attached allowing an

additional50mmforafastspeedapproach.


Removethebottomblocktriggerfixingssuchthatthebottomblocktriggercanbesplitintwo. Positionthebottomblocktriggeraroundthehoistrope.

1 The bottom block trigger must be positioned around the fixed rope on the reevingarrangementi.e.theropewhichterminatesatthewedgeandsocketseeFigure35.

Replaceblocktriggerfixings. Adjustthelengthofthestrainerwireandpositionofthebottomblocktriggersuchthatthelimitswitch

operates Testtheoperatingpositioninslowspeedatfirstrepeatingthetestinfastspeedraising/loweringthe

bottomblocktriggerwherenecessary. Trimorsecureanyexcessstrainerwire. Checkthattheredwarninglightinthebaseofthecontrolpanelilluminates. Setthenormalupperlimitsothatitoperatesapproximately75100mmbelowtheultimateupperlimit

(see3.7.2/3.8.2).



3.11 LOWHEADROOMHIGHESTHOOKPOSITION2FALL&4FALL

ZX6 ZX8

ZX62FALL

ZX82FALL

ZX64FALL

ZX84FALL

1 Topreventaccidentaldamagetothehoistunit,alllowheadroomhoistsaredespatchedfromStreetCranewithupperandlowerlimitswitchessettosuita500mmrunwayflange.Aspartofthe commissioning procedure, the upper and lower limit switches should be adjusted toachievetheoptimumCDIMENSIONfortherunwayflangewidth(see3.7/3.8).



3.12 LOWHEADROOMHIGHESTHOOKPOSITIONZX86FALL&8FALL

ZX8LOWHEADROOM6&8FALLS

HOIST FALLSRUNWAY

WIDTH(mm) BARREL'C'DIMENSION

(mm) DATASHEETZX8 6 300700 NB,LB,ELB 1175 DZX1109ZX8 8 300700 LB,ELB 1282 DZX1110

3.13 FOOTMOUNTHIGHESTHOOKPOSITIONZX6&ZX8

ZX6FOOTMOUNT

HOIST FALLS BARREL'C'DIMENSION

(mm) DATASHEETZX6 2 NB,LB,ELB 526 DZX1051ZX6 4 NB,LB,ELB 495 DZX1054

ZX8FOOTMOUNT


(mm) DATASHEETZX8 2 NB,LB,ELB 585 DZX1151ZX8 4 NB,LB,ELB 550 DZX1154ZX8 6 LB,ELB 645 DZX1157ZX8 8 LB,ELB 637 DZX1160



3.14 DOUBLEGIRDERPARALLELCRABHIGHESTHOOKPOSITIONZX6&ZX8

ZX6DOUBLEGIRDERPARALLELCRAB900mmGAUGE


(mm) DATASHEETZX6 2 NB,LB,ELB 104 DZX1016ZX6 4 NB,LB,ELB 71 DZX1019

ZX8DOUBLEGIRDERPARALLELCRAB1400mmGAUGE


(mm) DATASHEETZX8 2 NB,LB,ELB 295 DZX1116ZX8 4 NB,LB,ELB 260 DZX1122ZX8 6 NB,LB,ELB 372 DZX1128ZX8 8 LB,ELB 421 DZX1134

3.15 DOUBLEGIRDERPERPENDICULARCRABHIGHESTHOOKPOSITIONZX8

ZX8DOUBLEGIRDERPERPENDICULARCRAB14002600mmGAUGE


(mm) DATASHEETZX8 2 NB,LB,ELB 295 DZX1119ZX8 4 NB,LB,ELB 260 DZX1125ZX8 6 NB,LB,ELB 555 DZX1131ZX8 8 LB,ELB 547 DZX1137



3.16 CHECKING/ADJUSTINGTHERATEDCAPACITYLIMITERTheratedcapacity limiter isusedtopreventthehoistfrom liftinga load inexcessoftheratedcapacity(safeworking load). Ifthehoist isoverloaded,the limitswitchwilltripandtheUPdirectionwillbecome inactive.The hoist will be allowed to lower only. Once the load has been removed then the limit switch willautomaticallyresetandallmotionswillbecomeactiveagain.Theratedcapacitylimiterispresetatthefactorypriordespatchandissettoratedcapacity+7.5%.Checkingof the ratedcapacity limiterwill requirecalibrated testweightsequal to the ratedcapacityof thehoistandratedcapacityplus10%,(SWLandSWL+10%).Lifttheloadjustclearofthefloorwiththetestloadattached.The limitdoesnotrequireanyadjustment if thehoistpicksup itsratedcapacity (SWL)butdoesnot lift theratedcapacity+10%(SWL+10%).Ifthelimittripseitherbeloworabovetheselimits,adjustthelimitbyturningthegrubscrew.3.16.1 AdjustingtheRatedCapacityLimiterforProofLoadingForproofloadtestingofahoistorcraneataloadgreaterthantheratedcapacity,proceedasfollows: Releasethegrubscrewbyapproximatelyhalfaturn. Carryouttheproofloadtestsonthehoist/craneasrequired. Attachacalibratedtestloadtothehookof(RatedCapacity+10%).Lifttheloadjustclearofthefloor

andtightenthegrubscrewuntilthelimitswitchjustoperates. Lowertheloadtothefloorandrepeattheliftseveraltimesatslowhoistingspeedmakingsurethatthe

limitertripseachtime. Repeatthetestatratedcapacity,thistimeensuringthatthe limiterdoesnotactivate.

Figure36RatedCapacityLimiter



3.17 TRAVERSELIMITS(OPTIONAL)Thetraverselimitarrangementemployseitheraoneortwostagecruciformswitchdependingonthetypeofstoppingarrangement.Besureofthetypethatisfittedtoyourhoist. Asinglestagelimitswitch(typePF33710100)isemployedtostopthemotioncompletelywhenthelimit

isreachedortoallowthehoisttoproceedatslowspeedonlyuntiltheendstopisreached.Thesinglestagelimitemploysoneactuatingarmateachendoftravel.

The two stage switch (typePF26755100) isemployed to firstly slow the speed from fast to slowandthen tostop themotioncompletelyon reaching thesecondstage. The twostage limitemploys twoactuatingarmsateachendoftravel.

NOTE:Oneachoftheabove,whenthelimitistripped,normaloperationisavailableintheoppositedirection.Reversingawayfromthestopisatthespeedselectedbytheoperator(sloworfast).3.17.1 SettingtraverselimitsToensurereliableoperationoftheswitch,theactuatingarmshouldbepositionedtostrikethe limitbarasshowninFigure37.Thearmshouldbepositionedsothattheswitchrotatesthrough90eachtimeitpassesanarm.Theshortbarontheswitchoccupiesthemid(0)positionwhentheswitchisbetweenthetwoactuatingarms.Thebarontheswitchwillthenrotatethrough90clockwiseoranticlockwiseeachtimeitpassesanactuatingarm.

1 Failuretosettheswitchandactuatingarms,asshown,willresultinpermanentdamagetotheswitch.

Figure37SettingtheTraverseLimitSingleGirderArrangement



Figure38TraverseLimitDoubleGirderarrangement(SeeFigure37forsettingdimensions)

Whensettingthepointofoperationforthe limitswitch,accountshouldbetakenofthehoistspeedandthestoppingdistance.Thepointofoperationshouldbesettoallowafullyloadedcrane/hoisttostopfromfastspeedbeforereachingtherequiredposition.



3.18 CONNECTINGTHEPOWERSUPPLY

1 Connectionofthepowersupplymustbecarriedoutbyacompetentperson.Ensurethatthesupply to the hoist matches the information in the hoist technical data and on the hoistnameplate.Alsoensurethatthesupplyhasbeencorrectlyinstalledandprotected,i.e.voltage,phase,frequency,fusesize,cable/conductorsize.Checkthatthevoltageatthepointofsupplyiswithinthetoleranceof5%andthenominalfrequencyiswithinthetoleranceof1%oftheratedvalues.

3.18.1 Supplycables/fusesThe size of the supply cables to the hoist must be selected in accordance with the table in section 7.6.Terminalsmustbeofa sizeappropriate to the cable sizeand securely fixed. Selectionofa suitable sizeofmainsfuseisgiveninsection7.5.FusesofclassgL/gGshouldbeused(ortypeJforCSAinstallations).3.18.2 Mainisolatorsupplyswitch(byothers)Themainisolator(supplyswitch)mustdisconnectallphasesofthesupplytothehoist,mustbeclearlymarkedandlocatedinaneasilyaccessibleposition.TheswitchshouldbecapableofbeinglockedintheOFFpositionwhilstanymaintenanceworkisbeingcarriedout.Themainisolator,ifreasonablyaccessible,mayalsobeusedfor emergency stop or emergency off purposes. NOTE a separate emergency stop is located on the hoistcontrollersee4.4.5.3.18.3 ConnectingtothemainssupplyConnectthecablesinaccordancewiththecircuitdiagramsviatheplugandsocketlocatedonthesideofthehoistcontrolpanel.

Figure39HoistElectricalConnections

Check the settingofboth the Traverse Fast to Slow and theHoist Slow to Fast speeddelay timers.

TheseshouldcorrespondwiththesettingsinFigure40. CheckthesettingsonthePhaseFailureRelaycorrespondwithFigure41. Checkthattheconnectionstothecontroltransformermatchthesupplyvoltage(seeFigure42). Before switching the power on carry out Earth continuity and insulation resistance tests on the

completedinstallation.



Figure40DelayTimers

Figure41PhaseFailureRelay

POTENTIOMETERSETTINGSSupply H1 H2

380V50Hz 12.5% 12.5%380V60Hz 15% 15%400V50Hz 12.5% 12.5%415V50Hz 12.5% 12.5%440V50Hz 12.5% 12.5%460V60Hz 12.5% 12.5%575V60Hz 12.5% 12.5%



Figure42ControlTransformerConnections

3.18.4 ElectromagneticcompatibilityThehoist itselfcomplieswith the requirementsofBSEN6100062/4with regard toEMC. Theusershouldtakecaretoensurethattheremainderoftheinstallationmeetstheserequirements.3.18.5 ConnectingthePendantcontrollerLowHeadroomWhereacontrolpendantistobeattacheddirectlytoalowheadroomhoist,itmustbesupportedbythetwostrainerwiresoneithersideofthependantcable.Theelectricalcableorterminalsmustnotsupportanyload.ConnectthetwopendantstrainerwirestotheM6screwsonthesuspensionbracketasshown.TightentheM6fixingsto9Nm.Connecttheplugontheendofthependantcabletothesocketonthesideonthehoistcontrolpanel.

Figure43StrainerWireConnections



3.19 COMMISSIONINGPROCEDURE

1 Checkstobecarriedoutbeforeswitchingonthepowersupply. Checkthatthehoistinstallationiscompleteandallfixingscrewsaresecure. Checkthatthecorrectendstopsareinplace. Check that theelectrical installation iscompleteand installedas section3.18. Ensure that theEarth

continuityandinsulationresistancetestsweresatisfactorilycarriedout.

1 Oncepowersupplyisconnected: Checkthattheemergencystopfunctionscorrectly. Check eachmotionby firstmoving at SLOW speed andmoving theminimumpossibledistance also

ensuringthatthedirectionofmovementscorrespondtothelegendsonthecontroller. Double girder Travel the crab unit the full length of the crane to ensure that there is sufficient

clearancebetweenthewheelflangesandtherail. SinglegirderTravelhoistfulllengthofrunwaytoensurethatadequateclearanceexistsbetweenguide

rollersandrunway.Checkthattheclearancedoesnotbecomeexcessive.Checkthatthereactionrolleroperatessatisfactorily.

Checkthattherunwayendstopsfunctioncorrectly. Setandchecktheupperandlowerlimits(section3.7). Settheultimateupperlimit(rotarytypeseesection3.9,blockoperatedtypesee3.10)andthetraverse

limit(section3.17)iffitted. Checkandadjust,ifnecessary,theratedcapacitylimiter(seesection3.12).Ifthehoististobesubject

toaproofloadtestaspartofacraneorrunwayinstallation,seetheinstructionsforbypassoftheRCLinsection3.16.1.

Runthehoistseveraltimesunder light load(approx10%ofSWL)andatslowspeedtoallowthewireropetobeddownand improve itsservice life. Aftertherunning inperiod,checkthatthewedgeandropehasseatedcorrectlyinthesocket.Removeanytwistimpartedintheropeduringinstallation,seesection5.8.2.4.

Thehoistisnowreadyforproofloadandperformancetestingasrequired.Confirmthatcommissioninghasbeendulycarriedoutandcompletethetestlogbookinsection7.7.

3.20 DISMANTLING/REMOVALOFTHEHOISTThefollowinghoistdismantlingandremovalprocedureassumesthatthehoist isstill in itsoriginalconditionandworkinginthesameenvironment.Ifthehoisthasbeenmodifiedsuchthatitnolongerresemblestheoriginalinstallation,thecompetentpersonmaydecideonanalternativemethodofremovalanddismantling. Raise the hook to its upper level. Alternatively the hook and rope may be removed if required.

See5.8.2.1 Electricallyisolatethecrane,disconnectallelectricalcables. Removeanyattachmentssuchaslimitbrackets,cabletowingarms,pendantetc. Supporttheweightofthehoistatitsappropriateliftingpoints.See3.3 DoubleGirderCrabscanbeloweredtotheground. ForFootMountedHoistsremovethefootboltsandcheckthereisnoadhesionofthefootplatesbefore

loweringtotheground. For2&4FallLowHeadHoists: Releasethereactionroller.See3.4.1 Removethelockinggrubscrews.See3.4 Openthelowheadtrolleyframeuntilthewheelscleartherunwayflange. Lowertothefloor. For6&8FallLowHeadHoists: Removetrolleyspacers.See3.5 Openthelowheadtrolleyframeuntilthewheelscleartherunwayflange. Lowertothefloor. Ifthehoistisnottobereused,disposeofinanenvironmentallyfriendlymanner.



4 OPERATINGINSTRUCTIONS

4.1 INTENDEDUSEThecrane/hoistisdesignedforlifting,movingandloweringloads,uptotheratedcapacityoftheequipment,bymeans of a hook or other similar load handling device. The equipment should not bemodified or anyadditionsmadewithouttheapprovalofStreetCraneCoLtd. Theequipmentisnotintendedfortransportinganypersonseithersuspendedinabasketfromthehoist

orforpersonstravellingonthecranebridge. Thecrane/hoistisnotintendedforpullingloadsatanangleandnotfortowingordraggingloadsalong

thefloor.Thehoistisdesignedforliftingaloadinaverticalpathonly. Ensurethatthehoistisalwaysoperatedwithinitsratedcapacity(SWL).Theweightofanyliftinggear

shouldbetaken intoaccountwhenassessingthe loadonthehoist. Itmayalsobenecessarytoallowforanyadhesionbetweentheloadanditssupports.

1 Overloadingcanleadtoapossiblefailureofsomeoftheloadcarryingparts.Overloadingthecrane/hoistmaystartadefect,whichcouldleadtofuturefailureevenatlessthantheratedcapacity.

Donotuse thecrane/hoist forpulling loads loose, i.e.pullingcomponents frommouldsandalwaysmakenecessaryallowancesforanyadhesionbetweentheloadanditssupports.

The end of travel limits, (hoist or travel), are not intended to be a regularmethod of stopping themotion.Theyaresafetydevicesandtheyshouldbeapproachedwithcaution.

Thehoistisnotintendedtooperatewithaslackrope.4.2 DUTIESOFTHEOPERATOR/SAFEHOISTINGPRACTICESAtthestartofeachworkingdayorshift,carryoutthedailypreusechecksseesection5.4.Donotworkwithanycraneorhoistifanydefectsarefoundwhichmaycompromisesafety.Thefollowing informationservesasaguideforsafehoistingpracticesandanoperatoradheringtothesewillquicklyfindthathe/sheisabletoworkbothsmoothlyandquickly,withoutprejudicingsafetyandequipment.

1. Knowwherethesafety,fireandfirstaidequipmentislocatedandhowtouseit.2. Ensurethatnooneisworkingonthecranetrack,craneplatform(iffitted)orwheretheycouldbe

struckbythecrane/hoist.3. Beforeusing thecrane/hoistmakea fullvisual inspection toascertain that theequipment is in

good working order, paying particular attention to the rope and hook. See 5.4 Daily preuseinspections.

4. Donotusethecraneforanythingotherthanitsintendedpurpose.5. Ensurethecrane isproperlymaintainedandthatallthenecessaryexaminationandmaintenance

recordsareuptodate.6. Allrelevantaccidentprevention,safeliftingandslingingproceduresshouldbeobeyed.7. Constantlymonitorallcraneandhoistmovementsandbe ready toactivate theemergency stop

shouldanyabnormalcircumstancesarise.Beespeciallyawareofinstanceswherethecrane/hoistmay fail to stop when the push button/joystick is released or if the crane / hoist movesunexpectedly.

8. Alwaysoperatethecranewithcareandconsideration.Careshouldbetakentoavoidtheswingingofloads.

9. EnsurethattheSWLdataplatesareclearlyvisibletotheoperatoratalltimes.10. Centre thehoistover the loadbefore lifting. Donot sidepullas this candamage thehoistand

endangertheoperator.11. Donotlowerthehook/bottomblocksofarastoallowthehoistropestobecomeslack.

1 Ifthisdoeshappen,theoperatorshouldsatisfyhimselfthattheropeiscorrectlyreevedonthesystemofsheaves&hoistbarrelbeforecontinuingtooperatethecrane.

12. Donotliftaloadunlessyoucanseeitissecurelyslungwithsuitableliftingtackle.



1 LiftingtackleshouldonlybedeemedsuitableifinaccordancewithLOLER98.(Othernationalregulationsmayapply).

13. Alwaysgentlyinchthehoistintotheload.

1 Running intothe loadat fullhoistspeed imposesexcessiveoverloadsonthehoistandcouldresultinfailureofpartsand/orsupportingstructure.

14. Donotinchthehoistunnecessarily.Excessivestoppingandstartingcauseshightemperaturesinthemotorandbrakeandmayresult inoverheatingorburnoutofthecomponent ifcontinuedtoexcess.

15. Donottryandmoveintheoppositedirectionuntilthecrane/hoisthascometoacompletestop.

3 Donotstandbelowasuspendedloadorallowanyotherpersonneltodoso.16. Prior to operating the travel or traversemotion, the operator shouldmake personnel aware of

approachingloadsusingaudiblewarningswherenecessary.

3 Donotmovetheloadsovertheheadsofotherpersonnel.17. Donotrunthehoistorcraneintothetravelstopsatfullspeed.Ensurethattherubberbufferisin

placeandnotdamaged.18. Ensurethatadequateclearanceismaintainedbetweentheloadorliftingattachmentandthehoist

orcranestructure.SeeFigure44.

Figure44Clearancestoconsiderwhenlifting

19. Ensurethatyoucanseethehookorloadclearlyatalltimesorarereceivingsignalsfromsomeone

who can. Ensure thatbothparties know the fullmeaningof thehand signals foroperating thecrane/hoist.SeeFigure45forrecommendedhandsignals.

20. Do not continue to travel or traverse once the crane or hoist has come to a stop against theendstops.Thiswillcauselocaliseddamagetotherailorrunwaybeam.

21. Neverleavealoadsuspendedintheairunsupervised.22. Donotparkthecraneoverfumes,steamordangerousprocesses.Foroutdoorcranes/hoists,park

inashelteredareawherepossible.23. Do not leave outdoor cranes/hoists unattended for long periods without applying the storm

anchors.



Figure45RecommendedHandSignals

4.3 REMOTECONTROLLEDCRANES/HOISTSTopreventunauthoriseduse,theoperatorshouldeitherretainthetransmitter intheirpossessionorremovethekeyfromitskeylockswitchand,forshortperiods,retainthekeyintheirpossession.Forlongerperiods,orwhenthecraneisnotinuse,thetransmittershouldbedepositedinadesignatedsafestorageplace.When the transmitter is fittedwith a belt or harness, the operator should bewearing the harness beforeswitching the transmitteron. Thiswillpreventaccidentaloperationof the crane /hoistwhilst fitting. Thetransmittershouldalsobeswitchedoffbeforeremovingtheharness.



Ensure that the identification tagon the radio securitykeymatches the identificationnumberon the radiotransmitterandtheidentificationnumberonthecrane.4.4 CONTROLSTATIONOPERATINGINSTRUCTIONSThecontrolstationmaybefittedwitheitherpushbuttonsorjoysticks.Pendantswillbepushbuttonoperated,remotecontrolstationsmaybeeitherpushbuttonorjoystick.Inallcasesthepushbuttonorjoystickisspringapplied,which,whenreleased,willreturntotheneutralposition,themotionwillstopandtherelevantbrakewillautomaticallyapply.4.4.1 LegendNomenclatureAlegendcorrespondingtothedirectionofmotionislocatednexttoeachofthecontroldevices,(pushbuttonorjoystick).ThelegendplatesmaybeineitherEnglish(words)orInternationalsymbols.

Figure46ControlPendantLegends

Toimprovesafetyinoperation,therearedirectionalidentificationlegendsonthecranethatcorrespondtothelegendsonthecontroller.4.4.2 SwitchON

Establish power supply to the conductors via themain isolator (thismay be located on awall orsupportingcolumn).

Releasetheemergencystopbuttononthecontroller. Momentarilydepress theONpushbutton. Thiswillenergise the crane /hoistmain contactorand

allowsubsequentmotionstotakeplace.4.4.3 Pushbuttonoperation

1. Theoperatingcontrols(pushbutton)mustneverbemechanicallyblockedinanONposition.2. All opposing functions aremechanically interlocked e.g. hoist function cannot be operated at the

sametimeasthelowerfunction.3. Allcontrolpendantsarefittedwithdualpressure,twostage,pushbuttonstocontrolhoistandcrane

motions. Remote control stationsmay be fittedwith either push buttons or joysticks. For pushbutton operation depress the required pushbutton and the crane / hoist will move in thecorrespondingdirection. Selectthedirectionofmotionrequired. SlowSpeed.Tooperateslowspeedofadualspeedmotion,pressthebuttonintothefirststage. FastSpeed. Tooperatefastspeedofadualspeedmotion,pressthebuttonfully in(i.e.tothe

secondstage).



Change Speed from Slow to Fast. To change from slow speed to fast speed depress thepushbuttonfullyintothesecondstage.

ChangeSpeedfromFasttoSlowtravel/traversemotions.Tochangefromfastspeedtoslowspeed,reducepressureonpushbuttonandallowittocomeouttothefirststage. SwitchgearcontrolledThemotionwillfirststopandthencontinueatslowspeed. InvertercontrolledThemotionwilldeceleratetoslowspeed.

Change Speed from Fast to Slow Hoist. To change from fast speed to slow speed, removepressureonpushbuttoncompletelyandthenengageslowspeed.

SingleSpeed.Forcranes/hoiststhatareonlysinglespeed,pressthebuttontoeitherthefirstorsecondpressure.

4. Tomaintaintheselectedmotionthepushbuttonmustbehelddepressed.Releasingthepushbuttonwillstopthemotion.

5. PresstheEMERGENCYSTOPpushbuttonifnofurtheractionsaretobetaken.4.4.4 Joystickoperation

1. Theoperatingcontrols(joystick)mustneverbemechanicallyblockedinanONposition.2. All opposing functions aremechanically interlocked e.g. hoist function cannot be operated at the

sametimeasthelowerfunction.3. Control joysticksnormallyhave two stages to control thehoist and cranemotions, the first stage

being slow speed and the second stage fast speed. However, three or four stage units may besuppliedasanoption. Move the required joystick forwardand the crane /hoistwillmove in thecorrespondingdirection.Thespeedofthemotionwillbeproportionaltothestageselected. Selectthedirectionofmotionrequired. SlowSpeed.Tooperateslowspeedofadualspeedmotion,movethejoysticktothefirststage. Fast Speed. Tooperate fast speedof adual speedmotion,move the joystickdirectly to the

secondstage. ChangeSpeedfromSlowtoFast. Tochange fromslowspeedto fastspeed,movethe joystick

fromthefirststagetothesecondstage. ChangeSpeedfromFasttoSlowtravel/traversemotions.Tochangefromfastspeedtoslow

speed,returnthejoysticktothefirststage. SwitchgearcontrolledThecranewillfirststopandthencontinueatslowspeed. InvertercontrolledThecranewilldeceleratetoslowspeed.

Change Speed from Fast to Slow Hoist. To change from fast speed to slow speed, releasejoystickcompletelyandthenengageslowspeed.

SingleSpeed. For cranes /hoists that areonly single speed,move the joystick to anyof thejoystickstages.

4. Tomaintain the selectedmotion the joystickmustbeheld in the selectedposition. Releasing thejoystickwillstopthemotion.

5. PresstheEMERGENCYSTOPpushbuttonifnofurtheractionsaretobetaken.4.4.5 EmergencyStop

1 Before startingwork it is imperative to check the correct operation of the emergency stopbutton.Itisimportantthattheoperatorisconstantlyawareandmonitoringallcraneandhoistmovements and ready to activate the emergency stop should any abnormal circumstancesariseorsituationsoccurthatmayendangerthesafetyofpersonnelworkinginthevicinity.Beespeciallyawareofinstanceswherethecrane/hoistmayfailtostopwhenthepushbutton/joystickisreleasedorthecrane/hoiststartsormovesunexpectedly.

1. DepressingtheEMERGENCYSTOPpushbuttonwillcauseallmotionstostopandallbrakestoengage.2. Theemergencystopwilllockallcontrolsintheoffposition.3. Ifthebuttonisusedinanemergencystopsituation,ensurethatanyfaultsarereportedandrectified

beforereestablishingthepowersupply.4. Twist to release theEMERGENCYSTOPbutton. No functionswillbeoperativeuntil theemergency

stopisunlatchedandtheONpushbuttonoperat

Documents

Installation, Operation and Mantenance Instructions