ZX4 Hoist User Manual - ProservCrane Group...• BS 2573:Parts 1 and 2 - Rules for the design of Cranes. • 2006/95/EC - EC Low Voltage Directive. • EN ISO 12100 Parts 1 and 2 -

CDE Street Crane Company Limited Chapel-en-le-Frith High Peak SK23 0PH United Kingdom e-mail [email protected] web http://www.streetcrane.co.uk Tel +44 (0) 1298 812456 Fax +44 (0) 1298 814945 Street Crane Company Limited reserve the right to alter or amend the details given in this publication without prior notification. Street Crane Company Limited Document Reference: D1124.rev.H

ZX4 Hoist User Manual

Hoist Serial No.: __________

2008

(Hoist Unit)

FOREWORD

REF: mmmi006a.doc1/1

This manual has been carefully prepared to assistyou in the safe operation and maintenance of theStreet Hoist as described in the technical data sheet.It is in the interest of all parties involved in liftingoperations to ensure that procedures are carried outefficiently and safely.

Before using or starting any maintenance work on theHoist study this manual carefully. Obtain a completeunderstanding in order to ensure so far as isreasonably practical, the safe and efficient use of theHoist.

Provided that the recommended operation,maintenance and lubrication procedures are followed,you will maximise the Hoists life expectancy andtherefore have trouble free service.

The use of lifting equipment in the UK must be inaccordance with Health and Safety at Work Act 1974and the Factories Acts. Statutory regulations requirethat lifting equipment should be inspected andcertified at prescribed intervals by competentpersonnel (Factories Act, Section 27 Subsection 2).

These regulations further prescribe that theequipment be properly maintained (Factories ActSection 27 Subsection 1).

Street Crane Co. Limited, do not accept responsibility either for the manner in which these instructions areobserved or for any consequences thereof.

(ZX4 Hoist Unit) CONTENTS SHEET

REF : D1124CONT

CDE Page 1 of 1

Nameplates & Model Code Operating Instructions Inspection & Maintenance Schedule Hoist Lubrication Schedule SK-F Drive Unit Lubrication Schedule �ABM� Drive Unit Lubrication Schedule Hoist Brake Hoist Motor & Coupling Upper & Lower Limit Switches Rated Capacity Limiter Removal & Fitting of Wire Rope/Rope Guide �Slack Rope� Check On Hoist Units Rope terminations: Wedge & Socket Bottom Block Inspection & Maintenance Of Travel Drives Low Headroom Cross Travel Wheels �SK-F� Drive Unit Travel Brake Motors Type �EFB2� & �EFB3� Fault Finding Steel Wire Ropes Optional Extras

• 7101 Travel / Traverse Limit Switch • Ultimate Limit Switch • Control Pendants

Inspection & Maintenance Log

REF: MMMI014D

CDE 1/1

This Street Crane product has been designed in accordance with the following standards and regulations:-

The symbol specific to your product is displayed on hoist nameplate

• BS 466:1984 - Power driven overhead travelling

Cranes.

• BS 2573:Parts 1 and 2 - Rules for the design of

Cranes.

• 2006/95/EC - EC Low Voltage Directive.

• EN ISO 12100 Parts 1 and 2 - Safety of

Machinery.

• BS EN60204-1 Safety of Machinery, Electrical

equipment and machines.

• BS EN60204-32 Requirements for hoisting

machines.

• 98/37/EC - Machinery Directive (as amended).

• EMC Directive 89/336/EEC (as amended).

• BS EN61000-6-2 EMC Generic Immunity

Standard.

• BS EN61000-6-4 EMC Generic Emissions

Standard.

As stipulated by Annex V of the EC machinery

Directive.

• EC symbol affixed to equipment

• Technical documentation filed in

manufacturer’s works.

• BS 466:1984 - Power driven overhead

travelling Cranes.

• BS 2573:Parts 1 and 2 - Rules for the design

of Cranes.

• BS EN60204-1 Safety of Machinery,

Electrical equipment and machines.

• BS EN60204-32 Requirements for hoisting

machines.

• CSA Standard C22.2 No.33-M1984

Construction Of Cranes & Hoists.

• CAN/CSA Standard C22.2 No. 14-95

Industrial Control Equipment.

• UL Standard 508 Industrial Control

Equipment.

Brian Wood Quality Manager

30 April 2008

(ZX Series Hoist Units)

NAMEPLATES & MODEL CODE

REF: MMZX011A.DOC

1/2

NameplatesEach ZX series hoist unit distributed from Street Crane Company’s works is fitted with two nameplateswhich identify the characteristics of that particular model of hoist. Example nameplates are picturedbelow showing their position on the different constructions of hoist unit Each motor on the hoist is alsofitted with its own nameplate.When ordering spare parts for the ZX Hoist unit please supply all details from both nameplates.


NAMEPLATES & MODEL CODE

REF: MMZX011A.DOC

2/2

Hoist Model Code Breakdown

OPERATING INSTRUCTIONS ZX SERIES HOIST UNITS

REF: OIZX002D

CDE 1/7

This document should be kept in a safe place and all the personnel who are directly involved with the Hoist's operation should be made aware of its presence and location. The manual has been compiled to ensure the safety of personnel and to assist in maintaining the Street Hoist at its designed performance level. The manual provides details and explanations, concerning operation of the Hoist, procedures for planned inspection, overhaul and maintenance. These are imperative to maximise the Hoists life expectancy and avoid time lost to breakdown. It is important that all functions are carried out by fully trained and competent personnel.

In Great Britain a code of practice exists for the Safe Use of Cranes. BS 7121 covers the following subjects: -

• Safe systems of work.

• Management of the lifting operation.

• Planning of the lifting operation.

• Selection and duties of personnel and their minimum attributes.

• Maintenance of Cranes.

• Inspection, Testing and Examination.

It is advisable that a copy of this code of practice be kept alongside this manual.

In addition management and supervision have an important role to play in any safety programme by ensuring that: -

• The equipment is suitable for the job intended.

• A safety procedure is adopted for emergency situations i.e. power failure.

• A safe system of work is adopted for maintenance personnel.

Scope This document gives guidance on Street Crane Company's standard designs of ZX Hoist units.

Nomenclature Throughout the manual words appear in bold capital letters, these words are defined as follows:-

WARNING: Information that draws attention to the risk of injury or death. CAUTION: Information that draws attention to the risk of damage to the Hoist, process or

surroundings. NOTE: Information that draws attention to special methods of particular features.

Hoist Description. The Hoist / Crab Unit is of the wire rope type. The vertical motion is provided by an electrically driven drum. As the drum rotates the wire rope scrolls around the drum providing vertical movement of the hook. The hoist is fitted with a brake, which automatically applies when the motion is switched off.

The Cross Travel (where fitted) is the motion along either the Crane bridge girder(s) or along a single runway beam. The cross travel motor is fitted with a brake, which is applied automatically when the motion is switched off.


REF: OIZX002D

CDE 2/7

The Hoist has a maximum load that it is permitted to lift. This is referred to as the Safe Working Load (SWL). The SWL is clearly marked on the Hoist and the hook. For Crabs with a main and auxiliary hoist, a selector switch is provided which allows only one hoist to be used at any one time. A load must ONLY be attached to the selected hoist. Also located on the Hoist are data plates identifying the following: -

• The manufacturers name.

• The serial number.

• The year of manufacture.

• Hoist classification.

• Mechanism classifications.

The information on these data plates will be required when ordering replacement component parts.

Control Equipment (where fitted) The electrical control equipment is located in the hoist panel, which is mounted on one end of the hoist/crab and contains switches for the hoist and cross traverse motions. This panel contains fuses for protection against short circuit.

The Hoist movement is controlled from pushbuttons located in a Pendant. One button is provided for each direction of movement. There are also buttons for switching the Hoist controls ON and OFF.

The ZX range of hoist units is available in three constructions to suit varying applications (ZX3 hoist units pictured): -

• Stationary hoist - Suitable for base mounting (see Fig OI0002/1.).

• Low Headroom - Suitable for running on a single girder runway beam (see Fig OI0002/2.).

• Crab Unit - Suitable for running on a double girder crane (see Fig OI0002/3.).

Fig OI0002/1. Fig OI0002/2. Fig OI0002/3.

Classification A method of classification exists which defines the duty of each hoist dependant upon its application. Each hoist and its individual components are designed to suit their particular application. This can vary from light duty to very heavy duty. The classification not only gives an indication of the type of duties that the hoist will perform but also its design life and the frequency of maintenance routines.

The classification for the hoist and the cross travel as a whole is represented by the letter “M”. This letter is followed by a number from 1 to 8. Generally the higher the number, the more arduous the duty. For a more detailed explanation of the classification method refer to BS 466:1984.

The classification of each hoist is marked on the hoist nameplate and is also indicated on the Technical Data Sheet. It is essential that you understand the system of classification and operate the hoist within its rating. “KNOW YOUR HOIST”.


REF: OIZX002D

CDE 3/7

Service Conditions Street Cranes Overhead Travelling Cranes are designed to operate in “Normal service conditions” as defined in BS 466:1984 namely: -

• Indoor use.

• Ambient temperatures from -10 to +40°C with no sources of local heating, such as furnaces or radiant panel heaters.

• For use in clean still contamination free atmosphere at normal levels of humidity.

Requirements For Outdoor Hoist Units Hoists for outdoor use are supplied with additional special equipment for protection against the elements. They should not be used outdoors unless this special equipment is fitted. Street Crane Company recommends that hoist units be parked under a protective canopy when not in use.

General There is no single factor more important than minimising the possibility of injury to the Operator and/or those working in the area, or damage to property, equipment and/or materials. No Operator should be permitted to use the equipment unless they are familiar with its operations. They should be physically and mentally fit and trained in Safe Hoisting Practices. Hazards can only be minimised by care, common sense and the operator being alert at all times.

Apart from Hoist operation, Safe Hoisting Practices involve a programme of periodic inspection and preventative maintenance. Part of the operator's training should be to make him/her aware of potential malfunctions requiring adjustments or repairs and the need to bring these to the attention of the supervisor for corrective action (see ‘Fault Finding’).

Safe Hoisting Practices The following information serves as a guide to safe hoisting practice and an operator adhering to these will quickly find that he/she is able to work both smoothly and quickly, without prejudicing safety and equipment.

It should be emphasised that the safety advice and maintenance details included in this document should be made available where they can be most effective. It is your responsibility to ensure that this information is made available at THE PLACE OF WORK.

General Operating Conditions 1. Read these instructions carefully.

2. Know where the safety, fire and first aid equipment is located and how to use it.

3. Ensure that the Hoist is operated within its safe working load (SWL).

NOTE: The weight of any lifting gear should be taken into account when assessing the load on the Hoist (it may be also be necessary to allow for any adhesion between the load and its supports).

4. Ensure that the SWL data plates are clearly visible to the operator at all times.

5. All the relevant accident prevention, safe lifting and slinging procedures should be obeyed.

6. Use only properly trained and competent personnel who have been made aware of their relevant responsibilities under the National regulations, norms and guidelines.

7. Check all around visibility and carefully note both permanent and temporary hazards.


REF: OIZX002D

CDE 4/7

8. Work with an authorised slinger and operate only to his signals.

9. Ensure that the operator knows the full meaning of the hand signals.

10. Do not park over fumes, steam or dangerous processes when in operation.

11. Do not use the Hoist for anything other than its intended purpose.

12. Ensure that all the necessary test certificates and maintenance records are up to date.

Pre-Start Checks 1. Ensure that a “MEN WORKING OVERHEAD” or a “PERMIT TO WORK” is NOT in force.

2. Ensure that no one is working on or around the Hoist where they could be struck.

3. Make a visual inspection to ascertain that the Hoist is in good working order, paying particular attention to the rope and hook.

Daily Checks ( at the start of each day/shift ) 1. Ensure that each function button on the pendant performs its stated operation.

2. Check the overhoisting and overlowering limit switch devices work properly. To do this raise or lower the empty hook slowly into its respective limit position and prove operation of the switch.

3. Check the operation of any travel limit switches.

CAUTION: Do not use any of the limit switch devices as a regular method of stopping a motion. They are intended as emergency devices for the safety of personnel.

4. Check the operation of the hoist brake. To do this lift a load just clear of the ground and release the UP pushbutton.

In the event of malfunctioning equipment or should any anomalies be noticed then they should be reported immediately. Do not operate the Hoist until the fault has been REPAIRED by a qualified person.

Operating Or Lifting Load 1. Before lifting, ensure that the hoist is directly above the load and that it is slung evenly and

correctly.

2. DO NOT side pull. Lift all loads in a vertical plane.

3. Ensure you can either see the hook or load clearly or are receiving signals from someone who can.

4. Ensure that the load is free to lift.

5. Ensure the path of the load and Hoist are clear of personnel and objects.

6. ALWAYS hoist into the load at slow speeds, avoid snatching or sudden hoist movement. Running into the load at full speed imposes excessive overloads on the Hoist and could result in failure of parts and/or the supporting structure.

7. DO NOT repeatedly press and release the motion buttons more than necessary. Each start causes an in-rush of current greater than the running current which leads to overheating or burnout of the motor if continued to excess.

8. DO NOT run hoist into the travel stops at full speed.

9. DO NOT continue to travel once the hoist has come to a stop against the travel stops. This will cause localised damage to the rail or runway beam.


REF: OIZX002D

CDE 5/7

10. DO NOT lower the hook so far as to allow the ropes to go slack. If this happens the operator should determine that the rope is properly reeved on the drum before moving a load.

11. DO NOT leave a load suspended from the hoist unsupervised.

12. DO NOT stand below the load or allow any other personnel to do so.

13. DO NOT lift loads over people. Make personnel aware of approaching loads using audible warnings when necessary.

14. DO NOT travel with a load dragging along the floor.

15. DO NOT use the Hoist for handling personnel.

16. ENSURE that adequate clearance is maintained between the load or lifting attachment and the hoist or crane structure (see Fig. OI002/4).

Fig OI002/4

Leaving The Hoist 1. The Pendant control: -

• Must always be turned OFF when not in use.

• The operating controls must never be mechanically blocked in an ON position.

2. Never leave the Hoist unless the mains isolator is in the OFF position.

3. Always leave the Hoist in a safe condition. Remove any slings from the hook and raise the hook to the upper position.


REF: OIZX002D

CDE 6/7

Power Failure The Crane supervisor should establish a safe operating procedure if there is a power failure. The following procedure is recommended: -

1. Switch off the power supply to the Crane at the main isolator until the electrical supply is restored.

2. A load left suspended in mid-air and considered to be a hazard should be lowered to the floor using the hand brake release lever.

• Fence off and clear all personnel from the area under the load.

• Obtain a permit for access to the hoist brake.

• Carefully lower load to the floor using the hoists hand release fail-safe brake. The load must be lowered under strict control only a few inches at a time before re-applying the brake.

CAUTION: Serious damage and subsequent failure, of the gearbox may result if the load is allowed to run away.

• When load is firmly supported at ground level, re-apply the brake mechanism.

3. When the electrical supply is restored, re-establish the Crane power supply.

4. Carry out the Pre-Start/Daily checks.

Legend Nomenclature The legend plates on control units are provided in either English or International symbols.

Pendant Operating Instructions (where fitted)

Operating Functions All control pendants are fitted with dual pressure pushbuttons to control hoist and crane motions. To maintain the selected motion the pushbutton must be held depressed. All the motion pushbuttons are spring loaded so that when a button is released the particular motion ceases and the brake is automatically applied.

Single Speed. To operate a single speed motion, press the button fully in.

Slow Speed. To operate slow speed of a dual speed motion, press the button in to the first stage.

Fast Speed. To operate fast speed of a dual speed motion, press the button fully in (i.e. to the second stage).

Change Speed. (Slow - Fast All motions). To change from slow speed to fast speed depress the pushbutton fully in to the second stage.

Change Speed. (Fast - Slow for the long travel motion). To change from fast speed to slow speed, reduce pressure on push button and allow it to come out to the first stage.

• Switchgear controlled - The crane will first stop and then continue at slow speed.

• Inverter controlled – The crane will decelerate to slow speed.

Change Speed. (Fast - Slow hoist and traverse motions). To change from fast speed to slow speed, release the push button to the first pressure. The hoist will decelerate to slow speed.


REF: OIZX002D

CDE 7/7

Emergency Stop. (EMG. STOP) WARNING: Before starting work it is imperative to check the correct operation of the

emergency stop button. 1. Depressing the EMG. STOP push button will cause all motions to stop and all brakes to

engage.

2. The emergency stop will lock all controls in the off position.

3. If the button is used in an emergency stop situation, ensure that any faults are rectified before re-establishing the power supply.

4. Twist to release the EMG. STOP button.

NOTE: No functions will be operative until the emergency stop is unlatched and the ON pushbutton operated.

Switch ON 1. Establish power supply to the conductors via the main isolator (this may be located on a wall

or supporting column).

2. Set the isolator on the end of the crane panel to ON.

3. Momentarily depress the ON pushbutton. This will energise the main contactor and allow subsequent motions to take place.

Pushbutton Operation 1. Depress the required pushbutton. The crane/hoist will move in the corresponding direction.

2. Releasing the pushbutton will stop the motion and apply the corresponding brake(s).

3. Press the EMG. STOP pushbutton if no further actions are to be taken.

Safety Switches An overhoist/overlower limit switch is fitted to all hoists. This prevents the hook from going too high and damaging the hoist and from going too low so as to allow the ropes to go slack. This is a safety device and should not be used as a normal method of stopping the hoist.

CAUTION: Certain crane configurations allow the upper hook position to be set at a higher level than the underside of the bridge girders. In such instances the operator must take extreme care when lifting to ensure that adequate clearance is maintained between the load or lifting attachment and the hoist or crane structure (see Fig. OI001/4).

The ultimate limit switch (optional) is used as an emergency limit should the hoist limit fail. It is operated by the bottom block and will trip out the mains contactor. The bottom block must be lowered manually and the limit must be reset manually. Should the ultimate limit switch operate, then the reason for the bottom block passing the normal working limit must be investigated before continuing to use the crane.

ZX SERIES OVERHEAD TRAVELLING CRANES & HOISTS INSPECTION & MAINTENANCE SCHEDULE

REF: MMZX007C

CDE 1/4

General To ensure that your overhead travelling crane continues to be safe in operation and operates as efficiently as possible, regular planned inspection and maintenance of all the associated equipment is essential. A preventative maintenance programme is included in the following pages. Preventative maintenance is essential maintenance work, including lubrication, which is undertaken at pre-set intervals with the objective of keeping the crane or hoist in a serviceable condition.

Follow the recommended maintenance and lubrication procedures to provide maximum protection for the equipment. Where replacement components are required use only genuine Street Crane parts. Modifications to the crane or any of its mechanisms should not be carried out without the approval of Street Crane Company Limited. Failure to adopt these recommendations may invalidate your warranty.

Attention is drawn to the daily checks, which should be performed before operating the crane or hoist.

In addition, the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) require that cranes and hoists are examined at regular intervals throughout its life in accordance with an appropriate examination scheme. The user has the responsibility for ensuring compliance with these regulations. BS 7121-2:2003 gives recommendations for the pre-use checks, in-service inspection, thorough examination and testing of cranes, including associated equipment, and the means by which tests are to be carried out. The user should maintain records of all inspections.

Operating and Maintenance Personnel Only competent personnel should be permitted to operate and maintain the equipment. You should ensure that the person carrying out the task has such appropriate practical and theoretical knowledge and experience of the equipment in question as will enable them to perform the task safely and recognise any hazards associated with the work. They should be physically and mentally fit and trained in Safe Hoisting Practices.

Anyone working with or on the equipment should be made aware of their relevant responsibilities under the Health and Safety at Work Act 1974 and Lifting Operations and Lifting Equipment Regulations 1998. No work of any kind should be authorised to persons who are under the influence of narcotics, alcohol or medication, which affects their ability to react.

Hazards can only be minimised by care, common sense and being alert at all times.

If required, Street Crane Company is able to provide trained service technicians to assist in maintenance procedures.

Maintenance Access The crane may be fitted with full or partial maintenance access platforms or, for certain types of crane, no provisions all. The extent of any crane platforms and access to these platforms has been agreed with the purchaser and Street Crane. Where no platforms or only partial access has been provided on the crane, separate or additional access equipment will be required to service some of the components. These components should be accessed via a secure, mobile or temporary structure e.g. tower scaffold, self-standing stair platforms, scissor-lift or cherry picker. All access equipment should be assembled and operated by trained personnel in accordance with the manufacturers instructions following the appropriate health and safety regulations and procedures.

The following should be considered when choosing the most appropriate type of maintenance access equipment.

• Floor space available for the access equipment

• Working height above floor level

• Number of personnel required to gain access at high level

• Total weight of any parts to be removed/replaced


REF: MMZX007C

CDE 2/4

Maintenance Safety Procedure When personnel are required to work on cranes for inspection, maintenance or other reasons, a system should be in operation to ensure that they are not endangered by movement of the crane and that a secure working place is provided. Personnel should follow such a procedure. Where no formal procedure exists, Street Crane would recommend the following:

On commencing any maintenance work on the crane or hoist:

1. Obtain the necessary authorisation / permit to work.

2. Park the crane or hoist in a designated maintenance position.

3. Follow the appropriate health and safety regulations and procedures.

4. Remove any loads or attachments from the hook and ensure that the bottom block is suitably supported to prevent accidental runaway.

5. Disconnect the mains switch and safeguard against unauthorised powering up, by placing locks and warning notices in the appropriate positions.

CAUTION: Some maintenance procedures are more effectively performed with power to the equipment. If work has to be carried out on live parts, an additional competent person must be available to actuate the power isolating switch in an emergency.

6. To avoid injuries, use only insulated tools and equipment.

7. On completion of any maintenance work, ensure all fixings, guards, covers, drip trays, etc. are replaced.


REF: MMZX007C

CDE 3/4

MECHANICAL Duty A B C D E

M3 • M4 • M5 •

BRAKES: Carry out a functional check of each of the motion brakes to ascertain that they operate efficiently. Clean, adjust and renew worn parts where necessary. In particular check wear on the rotor, and the condition of the spline on both rotor and hub. Also check the condition of the hub key and keyway.

M6 •

M3 • M4 • M5 •

MOTORS & COUPLINGS: Clean motor fins and fan cowling. Check security of motor and coupling fixings.

M6 • M3 • M4 • M5 •

GEARBOXES: Inspect around gearbox casing, filler and drain plugs and around oil seals for signs of lubrication seepage. Clean ventilation plug. Tighten fixings and renew seals if necessary. M6 •

M3 • M4 • M5 •

GEARBOXES: When gearbox oil is drained during oil replacement, remove the gearbox inspection cover and visually check the gear teeth for wear. Check keys and keyways for security. M6 •

M3 • M4 • M5 •

WIRE ROPE AND FIXINGS: Visually inspect the hoist rope for damage, wear and broken wires. Maintain or renew as necessary. Check security of the rope anchors fixings.

M6 •

M3 • M4 • M5 •

ROPE GUIDE:

Examine for signs of wear or damage.

M6 • M3 • M4 • M5 •

HOIST BARREL & ROPE SHEAVES: Examine the rope groove for wear or damage due to rope indentations.

M6 • M3 • M4 • M5 •

DRIVEN COMPONENTS: Check the condition of the wheels for signs of wear on the tread and inside of the flanges. Inspect the condition of the geared pinions and wheels for damage and wear. Ensure correct meshing. M6 •

M3 • M4 • M5 •

BOTTOM BLOCK: Check for cracks, cold deformation, wear and freedom of rotation of the sheaves and hook. Ensure hook safety catch operates correctly. Check security of hook nut. M6 •

M3 • M4 • M5 •

ENDSTOP & TORQUE ARM RUBBER BUFFERS (where fitted): Check the condition of the end stops and rubber buffers. Replace if damaged.

M6 •

Maintenance Intervals: - A = Weekly, B = Monthly, C = 3 Monthly, D = Annually, E = Every 2 Years


REF: MMZX007C

CDE 4/4

MECHANICAL Duty A B C D E

M3 • M4 • M5 •

HOIST / CRANE STRUCTURE Visually inspect overall structure for damage and unusual rubbing marks. Check rail for wear or localised damage. Check security of a reasonable quantity of the bolts. Visually examine welds for signs of cracks. Clean off any corrosion and apply an approved protective treatment to the surface.

M6 •

ELECTRICAL Duty A B C D E

M3 • M4 • M5 •

ELECTRCIAL CABLES: Check for damage or loose connections. Check cable insulation shows for signs of brittleness (does not crack when flexed) or overheating (discolouration). Replace where necessary. M6 •

M3 • M4 • M5 •

DOWNSHOP LEADS (Overhead Crane Only): Inspect collector arms and carbon shoes for signs of damage or wear. Replace where necessary. Check joints and insulation for signs of arcing. Rectify as necessary. M6 •

M3 • M4 • M5 •

TRAVEL/TRAVERSE LIMIT SWITCHES (When fitted): Inspect for wear or damage. Check for correct operating position.

M6 • M3 • M4 • M5 •

OVERHOIST/ LOWER LIMIT SWITCHES. Inspect for wear or damage. Check for correct operating position.

M6 • M3 • M4 • M5 •

OVERLOAD SWITCH (RCL): Physically check components for wear or damage. Check cables, connections and mounting.

M6 •

Verify calibration of RCL by applying the necessary calibrated load. ALL •

M3 • M4 • M5 •

PENDANT AND/OR RADIO CONTROLLER (where fitted): Check that controller casing, pushbuttons and their rubber seals are undamaged. Pendant strainer wire fixings secure. Cable entry seal undamaged. M6 •

M3 • M4 • M5 •

ELECTRICAL PANELS: Inspect relays and contactors for security and physical damage. Renew if signs of damage or overheating are apparent. Ensure enclosure door closes securely. Lightly lubricate panel hinges and seals. Clean enclosure filters where fitted.

M6 •

Maintenance Intervals: - A = Weekly, B = Monthly, C = 3 Monthly, D = Annually, E = Every 2 Years

(Spur & Pinion Travel Drive Assembly)

INSPECTION & MAINTENANCE SCHEDULE

REF : mmlt004a.doc1/1

Duty A B C D E

BRAKES: M3 •Carry out a functional check of the motion brakes to ascertain that M4 •they operate efficiently. If not, dismantle, clean, adjust and renew M5 •worn parts where necessary. M6 •DRIVEN COMPONENTS: M3 •Check the condition of the wheels for signs of wear on the tread & M4 •flanges. Inspect the condition of the geared pinion and wheels for M5 •damage and wear. Ensure correct meshing. M6 •AXLE AND BEARINGS M3 •Check wheel axle and bearings for signs of damage or wear. M4 •

M5 •M6 •

WIRES AND CABLES: M3 •Inspect wires and cables for signs of damage and ensure that M4 •each wire is secure. M5 •

M6 •Maintenance Intervals:- A = Weekly, B = Monthly, C = 3 Monthly, D = Annually, E = Every 2 Years

(ZX4 Series Hoist Units) LUBRICATION SCHEDULE

REF : MMLU010D

CDE 1/1

ITEM Duty A B C D E Qty Lubricant Characteristics M3 • M4 • As M5 M6 • Req�d

HOIST GEARBOX: ! Check level via level plug and top up as required.

M7 • M3 • M4 •

Low Headroom

14L M5 • M6 •

Drain and refill to level plug with new oil

M7 •

Stationary Hoist & Crab

10 L

Industrial gear oil :- ISO classification 460 Specific gravity 0.904 Pour point -18°C Closed flash point 215°C Viscosity @ 40°C 460cSt @100°C 32cSt Viscosity Index 96

M3 • M4 • M5 • As M6 • Req�d M7 •

WIRE ROPE: " Ensure that rope is clean and free from dirt/grit. Apply lubricant to the full length of rope using a brush, swab or spray.

�Street-Drako Compound� or similar oil based rope lubricant with additives for good penetration, adherence and corrosion protection. Effective temperature range -20 to +60°C.

M3 • M4 • M5 • As M6 • Req�d M7 •

OPEN GEARS: # Apply evenly to all teeth. Ensure that no grease reaches the runner tread.

Gear compound :- Appearance : Heavy black fluid Specific gravity 1.15 Timken OK load 60lbs Viscosity @ 40°C 1000-1300 cSt @100°C 450-550 cSt

M3 • M4 • M5 • 3 M6 • shots M7 •

HOOK BLOCK THRUST BEARING: $ Apply via grease nipple located on hook crosshead.

EP Grease :- Drop point 175°C Pour point -10°C Flash point 280°C Timken OK load 45lbs Viscosity @ 40°C 175cSt Viscosity Index 80

Unless otherwise specified, the above lubrication schedule is suitable for an ambient temperature range of -10 to +55°C Lubrication Intervals:- A = Weekly, B = Monthly, C = 3 Monthly, D = Annually, E = Every 2 Years

Lubrication Points Stationary Hoist & Crab Unit Low Headroom Hoist Unit

(“SK-F” Drive) LUBRICATION SCHEDULE

REF : MMLU017A 1/1

ITEM Duty A B C D E Qty Lubricant Characteristics

GEARBOX : M3 • Industrial gear oil :- Check level via inspection M4 • ISO classification 220 plug and top up as required. M5 • As Specific gravity 0.897 M6 • Req’d Pour point -18°C M7 • Closed flash point 205°C M8 • Viscosity @ 40°C 220.2cSt Drain and refill with new oil. M3 • @100°C 19.5cSt M4 • Viscosity Index 100 M5 • As M6 • Req’d M7 • M8 • GEARBOX AND MOTOR M3 • EP Grease :- BEARINGS : M4 • Drop point 175°C Only applicable to frame M5 • 2 Pour point -10°C sizes 225 or higher M6 • shots Flash point 280°C Apply via grease nipple. M7 • Timken OK load 45lbs M8 • Viscosity @ 40°C 175cSt Viscosity Index 80

The above lubrication schedule is suitable for an ambient temperature range of -10 to +55°C Lubrication Intervals:- A = Weekly, B = Monthly, C = 3 Monthly, D = Annually, E = Every 2 Years

�ABM� Drive LUBRICATION SCHEDULE

REF: MMLU012A

CDE 1/1

ITEM Duty A B C D E Qty Lubricant Characteristics M3 M4 Non M5 M6 M7

GEARBOX:

M8

Gearbox is greased filled and does not require any lubrication.

The above lubrication schedule is suitable for an ambient temperature range of -10 to +55°C Lubrication Intervals:- A = Weekly, B = Monthly, C = 3 Monthly, D = Annually, E = Every 2 Years

HOIST BRAKE

REF: MMN4002G

CDE 1/6

Brake Parts List Ref Description Ref Description 1 Armature plate 7 Stator 3 Hub 10 Assembly fixings 4 Rotor 13 Brake seal (optional) 6a Mounting Flange 14 Hand release (optional) 6b Friction plate

Brake Identification Content Nameplate example: Size 06 – 16

Brake type – brake size Type no.

Rated voltage Rated power Rated brake torque

Date of manufacture

Content Nameplate example: Size 18 – 25

Brake type – brake size

Rated voltage Rated power

Rated brake torque Date of manufacture

Type no

HOIST BRAKE

REF: MMN4002G

CDE 2/6

Brake Data

BFK458- 06

BFK458-08

BFK458-10

BFK458-12

BFK458-14

BFK458-16

BFK458-18

BFK458-20

BFK458-25

Nominal Air Gap ‘a’ (mm) + 0.1mm - 0.05mm

0.2 0.2 0.2 0.3 0.3 0.3 0.4 0.4 0.5

Max Air Gap ‘a’ (mm) 0.5 0.5 0.5 0.75 0.75 0.75 1.0 1.0 1.25

Max. Rotor thickness (mm) 6.0 7.0 9.0 10.0 10.0 11.5 13.0 16.0 20.0

Min Rotor thickness (mm) 4.5 5.5 7.5 8.0 7.5 8.0 10.0 12.0 15.5

Max. adjustment admissible wear (mm)

1.5 1.5 1.5 2.0 2.5 3.5 3.0 4.0 4.5

Tightening torque of assembly fixings (Nm)

2.8 5.5 9.5 9.5 23 23 23 46 46

Tightening torque of hand release lever (Nm)

2.8 2.8 4.8 4.8 12 12 23 23 40

Mass of brake assembly complete (kg)

0.75 1.2 2.1 3.5 5.2 7.9 12.0 19.3 29.1

HOIST BRAKE

REF: MMN4002G

CDE 3/6

Maintenance of the Brake To maintain a safe and efficient braking action, regular inspection of the brake is essential. When inspecting the brake, particular attention should be made to checking the air gap and the condition of the spline.

Checking / Setting the Air Gap The air gap ‘a’ (between the stator and the armature plate) should be checked in at least three positions around the brake using non-magnetic feeler gauges. The air gap should not exceed the max. Air Gap figure stated (see Brake Data).

Where adjustment is required, slacken the assembly fixings (10)

Adjust air gap by turning the adjustment tubes (9) until the nominal air gap ‘a’ is reached.

• If the air gap is too large, screw the adjustment tubes into the stator (7).

• If the air gap is too small, screw the adjustment tubes out of the stator (7).

NOTE: 1/6 turn adjusts the air gap by approx. 0.15mm

• Re-tighten the assembly fixings to the recommended torque value (see Brake Data)

• Re-check the air gap and repeat adjustment if necessary.

HOIST BRAKE

REF: MMN4002G

CDE 4/6

Changing the Rotor (brake disc) / Inspecting the brake hub

CAUTION: Before changing the rotor, lower the bottom block to a suitable level (floor or

platform) and allow it to rest on a solid support.

• Disconnect the supply to the brake.

• Remove the brake seal (where fitted).

• Loosen the assembly fixings evenly and remove them (take care to support the brake body).

• Remove the brake body, taking note of its orientation.

• The old rotor (brake disc) will now be exposed. Withdraw the rotor from its hub by hand.

• Before replacing the brake rotor, check the condition of the splining on the brake hub. Replace if damaged.

• Check the braking surface on the mounting flange or friction plate. Replace where strong scoring is observed.

• Measure both the new rotor thickness and length of protrusion of the adjustment tubes from the back of the brake.

• Calculate the distance between the stator and the armature plate as follows: -

Distance = Rotor thickness + Nominal Air Gap ‘a’ – adjustment tube height

• The adjustment tubes should be unscrewed until the calculated distance between the stator and the armature plate is reached.

• Slide the new rotor onto the hub.

• Replace the brake assembly in the same orientation as originally.

• Replace the assembly fixings and torque to the value stated in Brake Data.

• Check and adjust, if necessary, the Brake Air Gap ‘a’.

• Replace the brake seal (where fitted).

• Re-connect the brake supply.

HOIST BRAKE

REF: MMN4002G

CDE 5/6

Fitting the Brake Seal (optional) • Pull the cable through the seal (13)

• Push the seal over the stator (7)

• Press the lips of the seal (13) into the grooves in the stator (7) and the mounting flange (6). Where a friction plate is fitted, the lip of the seal must be pulled over the flared flange.

HOIST BRAKE

REF: MMN4002G

CDE 6/6

Fitting the Hand Release (optional) The hand release mechanism serves to release the brake manually. For safety reasons, the hand release is spring loaded and returns to its original position (brake applied) automatically.

• Insert the compression springs (14.2) into the bore holes of the armature plate

• Fit the washers (14.3) onto the hexagon screws (14.4) and assemble through the compression springs (14.2) and the stator (7)

• Fit the barrel nuts (14.5) into the holes provided in the hand release (14.1)

• Position the hand release (14.1) over the stator (7) and tighten the hexagon screws (14.4) into the barrel nuts (14.5) until the armature plate (1) moves towards the stator (7)

• Adjust the gap between the armature plate (1) and the stator (7) using the hexagon screws (14.4) to achieve dimension (‘s’+’a’)

• Fit the complete brake assembly onto the hoist. Torque the assembly fixings to the value stated in Brake Data

• Check, and adjust if necessary the Hand Release Clearance (‘s’) and Nominal Air gap (‘a’) using hexagon screws (14.4)

• Fit the hand release lever to the hand release (14.1). Torque to the value stated in Brake Data

Brake Size Nominal Air

gap ‘a’ (mm)

Hand Release Clearance ‘s’

(mm) ‘s’ + ‘a’ (mm)

06 0.2 1 1.2

08 0.2 1 1.2

10 0.2 1 1.2

12 0.3 1.5 1.8

14 0.3 1.5 1.8

16 0.3 1.5 1.8

18 0.4 2.0 2.4

20 0.4 2.0 2.4

25 0.5 2.5 3.0

(ZX4 Series Hoist Unit)

HOIST MOTOR & COUPLING

REF : MMZ4003A.DOC

1/2

Warning: Ensure that the mains power is isolated before starting any maintenance work.

Maintenance All hoist motors fitted to ZX4 hoists are maintenance free and require no lubrication.

Hoist Motor Replacement • Disconnect the power cables from the motor terminal box making notes of each cable and its

relative terminal connection.• Support the motor and remove the four retaining nuts and spring washers which fasten the motor to

the gearbox.• Carefully withdraw the motor noting the orientation of the motor terminal box.• Remove the old motor complete with key and replace with the new ones. Note: The motor coupling

should be re-used if servicable.• Carefully refit the full assembly (including coupling) onto the side of the hoist gearbox ensuring that

the orientation is correct and that the coupling meshes correctly• Replace the retaining nuts and spring washers and torque to 43Nm.


HOIST MOTOR & COUPLING

REF : MMZ4003A.DOC

2/2

Single Speed Terminal Connections

Dual Speed Terminal Connections Slow supply connections 1U, 1V, 1WDual supply connections 2U, 2V, 2W


UPPER & LOWER LIMIT SWITCHES

REF : MMZ4004A.DOC

1/1

Each ZX4 model hoist unit is fitted with the upper and lower limit switches. These are intended as asafety feature and should not be used deliberately to prevent overhoisting or overlowering. The limitswitches are actuated by the travel movement of the rope guide.

Setup • Lower the hook to the desired lowest operating level. (Normally the lower limit is set to stop the hook

approx. 150mm clear of the operating level when lowering at full speed). CAUTION: Ensure that there is a minimum of 10mm between the rope guide at its lowest position and the rope anchors onthe barrel.

• Slacken the two bolts securing the limit switch mounting bracket and slide the limit switch up to therope guide until the limit switches.

• Tighten the bracket bolts. CAUTION: Do not run the hoist until the lower limit switch bracket has been tightly fixed or correctly positioned.

• Test the limit position.• The upper limit switch is pre-set for both the stationary hoist and the crab unit to suit the hoist

design. CAUTION: The factory pre-set should not be tampered with. • The position of the upper limit switch for a low headroom hoist unit should be set by the end user

depending on its respective runway flange width (F). The figures shown in the graphs below indicatehighest positioning of the bottom block for the varying flange widths. CAUTION: Serious damage to the hoist unit / rope may result if the upper limit is set at less than the recommended ‘C’ dimension.


RATED CAPACITY LIMITER (WHERE FITTED)

REF: MMZ4005A.DOC

1/1

The rated capacity limiter is used to prevent the hoist from lifting a load in excess of the Safe WorkingLoad (SWL). If the hoist becomes overloaded, the limit switch will trip and all motions will becomeinactive with the exception of the hoist lower motion. Once the load has been removed then the limitswitch will automatically reset and all motions will become active again.Each rated capacity limiter despatched form Street Crane is pre-loaded to suit the SWL and thenumber of falls of the hoist unit.

Setting the Rated Capacity Limiter

• Ensure that the grub screw directly above the limit switch is unscrewed to clear the switch actuator.• Load the hoist with the calibrated test weight. To set the rated capacity limiter it is recommended

that a load of SWL + 5% is applied (Table Z4005/1). Where a dual switch rated capacity limiter isfitted, the first limit should be set to warn of approach of the SWL (approx. 95% of SWL).

• Tighten the grub screw directly above the limit switch until the switch just operates.• Lower the load and repeat the lift at slow hoisting speed to prove the operation of the switch.

Safe WorkingLoad (kg)

Setting Load forOverloadprotection

(SWL + 5%) (kg)

Safe WorkingLoad (kg)

Setting Load forOverloadprotection

(SWL + 5%) (kg)500 525 6300 6615630 661.5 7500 7875800 840 8000 84001000 1050 10000 105001250 1312.5 12500 131251600 1680 15000 157502000 2100 16000 168002500 2625 20000 210003200 3360 25000 262504000 42005000 5250

Table Z4005/1

(ZX4 Series Hoist Units)

REMOVAL & FITTING OF WIRE ROPE / ROPE GUIDE

REF: MMZ4001B.DOC

1/3

The following operations are most effectively carried out with the power supply to the hoist switched ON.

Suitable safety precautions must be made to ensure that travel & traverse motions are not accidentally activated.

Removal of Wire Rope• Lower the bottom block to a suitable level (floor or platform) and allow it to rest on a solid support.• Release the end of the rope which is anchored at the wedge and socket.• Remove the two side frame fixings and pivot the side frame open. (see Fig. Z4001/1)• Remove the two fixings which hold the limit bar in place and remove the limit bar assembly.• Remove the rope guide.• Allow the remainder of the rope to turn off the barrel.• Remove the barrel clamps.• Remove the old rope.

Fig. Z4001/1

Before fitting a new rope a visual inspection of the sheaves, barrel grooves and rope guide should bemade (see Steel Wire Ropes : Sheave Groove Inspection). Check the specification of the replacementsteel wire rope ensuring that it is exactly the same as that of the old rope. Fitting Of Wire Rope • Mount the new rope coil on a pair of stands, supporting it with a shaft through the centre.• Anchor one end of the rope to the hoist barrel using the barrel clamps (Torque to 29Nm) allowing

the end of the rope to project 30-40mm. Do not forget the spring washers.• Tightly wind approx. 15 turns of the rope onto the barrel applying tension to the rope with suitably

gloved hands.• Fit the rope guide (see Fitting the Rope Guide).• Replace the hoist limit bar assembly ensuring that the rope guide roller bearing is seated in the

channel section and that the limit switch is located correctly.



REF: MMZ4001B.DOC

2/3

• Wind the remainder of the rope onto the barrel, leaving just enough rope to pass through the firstbottom block sheave. Note: The closer the bottom block to the underside of the hoist at this stage,the less chance of incurring any twist in the wire rope.

• Pass the end of the rope through the first pulley on the bottom block using a pulling stocking or apiece of string to guide the wire rope. Ensure that the correct reeving arrangement is maintained(see Fig Z4001/2).

2 fall hoist units only• Anchor the free end at the wedge and socket (see Rope Terminations)

4, 6 & 8 fall hoist units• Unwind the hoist rope sufficient to pass through the sheave on the hoist.• Pass the wire rope through the sheave on the hoist.• Continue to thread the free end of the rope through the system of pulleys, unwinding

sufficient wire rope between each pass. This will minimise the chances of incurring any twistinto the wire rope. Ensure that the correct reeving arrangement is maintained(see Fig Z4001/2).

• Anchor the free end at the wedge and socket (see Rope Terminations)• Fit the wedge and socket into the anchor housing on the hoist unit and secure with split pin.• Pivot the side frame into position and replace the fixings.• Run through the hoists operating cycle for a number of operations at reduced speeds and loads to

allow the rope to adjust to the working conditions.• Check the operation of the limit switches.• Check the security of the barrel clamps.• Check the wedge and socket termination to ensure that the rope has not slipped. Fitting The Rope Guide• Smear the inside of both halves of the rope guide with rope lubricant (see lubrication schedule).• Fit the bottom half of the rope guide (see Fig Z4001/3) to the open side of the barrel and rotate it

round to the bottom ensuring that the slot collects the rope which leaves the barrel centrally. Caremust be taken when doing this that tension is maintained in the rope and that no “slack rope” isintroduced behind the rope guide.

• Feed the tension spring through the groove in the bottom half of the guide and hook the endstogether.

• Fit the two M5 socket cap head screws to the top half of the rope guide and secure using the twoplastic anti-loss washers.

• Fit the top half of the rope guide over the barrel ensuring that the tension spring seats in the correctgroove.

• Screw the two halves of the guide together. Rotating the rope guide slightly will allow easier accessto the screws.

• Check that the rope guide is not too tight and can be rotated backwards and forwards freely whenmoderate pressure is applied. If this is not the case then; a) the rope guide has been fittedincorrectly, b) the barrel is damaged, c) the rope guide is damaged.



REF: MMZ4001B.DOC

3/3

Fig. Z4001/2

Fig. Z4001/3


“SLACK ROPE” CHECK ON HOIST UNITS

REF: MMZX015B.DOC

1/1

During packing and shipping it is possible for the rope to have been pushed into the rope guidecausing “slack rope” behind the rope guide. This can also occur if tension is not applied to the ropewhilst fitting a rope guide (see fig ZX015/1).

CAUTION: If the hoist is operated prior to rectifying the condition then both the rope guide and rope willbe damaged.

Fig ZX015/1

To rectify “Slack Rope” try any of the four methods listed below

Method 1 If the amount of slack rope is small it is some times possible to remove it by applying alarge load to the hook (approx. 75% of the safe working load) and carefully loweringand lifting the load by 100mm. This should be repeated 10 or 20 times.CAUTION: If the rope behind the rope guide “backs up” ie. starts to lift out of the barrelgroove, stop immediatley as this will eventually damage the rope guide.

Method 2 Remove the rope guide channel. For a ZX3 hoist this means one of the side framesand for a ZX4 hoist it means the bolt on limit bar. Holding the rope which falls off thebarrel firmly, rock the rope guide backwards and forwards. This has the effect ofworking the rope through the rope guide.

Method 3 Slacken off the rope guide clamping screws and repeat method 2.

Method 4 Completley remove the rope guide and tighten the rope onto the barrel.

(ZX4 Hoist Unit) ROPE TERMINATIONS : WEDGE & SOCKET

REF: MMRP003A

CDE 1/1

The wedge and socket anchorage system consists of a flat, pear shaped wedge with a radiused groove to accommodate the wire rope This fits inside a suitably tapered socket or body usually of the clevis type with an eye and a pin fitting (see Fig.RP003/1).

Installation Each wedge and socket is designed to be used as a pair and under no circumstances should different sized wedges and sockets be used together. Similarly wedges and sockets supplied from different manufacturers should not be mixed even though they may be labeled for the same rope size. The rope should be fitted so that the live or loaded section of the rope is not kinked where it leaves the socket, but pulls directly in line with the point of attachment of the socket. Incorrect fitting will lead to premature failure of the rope. The tail end of the rope should be fitted with a simple clamp or wire rope grip and laid parallel to the loaded rope. If a wire rope grip is used then a length of rope or bar with same diameter to that of the rope will be necessary to ensure the rope is adequately gripped The length of the tail should be at least 100mm long. (see Fig RP003/2). The wire rope grip is required to ensure that the rope does not slip through the anchorage before the wedge has had chance to seat adequately. The rope grip should be placed well away from the fused end of the wire rope. Once a new rope has been fitted, the load should be applied gradually before re-checking that the wedge has seated correctly in the socket. Inspection A wedge and socket termination should be visually inspected in accordance with the maintenance schedule. In particular, inspect for damage to the rope where it emerges from the socket. The socket itself should also be noted and should be inspected for deformation and cracks particularly if the wedge is seen to protrude excessively. If any damage whatsoever is seen on either the wedge or socket then the pair should be replaced before the hoist is put back into service.

Fig.RP003/1

Fig.RP003/2

(ZX Series Hoist Unit)

BOTTOM BLOCK

REF: MMZX010A.DOC

1/2

Each bottom block is clearly labelled with the hoists maximum capacity (safe working load). Twoexamples of different types of ZX hoist bottom block are illustrated in Fig ZX010/1.

Inspection All bottom blocks should be inspected and maintained at prescribed intervals specified in the“Inspection & Maintenance Schedule” (MMZX007A) in accordance with the following instructions.• Ensure that the hook is in good condition and is free from cracks and deformation. Check that the

hook rotates freely.• Examine the condition of the sheave(s) and ensure that they are free from cracks or damage due to

rope indentations. Check that they can be rotated freely.• Ensure that the capacity of the hoist is clearly displayed on the bottom block• Check that the safety catch operates and springs fully closed against the hook• Check the condition of the sheave covers ensuring that they are free from cracks and chips• Check the security of the sheave cover fixings

Lubrication All bearings fitted in the sheaves of a ZX hoist bottom blocks are sealed for life and require nolubrication. The thrust bearing, located on the hook crosshead requires lubricating via a greasenipplein accordance with the the “Lubrication Schedule”.For most models, the greasenipple is clearly located on the crosshead (Fig. ZX010/1). However somemodels have a greasenipple inside the sheave cover. A groove in the crosshead indicates which covermust be removed (Fig. ZX010/2). Once the cover has been removed the greasenipple can be chargedby rotating the sheave until a hole in the sheave lines up to allow access.

Fig ZX010/1


BOTTOM BLOCK

REF: MMZX010A.DOC

2/2

Fig ZX010/2


LOW HEADROOM CROSS TRAVEL WHEELS

REF : MMCT002A.DOC1/2

The cross travel drive assembly comprises of two single flanged wheels with separate gear wheelsattached to the back. The first drive wheel is driven by a pinion mounted on the output shaft of thedrive gearbox. The second drive wheel is driven by the first wheel via an intermediate idler wheel. Thetravel brake for the assembly is mounted on the rear of the motor shaft (see CT002/1.).

Warning: Ensure that the mains power is isolated before startingany maintenance work.

Drive Pinion Removal / Replacement• Disconnect the power cables from the drive terminal box making notes of each cable and its relative

terminal connection.• Support the drive unit and remove the four bolts which fasten the drive to the trolley.• Withdraw the drive unit noting the orientation of the terminal box and lower to a suitable working

level.• Remove the setscrew and washer which retain the pinion on the motor shaft.• Withdraw the pinion from the motor shaft using pullers if necessary.• Replace the old pinion and key with new ones.• Re-fit the pinion retaining setscrew and washer.• Carefully replace the drive unit ensuring that the orientation is correct.• Re-fit the drive fixing bolts.• Re-connect the power cables to the drive terminal box.

Wheel Bearing Removal / Replacement• Remove the outer retaining circlip.• Withdraw the wheel / Idler assembly from the axle.• Remove the bearings using pullers if necessary.• Smear the inside of the wheel with a thin film of oil prior to mounting the new bearing.

CT002/1.


LOW HEADROOM CROSS TRAVEL WHEELS

REF : MMCT002A.DOC2/2

• Fit the new bearings (Note: these should be an interference fit in the wheel housing).• Push the assembly onto its respective axle.• Replace the outer retaining circlip.

A wheel should be replaced if :-• Flange thickness is less than half or its original thickness.• Flange is damaged or distorted.• Wheel tread or gearwheel diameter has been reduced by max. of 5% of its original value.• Gear teeth are worn

Gear Wheel/Wheel Removal & Replacement• Remove the outer retaining circlip.• Withdraw the wheel / Idler assembly from the axle.• Remove the setscrews and spring washers which fasten the gear to the wheel / idler boss.• Replace the old gear wheel with a new one and tighten the retaining setscrews to 9Nm. Do not

forget the spring washers.• Push the assembly onto its respective axle.• Replace the outer retaining circlip.

SK-F DRIVE

REF: MMLT015B

CDE 1/3

932 Non-drive endshield 991 Setting bolt

936 Complete brake 992 Brake seal 1)

937 Manual brakereferse 993 Brake lining

938 Brake hub 994 Armature

939 Fan 995 Spring

940 Fan-cowl 996 Pressure plate **

946 Fixing screw 997 Adjusting ring **

971 O-Ring 998 Bushing / Seal

990 Friction plate 999 V-Ring

Operation of the Brake The brake is released by applying a DC current to the brake coil. The armature plate is pulled towards the stator. The rotor, connected to the drive shaft by a splined hub, is then released. When the brake coil is de-energised, the brake springs exert pressure between the armature plate, the rotor and the mounting flange, producing the braking torque. With power failure the brake is applied automatically, satisfying the fail safe braking principle. The brake can be overridden by operating the hand release mechanism.

Maintenance of the Brake To maintain a safe and efficient braking action, regular inspection of the brake is essential. Generally, a one monthly interval is sufficient, but for higher duty applications refer to the Inspection & Maintenance Schedule for specific frequencies. When inspecting the brake, particular attention should be made to the air gap, upon inspection, check this dimension complies with the min. air gap, as outlined below.

SK-F DRIVE

REF: MMLT015B

CDE 2/3

Braking Torque MB [Nm] 5 10 20 40

Power of coil P 20 [W] 22 28 39 42

Normal air gap a [mm] 0.2 0.2 0.2 0.3

Re-adjustment recommended at amax

[mm] 0.7 0.8 n/a 0.9

Max. permissible wear V [mm] 3.0 3.0 1.00 3.0

Min. permissible lining thickness [mm] 4.5 5.5 7.5 9.5

Table LT015/1

Checking / Setting the Air Gap (see LT015/1.) The air gap ‘a’ (between the stator and the armature plate) should be checked in at least three positions around the brake using non-magnetic feeler gauges. The air gap should not exceed the max.

Where adjustment is required, slacken the assembly fixings (10)

Adjust air gap by turning the adjustment tubes (9) until the nominal air gap ‘a’ is reached.

• If the air gap is too large, screw the adjustment tubes into the stator (7).

• If the air gap is too small, screw the adjustment tubes out of the stator (7).

NOTE: 1/6 turn adjusts the air gap by approx. 0.15mm

SK-F DRIVE

REF: MMLT015B

CDE 3/3

• Re-tighten the assembly fixings to the recommended torque value (see Table LT015/1)

Re-check the air gap and repeat adjustment if necessary.

Changing the Rotor (brake disc) CAUTION: Before changing the rotor, lower the bottom block to a suitable level (floor or

platform) and allow it to rest on a solid support.

• Disconnect the supply to the brake.

• Loosen the assembly fixings evenly and remove them (take care to support the brake body).

• Remove the brake body, taking note of its orientation.

• The old rotor (brake disc) will now be exposed. Withdraw the rotor from its hub by hand.

• Check the condition of the splining on the brake hub. If damaged, the hub should also be replaced.

• Check the braking surface on the mounting flange or friction plate. Replace where strong scoring is observed.

• Measure both the new rotor thickness and length of protrusion of the adjustment tubes from the back of the brake.

• Calculate the distance between the stator and the armature plate as follows: -

Distance = Rotor thickness + Nominal Air Gap ‘a’ – adjustment tube height

• The adjustment tubes should be unscrewed until the calculated distance between the stator and the armature plate is reached.

• Slide the new rotor onto the hub.

• Replace the brake assembly in the same orientation as originally.

• Replace the assembly fixings and torque to the value stated in Table LT015/1.

• Check and adjust, if necessary, the Brake Air Gap ‘a’.

• Re-connect the brake supply.

TRAVEL BRAKE MOTORS TYPE “EFB2” & “EFB3”

REF: MMLT005A.DOC

1/3

Operation Of The Brake

The travel brake is designed to provide a braking action with the removal of the electrical power, eitheraccidentally of intentionally.

The brake is released by applying a direct current to the brake coil. This causes the pressure plate tobecome magnetically attracted towards the brake end shield which in turn releases the brake disc (fan).When direct current is removed from the brake coil the central brake spring pushes the pressure plateonto the brake lining thus producing a braking force.

The direct current for the brake is derived from an AC/DC rectifier which is mounted in the drivetreminal box.

Warning: Ensure that the mains power is isolated before starting any maintenance work.

Maintenance Of The Brake

The travel drive fitted is a flange mounted helical geared brake motor. This type of drive has a sealedfor life gearbox which will not require re-lubricating. The only maintenance the motor will require is thechecking and adjusting, if necessary, of the brake Air Gap and the possible renewing of the brakelining.

Checking the Air Gap (see LT005/1.)

• Remove the Fan guard.

• Remove O-ring.

• Use non magnetic feeler gauges to check Air Gap. When the working gap exceeds that stated inTable LT005/1. then the brake must be adjusted.

Fig LT005/1.


REF: MMLT005A.DOC

2/3

Adjusting the Air Gap


• Loosen the binding screws.

• Remove O-ring.

• Insert a shim or non-magnetic feeler gauges between Brake end shield and the Pressure plate.Thickness should be 0.25 - 0.30mm

• Tighten the centre screw until the shim or gauges are a sliding fit (do not clamp tight).

• Check that the Air gap is constant at a minimum of three places around the brake.

• Evenly tighten the binding screws starting with the screw opposite the key. For tightening torquesee Table LT005/1.

• Re-tighten the centre screw.

• Replace O-ring and fan guard.

• Test run brake.

The brake lining should be replaced when it is not possible to re-set the Air gap to the recommendedsetting.

Brake Type(See motor Nameplate)

Nominal BrakeTorque (Nm)

(See motor Nameplate)

Maximum Air Gap(mm)

Tightening torque forbinding screws (Nm)

6.0 - 7.5 0.6

3.8 - 5.4 0.7

2.9 - 3.7 0.9

EFB2 2.1 - 2.8 0.55 5.5

1.5 - 2.0 0.65

1.0 - 1.4 0.9

0.7 - 1.1 1.1

20.2 - 25.0 0.6

15.2 - 21.6 0.8

EFB3 8.9 - 13.3 1.0 9.0

4.1 - 7.9 0.85

2.9 - 4.7 1.2

1.3 - 2.3 1.4

Table LT005/1

Renewing The Brake Lining / Fan


• Loosen the binding screws

• Remove the centre screw and the locking collar.

• Withdraw the fan, taking care not to loose the key.

• Replace the lining and fan which are supplied bonded together.

• Replace the locking collar and centre screw.

• Adjust the Air Gap.


REF: MMLT005A.DOC

3/3

Brake Rectifier Circuit Diagrams

FAULT FINDING

REF: MMZX013A.DOC

1/8

WARNING : Ensure that the mains power is isolated before starting any maintenance work.

Should you require any assistance from Street Crane Service Department please specify:• The hoist serial number• Details from both hoist nameplates• Motor nameplate details• Describe the nature and extent of the fault• Explain under what circumstances the fault occurred• State your suspected cause Street Crane Company Limited Chapel-en-le-Frith High Peak SK23 OPH Tel: +44 (0) 1298 812456 Fax: +44 (0) 1298 814945 General

Problem Possible Cause Remedy Each movement of the hoistdoes not correspond to thesymbols on the pendant

Power supply wronglyconnected.

Exchange 2 phases of powersupply to the hoist.

Hoist unit does not operate Emergency stop activatedi.e. hoist switched off.(where fitted)

Release emergency stop

Fuse blown or circuit breakertripped

Replace fuse or reset circuitbreaker. Investigate reasons forthe fault.

Pendant fault Check condition ofcorresponding pushbutton andpendant wiring

Main contactor fault(where fitted)

Check operation of maincontactor. Replace if necessary

Motion only operates whenON/O.RIDE pushbutton isdepressed(not in traverse limit zone)

Limit switch has not reset Check and rectify operation ofrelative motion limit switch

FAULT FINDING

REF: MMZX013A.DOC

2/8

Hoist Motion

Problem Possible Cause Remedy Hoist and lower motions do notcorrespond to their symbol onthe pendant

Power supply to motor wronglyconnected.

Exchange 2 phases of hoistmotor supply.

Both raise and lower motions donot operate

Pendant fault Check condition ofcorresponding pushbutton andpendant wiring



Contactor fault Check operation of hoist andlower contactors. Replace ifnecessary

Hoist will not raise Hook at raised limit switchposition

Lower to reset. Check setting oflimit

Load in excess of rated capacitylimiter

Lower load to floor. Do notapply any load greater thanrated capacity of hoist.

Motor over-temperatureprotection tripped

Allow motor to cool. Seeseparate fault finding guide formotors.

Pendant fault Check condition ofcorresponding pushbutton andpendant wiring.

Hoist contactor fault Check operation of hoistcontactor. Replace if necessary

Hoist will not lower Hook at lower limit switchposition

Hoist bottom block to reset limit.Check setting of limit


Lower contactor fault Check operation of lowercontactor. Replace if necessary

SWL cannot be lifted Rated capacity limit incorrectlyset.

Adjust setting of rated capacitylimit.

Motor operating through hoistbrake

Check operation of the hoistbrake

Loads in excess of SWL can belifted

Rated capacity limit incorrectlyset.

Adjust setting of rated capacitylimit.

Hoist lowers at excessive speedwhen either raise or lowermotion operated

Brake failure Check operation of hoist brake

Motor failure Check operation of hoist motorand that all phases are presentat the motor terminals.

Hoist contactor fault Check operation of hoistcontactor. Replace if necessary

FAULT FINDING

REF: MMZX013A.DOC

3/8

Hoist Motion cont’d

Hoist will not raise or slowly runsback when hoist motion isoperated.

Brake failure Check operation of hoist brake

Motor failure Check operation of hoist motorand that all phases are presentat the motor terminals.



Hoist will not switch from slowspeed to fast speed(two speed motors only)


Fast speed contactor fault Check the operation of the Fasthoist contactor. Replace ifnecessary

FAULT FINDING

REF: MMZX013A.DOC

4/8

Traverse Motion

Problem Possible Cause Remedy Traverse motions do notcorrespond to their symbol onthe pendant

Power supply to motor wronglyconnected.

Exchange 2 phases of traversemotor supply.

Traverse does not operate Pendant fault Check condition ofcorresponding pushbutton andpendant wiring



Motor fault See separate fault finding guidefor motors

Contactor failure. Check operation of contactors Traverse operates in onedirection only


Traverse contactor fault Check operation ofcorresponding contactor.Replace if necessary

Excessive stopping distance Brake fault See separate fault finding guidefor traverse brake

Traverse will not switch fromslow speed to fast speed(two speed motors only)


Fast speed contactor fault Check the operation of the Fasttraverse contactor. Replace ifnecessary

FAULT FINDING

REF: MMZX013A.DOC

5/8

Hoist and Traverse Brakes

Problem Possible Cause Remedy The brake will not release. Wrong voltage at the brake control

unit Check that the rectifier has thecorrect input and output voltage

Check the cable for continuityReplace if necessary

Loss of supply to the brake Check output from rectifier andcheck supply from brake contactor

Max permissible air gap exceeded Check the air gap and adjustwhere necessary

Voltage drop is greater than 10%at the leads

Ensure the voltage supply iscorrect

Brake coil fault or short circuit toframe

Change the complete brake andcontrol unit (trained servicespecialist). Check the switchingdevices

Brake overheating Inadequate cooling Clean brake and ensure freepassage of air around the brake

High ambient temperature Check that the ambienttemperature is within the designrange. Consult Street Crane

Rectifier output too high Check function of the rectifier Rotor cannot rotate freely Air gap too small Adjust the air gap Brake slow releasing Faulty rectifier Check function of the rectifier and

replace if necessary Excessive run throughwhen lowering/traversingor run back when hoisting

Working air gap or hand releaseclearance gap incorrectly set. Worn friction disc.

Check the working air gap & handrelease clearance gap. Check &replace if necessary the frictiondisc.

Brake lining worn Change the whole brake disc Manual release device incorrectly

set Adjust the hand release clearancegap

Excessive brake wear Motor running through brake Check operation of the brake.Check operation of the forcevoltage rectifier (where fitted)

Noise from the brake Wear of the carrier gearing causedby excessive starts

Replace the carrier

FAULT FINDING

REF: MMZX013A.DOC

6/8

Motor Units

Problem Possible Cause Remedy Motor will not start Lead broken Check and restore the

connections Fuse blown or circuit breaker

tripped Replace fuse or reset circuitbreaker. Investigate reasons forthe fault.

Motor contactor does notoperate, control system fault

Check the motor contactorcontrol circuit; rectify the fault ifnecessary

Motor will not start or starts withdifficulty

Motor designed for deltaconnection but is wired in star

Change connection

Voltage or frequency differsgreatly from the design,especially when starting.

Ensure that the supply voltageconditions are improved. Checkthat the cross section of thecables matches the design

Wrong direction of rotation Motor incorrectly wired Change over two phases Motor hums and has high powerconsumption

Faulty winding or rotor catchingon housing

Motor must be repaired byservice specialist

Fuses blow or circuit breakertrips immediately

Short circuit in the cable Repair the short circuit

Short circuit in the motor Motor must be repaired byservice specialist

Cables incorrectly connected Correct the connections Short circuit to earth at the

motor Motor must be repaired byservice specialist

Pronounced speed reductionunder load

Overload Ensure the motion is freerunning and clear of allobstructions.

Voltage drop Ensure that the supply voltageconditions are improved. Checkthe cross section of the cablesmatches the design

Motor overheats Overload Ensure the motion is freerunning and clear of allobstructions.

Inadequate cooling Ensure the cooling air passageis clear

Ambient temperature too high Check that the ambienttemperature is within the designrange. If too high consult StreetCrane

Motor connected in delta insteadof star

Change connection

Loose lead (intermittent twophase operation)

Repair the loose contact

Mains voltage deviates by morethan 10% of the motor ratedvoltage

The mains voltage and themotor voltage must match

Oil level in gear unit housing toohigh

Check oil level at roomtemperature. Correct ifnecessary

Brake slow releasing See brake fault finding

FAULT FINDING

REF: MMZX013A.DOC

7/8

Motor overheats Running period and/or startingclass are exceeded

Adjust the operating conditionsto the design cycle otherwiseconsult Street Crane

Motor too noisy Bearings distorted, damaged ordirty

Consult Street Crane

Rotating parts vibrate Consult Street Crane Foreign matter in the cooling air

passages Clean cooling air passages

FAULT FINDING

REF: MMZX013A.DOC

8/8

Gearboxes

Problem Possible Cause Remedy Unusual consistent runningnoise

Rolling / grinding noise- bearing damage

Check oil and condition ofsuspect bearing(s)

Knocking noise- gearing irregular

Check oil. Call customerservice

Unusual inconsistent runningnoise

Polluted oil or not enough oil Check oil / oil level

Oil is leaking:• at motor flange• at motor oil seal• at gear unit flange• at output side oil seal

Defective seal Call customer service

Oil is leaking at breather plug Excessive amount of oil Correct the oil level(where fitted) Breather plug fitted incorrectly Fit breather plug correctly

Frequent cold starting(oil is foaming)

Exchange breather plug for ventvalve

STEEL WIRE ROPES

REF: MMRP001A

CDE 1/2

All Street wire rope hoists use a multi-strand, low rotational type rope. These ropes are constructed from two or more layers of strands which are laid in opposite directions so that their rotational characteristics when under load act in opposition. The rope will therefore not twist when it is loaded or stretched. This low rotational characteristic between the strands is only maintained so long as the rope remains in good condition.

Storage Always follow the manufacturers storage recommendations for steel wire ropes. Generally, they should always be stored in a cool dry environment preferably indoors. The ropes should never be stored where they are likely to be affected by chemical fumes, steam or other corrosive agents. They should be stored off the ground on raised pallets and away from walls. If outdoor storage is unavoidable then the rope must be covered with a tarpaulin and air allowed to circulate to prevent the build up condensation and moisture. If the coils are to be stored for any length of time then they should be periodically rotated through 180° to prevent the lubricant draining to the bottom of the reel in hot weather.

Handling To avoid physical damage ropes should be offloaded with care. The reels or coils should be handled by inserting a steel bar through the centre hole of the reel and lifted by means of a suitable sling.

Installation To prevent the possibility of kinking or imparting any rotation into the rope, it should be uncoiled without slack and in a straight line. If the strands are disturbed, malformation of the rope may develop during subsequent use. Coils should be paid out from a turntable or on a pair of stands supported by a shaft, alternatively short lengths of rope can be uncoiled along the ground (see Fig. RP001/1.). The rope should never be uncoiled by throwing off turns from a stationary reel. During this operation the rope should be kept as clean as possible.

When transferring a rope from reel to barrel, make certain that the rope bends in the same direction. The reel and barrel should be spaced well apart and always reeved from top to top or from bottom to bottom (see Fig. RP001/2.). Whilst transferring the rope ensure that sufficient tension is applied to the reel to prevent loops forming. This tension can be provided by means of a simple plank rigged to bear against the reel flanges. For smaller ropes, tension can be applied with suitably gloved hands.

Fig. RP001/1

STEEL WIRE ROPES

REF: MMRP001A

CDE 2/2

Running In After installation of a new rope, it is important to run through the hoists operating cycle for a number of operations at reduced speeds and loads to allow the rope to adjust to the working conditions.

Maintenance & Inspection Regular maintenance of a rope will, in general, increase the life of a rope. This is generally confined to cleaning, application of fresh lubricant and the removal of the occasional broken wire end.

Wherever possible a visual inspection of the rope should be carried out at the beginning of each working period. In particular those areas of the rope that pass over the barrel or sheaves and around the end clamps or anchors. For a detailed inspection, maintenance and discard criteria refer to BS 6570:1986 and ISO 4309.

Sheave Groove Inspection In service, the life of the wire rope is influenced, amongst other factors, by the condition of the equipment with which it is to be used. It is therefore important to inspect the sheave and barrel grooves prior to installation of a new rope. All sheaves should rotate freely and all groove profiles should be circular, smooth and free from ridges.

Fig. RP001/2

Ñ°¬·±²¿´ Û¨¬®¿

7101 LIMIT SWITCH

REF: MMEL019A.DOC

1/1

The 7101 limit switch is normally used to indicate the position of the crane/hoist. The switch isoperated by a striker peg, which rotates an operating arm as it comes into contact with it.

Operation

Standard Setup - Once tripped then the relative motion becomes operable in slow speed only.

Optional Setup - Once tripped then the relative motion will stop.

On each of the above, when the limit is tripped, normal operation is available in the opposite directionto that which caused the switch to operate. Once the crane/hoist has passed back through the limitswitch, re-setting it, that motion will return to perform its original function.

Setup To ensure reliable operation of the switch, the dimension from the edge of the striker peg to the centreline of the horizontal arm should be as shown above. The striker pegs should be located so that theswitch is not rotated more than 90° in any one direction. Failure to comply with this will result inpermanent damage to the switch.

When setting the point of operation for the limit switch, account should be taken of the crane/hoistspeed and the stopping distance. The point of operation should be set to allow a fully loadedcrane/hoist to stop from fast speed before reaching the required position. After setting, the correctoperating position of the switch should be proven.

Contacts

7101 LIMIT SWITCH

REF: MMEL001B.DOC

1/1

The 7101 limit switch is normally used to indicate the position of the crane/hoist. The switch isoperated by a striker peg which rotates an operating arm as it comes into contact with it.

Standard Operation Once the crane/hoist has tripped the limit switch then all motions will stop. Each motion (with theexception of the hoisting motions) then becomes operable in slow speed only by retaining theon/override button depressed whilst pressing the appropriate motion pushbutton. Once the crane/hoisthas passed back through the limit switch, re-setting it, all motions will return to perform their originalfunctions. Dual speed travel motions can then be re-selected (where applicable).

Setup To ensure reliable operation of the switch, the dimension from the edge of the striker peg to the centreline of the horizontal arm should be as shown above. The striker pegs should be located so that theswitch is not rotated more than 90° in any one direction. Failure to comply with this will result inpermanent damage to the switch.

When setting the point of operation for the limit switch, account should be taken of the crane/hoistspeed and the stopping distance. The point of operation should be set to allow a fully loadedcrane/hoist to stop from fast speed before reaching the required position. After setting, the correctoperating position of the switch should be proven.

Contacts

ULTIMATE LIMIT SWITCH

REF: MMEL015A.DOC

1/1

The Ultimate Limit Switch, when operated, will interrupt power to the hoist unit. This will only occur ifthe hoists normal overhoist limit switch has failed to operate. NOTE: The reason for the normal overhoisting limit switch to become inoperative should be investigated and rectified, prior to putting thehoist back into service.

Re-setting After Tripping • Fence off and clear all personnel from the area under the load or hookblock.• Obtain a permit for access to the hoist brake.• Carefully lower load/hook to the floor using the hoists hand release fail-safe brake. The load must

be lowered under strict control only a few inches at a time before re-applying the brake. CAUTION: Serious damage and subsequent failure, of the gearbox may result if the load isallowed to run away.

• When load is firmly supported at floor level, re-apply the brake mechanism.• Return the ultimate limit switch device to its normal working position.• Re-set the limit switch.The hoist should now be available for normal use.

CONTROL PENDANTS

REF: MMEL005A

CDE 1/1

Maintenance • Ensure that all legends are clean and legible.

• Check to ensure that each button performs its stated function.

• Check the condition of each of the function buttons and their respective rubber seals. Replace damaged function buttons if necessary.

• Check the condition of the casing to ensuring that it is free from cracks. Replace if necessary.

• Check the condition of the cable entry rubber seal. Replace if damaged.

• Check security of all strainer wire fixings.

CDE

THIS PAGE IS INTENTIONALLY BLANK

Description of any Inspections, Maintenance work and Parts replaced :-

Date : Hours in service reading:(where fitted)

Signed :



Signed :



Signed :

Inspection & Maintenance LogCrane / Hoist Ref :



Signed :



Signed :



Signed :

Inspection & Maintenance LogCrane / Hoist Ref :

Documents

ZX4 Hoist User Manual - ProservCrane Group...• BS 2573:Parts 1 and 2 - Rules for the design of Cranes. • 2006/95/EC - EC Low Voltage Directive. • EN ISO 12100 Parts 1 and 2 -