EFFECTIVE: May 1, 2006 Owner’s Manual ELECTRIC WIRE ROPE TROLLEY HOIST RH ADVANTAGE SERIES 5, 7½ and 10T Capacity Hoist Code and Serial Number WARNING This equipment should not be installed, operated or maintained by any person who has not read and understood all the contents of this manual. Failure to read and comply with the contents of this manual can result in serious bodily injury or death, and/or property damage.
Table of Contents Section 1.0 2.0 3.0 4.0 5.0 Page Number Important Information and Warnings…………………………………………….……………………. 4 1.1 Terms and Summary 1.2 Warning Tags and Labels Technical Information …………………………….…………………………………………………….. 8 2.1 Specifications 2.2 Dimensions Pre-operational Procedures……………………………………………………………………….….. 13 3.1 General Information 3.2 Handling 3.3 Mounting Location 3.4 Assembly, Adjustments and Mounting 3.5 Electrical Connections 3.6 Reeving and Adjustments 3.
Section 6.0 Page Number Maintenance & Handling………………………………………………………………………….…… 37 6.1 Lubrication 6.2 Hoist Motor Brake 6.3 Trolley Motor Brake 6.4 Wire Rope 6.5 Storage 6.6 Outdoor Installation 7.0 Troubleshooting………………………………………………………………………………………… 48 8.0 Warranty…………………………………………………………………………………………………. 51 9.0 Parts List ……………………………………………………………………………………………….
1.0 Important Information and Warnings 1.1 Terms and Summary This manual provides important information for personnel involved with the installation, operation and maintenance of this product. Although you may be familiar with this or similar equipment, it is strongly recommended that you read this manual before installing, operating or maintaining the product. Danger, Warning, Caution and Notice - Throughout this manual there are steps and procedures that can present hazardous situations.
WARNING Equipment described herein is not designed for and MUST NOT be used for lifting, supporting, or transporting people, or for lifting or supporting loads over people. Equipment described herein should not be used in conjunction with other equipment unless necessary and/or required safety devices applicable to the system, crane, or application are installed by the system designer, system manufacturer, crane manufacturer, installer, or user.
DANGER HAZARDOUS VOLTAGES ARE PRESENT IN THE CONTROL BOX, OTHER ELECTRICAL COMPONENTS, AND CONNECTIONS BETWEEN THESE COMPONENTS. Before performing ANY mechanical or electrical maintenance on the equipment, de-energize (disconnect) the main switch supplying power to the equipment; and lock and tag the main switch in the de-energized position. Refer to ANSI Z244.1, “Personnel Protection – Lockout/Tagout of Energy Sources”. Only trained and competent personnel should inspect and repair this equipment.
1.2 Warning Tag and Labels The warning tag illustrated below in Figure 1-1 is supplied with each RH Advantage trolley hoist shipped from the factory. If the tag is not attached to the pendant cord for your hoist/trolley, order a tag from your dealer and install it. Read and obey all warnings attached to this Trolley Hoist. Tag is not shown actual size.
2.0 Technical Information 2.1 Specifications 2.1.1 Product Code: 2.1.2 Hoist and Trolley Size – The RH Advantage trolley hoists are available in 2 basic sizes. These sizes are referred to throughout this manual to identify what information applies to which trolley hoist. The 10th digit in the product code designates the sizes as shown in Table 2-1 below. Table 2-1 Hoist and Trolley Sizes TH 2.1.
Table 2-2 RH Advantage Trolley Hoist – Hoist Specifications Capacity (Tons) Lift Product Code Dual Speed Lifting Motor Lifting Speed Reeving (ft/min) (parts/ reeving) (ft) 3 Phase 60Hz Rope (mm) Output (Hp) Dual Speed 5 7 1/2 10 Rated Current (amps) @460V Net Weight (lbs) @230V RH05U23D4G-1-WA 23 991 RH05U33D4G-1-WA 33 1101 RH08U23D3G-1-WA 23 RH08U33D3G-1-WA 33 RH10U23D4L-1-WA 23 RH10U33D4L-1-WA 33 1 9 16/5 8.0/2.7 11.5/9.6 23.0/19.0 4/1 13 16.1/5.4 23.0/17.3 46.0/34.
2.2 Dimensions Table 2-4 RH Advantage Trolley Hoist – Dimensions Note: Capacity (Tons) 5 7 1/2 10 Ultra-Low headroom trolleys are suitable for use on S or W shaped beams. Refer to Table 2-3 for flange range dimension B. Refer to Table 2-5 for headroom dimension E. Product Code C C1 C2 D D1 D2 E1 E2 I1 ∅R S1 S2 S3 (in) (in) (in) (in) (in) (in) (in) (in) (in) (in) (in) (in) (in) RH05U23D4G-1-WA 23.6 5.3 11.2 7.1 RH05U33D4G-1-WA 39.4 8.3 23.2 7.9 5.3 11.2 7.1 6.
Table 2-6 Bottom Hook – Dimensions Capacity (Tons) 5 7 1/2 10 Product Code a b c d e f g h (in) (in) (in) (in) (in) (in) (in) (in) 2.6 2.1 2.3 1.8 2.5 2.8 1.7 6.7 3.5 2.8 3.0 2.4 3.1 3.5 2.0 8.
Table 2-8 Trolley Wheel – Dimensions Capacity (Tons) Product Code a (in) b (in) i (in) Wheel Dia. ∅R (in) Maximum Flange Thickness t (in) 1.38 1.14 0.47 4.92 0.91 1.77 1.50 0.75 7.87 1.50 RH05U23D4G-1-WA 5 RH05U33D4G-1-WA 7½ 10 RH08U23D3G-1-WA RH08U33D3G-1-WA RH10U23D4L-1-WA RH10U33D4L-1-WA Note: See Ultra- Low Headroom Trolley Wheel Reaction Forces Table 2-7 for reaction forces R1 and R2.
3.0 Pre-operational Procedures 3.1 General Information 3.1.1 When the RH Advantage trolley hoist is incorporated into lifting systems utilizing other equipment, follow and complete all pre-operational procedures and instructions provided with the equipment. Special wiring considerations must also be taken to complete the integration of the RH Advantage trolley hoist into the system. 3.1.
3.2.2 Lift points – The Advantage trolley hoists are equipped with lifting lugs to facilitate lifting the trolley hoist with a hoist or crane (see Figure 3-4). During lifting do NOT support the trolley hoist any other way. Figure 3-4 Lift Points 3.3 Mounting Location WARNING 3.3.1 Prior to mounting the trolley hoist ensure that the trolley beam and its supporting structure are adequate to support the trolley hoist and its load.
3.4 Assembly, Adjustments and Mounting 3.4.1 RH Advantage Trolley Hoist Installation 1) Make sure the mounting location complies with Section 3.3. 2) Install any additional devices, if any (power supply cords or pendants, for instance – see Section 3.5) onto the trolley hoist. If the trolley hoist is not secured to a pallet, place and secure it to one making sure that the trolley hoist is completely stable (see Figure 3-6). 3) Remove the Bottom Block from the pallet/packing and place it on the ground.
7) WARNING When installing the trolley hoist on a beam, ALWAYS raise the hoist into position with the trolley assembled together and securely attached to a pallet. Raise the trolley hoist with a forklift, lifting platform, or other similar means. NEVER use slings to raise and install the trolley hoist onto the beam (see Figure 3-8). 8) Using a forklift or another suitable means, position the pallet so that the horizontal axis of the beam is parallel to the horizontal axis of the hoist (see Figure 3-9).
14) Lower the pallet just enough until the trolley wheels are resting on the beam flange. 15) Check that all 4 trolley wheels rest correctly on the beam and that the clearance between the wheel edge and the edge of the beam is 5/64 inch (2 mm) maximum at all 4 wheels (see Figure 3-14). 16) Remove the straps/ropes securing the trolley hoist to the pallet and lower the pallet to the ground. 17) Reattach the Spacers (M) to the Stirrups (F).
3.5 Electrical Connections 3.5.1 3.5.2 3.5.3 3.5.4 CAUTION Ensure that the voltage of the electric power supply is proper for the trolley hoist. CAUTION Do NOT apply electronic soft-start control or voltage varying controls to the RH Advantage’s lifting or traversing motors. Use of such devices may cause the motor brake and other electrical components to malfunction. For variable frequency drives contact Harrington for more information.
3.5.5 Installing Pendant 1) Refer to Figure 3-16, the wiring diagram and the interconnection diagram provided with the Hoist. 2) Remove Control Cover (A). 3) Access to Terminal Strip: For hoists with the integral electrical enclosures (plastic cover), the Terminal Strips are located on the back side of the Panel (F). Gain access by removing the Socket Bolts (E) securing the Panel (F), loosening the Set Bolts (G) on the Support Bars (H), then slide and rotate the Panel (F) forward.
3.6 Reeving and Adjustments 3.6.1 Reeving the bottom hook 1) Working from a scaffold or lifting platform, remove the Retaining Ring (B) and Load Limiter Pin (D) from the Terminal Head Crossbar (A). Let the Load Limiter (C) rotate downward and remove the Terminal Head (F) from the Lever Support/Load Limiter Assembly (C) by pulling out the Terminal Head Pin (E). (see Figure 3-17). Note: the Load limiter is standard on the 7½T, optional on the 5T and 10T trolley hoists.
Figure 3-19 Install Wire Rope on Terminal Head 3.6.2 1) 2) 3) 4) Figure 3-20 Install Rope Clamp Figure 3-21 Install Terminal Head Adjusting the Limit Switches: WARNING The maximum upper and lower Limit Switch (B, C) adjustments are marked in red on the Section Bar (D). NEVER adjust the limit switches past the red marks (Figure 3-22).
8) Check, according to the foreseen configuration, that the height of approach of the hook going up is not less than that stated in Table 2-5 (dimension “H”).
3.7 Pre-operational Checks and Trial Operation 3.7.1 Refer to the trolley hoist’s nameplate and record the Product Code, and Serial Numbers in the space provided on the cover of this manual. 3.7.2 Perform pre-operational checks for the trolley hoist: WARNING Confirm the adequacy of the rated capacity for all slings, chains, wire ropes and all other lifting attachments before use. Inspect all load suspension members for damage prior to use and replace or repair all damaged parts.
4.0 Operation 4.1 Introduction DANGER DO NOT WALK UNDER A SUSPENDED LOAD WARNING HOIST OPERATORS SHALL BE REQUIRED TO READ THE OPERATION SECTION OF THIS MANUAL; THE WARNINGS CONTAINED IN THIS MANUAL, INSTRUCTION AND WARNING LABELS ON THE HOIST OR LIFTING SYSTEM, AND THE OPERATION SECTIONS OF ANSI/ASME B30.16 and ANSI/ASME B30.10. THE OPERATOR SHALL ALSO BE REQUIRED TO BE FAMILIAR WITH THE HOIST AND HOIST CONTROLS BEFORE BEING AUTHORIZED TO OPERATE THE HOIST OR LIFTING SYSTEM.
The operation of an overhead hoist involves more than activating the hoist’s controls. Per the ANSI/ASME B30 standards, the use of an overhead hoist is subject to certain hazards that cannot be mitigated by engineered features, but only by the exercise of intelligence, care, common sense, and experience in anticipating the effects and results of activating the hoist’s controls.
CAUTION Improper operation of a hoist can create a potentially hazardous situation that, if not avoided, could result in minor or moderate injury, or property damage. To avoid such a potentially hazardous situation THE OPERATOR SHALL: • Maintain a firm footing or be otherwise secured when operating the hoist. • Use the hoist manufacturer’s recommended parts when repairing the unit. • Check brake function by tensioning the hoist prior to each lift operation.
4.3 Hoist and Trolley Controls 4.2.1 Dual Speed Pendant Control – Pendant controls supplied with dual speed trolley hoists have two-step control buttons. For low speed depress the button to the first step and for high speed depress the button fully to the second step. Use the Up button to raise the hoist’s hook or the Down button to lower the hoist’s hook as shown in Figure 4-1. Depress the Forward and Reverse buttons to move the trolley horizontally. To stop motion release the buttons.
5.0 Inspection 5.1 General 5.1.1 5.2 The inspection procedure herein is based on ANSI/ASME B30.16. The following definitions are from ANSI/ASME B30.16 and pertain to the inspection procedure below. + Designated Person – a person selected or assigned by the employer or employer’s representative as being competent to perform the specific duties.
5.2.4 PERIODIC Inspection – visual inspection by a designated person with intervals per the following criteria: Table 5-2 Periodic Inspection Intervals 5.3 Service Hoist and Trolley Interval Normal Service Monthly Heavy Service Weekly to Monthly Severe Service Daily to Weekly Special or Infrequent Service As recommended by a qualified person before the first such occurrence and as directed by the qualified person for any subsequent occurrences.
5.4 Periodic Inspection 5.4.1 Inspections should be made on a PERIODIC basis in accordance with Table 5-4, “Periodic Inspection.” A designated person shall make evaluation and resolution of the results of PERIODIC Inspections such that the hoist is maintained in safe working condition. 5.4.2 For inspections where load suspension parts of the hoist/trolley are disassembled, a load test per ANSI/ASME B30.16 must be performed on the hoist/trolley after it is re-assembled and prior to its return to service.
5.6 5.7 Inspection Records 5.6.1 Dated inspection reports and records should be maintained at time intervals corresponding to those that apply for the hoist’s PERIODIC interval per Section 5.2.4. These records should be stored where they are available to personnel involved with the inspection, maintenance, or operation of the hoist/trolley. 5.6.
Table 5-5 Hoist (and Trolley) Inspection Methods and Criteria (continued) Item Method Criteria Action Hook Block – Sheave(s) and Shaft Visual, Function Sheave(s) should be free of significant wear. Sheave surfaces should be free of nicks, gouges, dirt and grime. Bearing parts and surfaces of Sheave and Shaft should not show significant wear. Sheave should rotate freely with no roughness or significant free play. Clean/lubricate, or replace as required.
Table 5-5 Hoist (and Trolley) Inspection Methods and Criteria (continued) Item Method Criteria Action WARNING The full length of the Wire Rope must be inspected for rope diameter, Broken strands or wires, and condition.
Table 5-5 Hoist (and Trolley) Inspection Methods and Criteria (continued) Item Method Criteria Action Trolley Wheel – Tread Visual, Measure Diameter of the tread surface should not be less than 5% of its original diameter as new. Replace. Trolley Wheel – Gear Visual Teeth should not be cracked, damaged, or excessively worn. Replace. Load Bar Visual, Measure Load Bar should be free of significant wear, cracks, nicks and gouges. Load Bar should not be bent. Replace.
Table 5-6 Bottom Hook Dimensions g1 Measured When New: _____________________ Hook Identifier (10th Character of the Hoist Product Code) G (4 Falls) L (4 Falls) (u) Dimension inch (mm) (t) Dimension inch (mm) Nominal (g1) Dimension* inch (mm) Standard Discard Standard Discard 1.97 (50) 2.28 (58) 2.17 (55.1) 1.77 (45) 1.68 (42.8) 2.48 (63) 2.95 (75) 2.81 (71.3) 2.36 (60) 2.24 (57) *These values are nominal since the dimension is not controlled to a tolerance.
Table 5-7 Wire Rope Wear Dimensions Maximum Allowable Number of Broken Wires Rope Diameter Hoist Size Standard Rope Diameter Discard For 6xDia. Length For 30xDia. Length Length (in) No. Broken Wires No. Broken Wires Length (mm) (in) (mm) (mm) (in) 2 9 8.4 0.33 9 3 2.1 6 10.6 3 13 12.1 0.48 13 7 3.1 14 15.4 Table 5-8 Braking Distance (inches) With Nominal Load No. of Falls Speed 4 Fall 16 ft/min ⇒ 1 2 3 4 Maximum Limit Before Adjustment 1.77 2.36 2.95 3.
6.0 Maintenance and Handling 6.1 Lubrication 6.1.1 6.1.2 6.1.3 6.1.4 6.2 Wire Rope: + For proper performance the Wire Rope must be maintained in a clean and well lubricated condition. + The rope should be lubricated every 3 months (more frequently for heavier usage or severe conditions). + To lubricate the rope, first remove any dirt, grime, moisture or other accumulations of contaminates. Then coat the Wire Rope with Agip 360 EP/F oil or equivalent.
3) Check that the brake adjustment has been performed correctly. Complete the brake test, first with no load and then with a nominal load (see Table 5-8). 4) Readjust the brake as necessary. 5) It is recommended that the brake be replaced after 3 adjustments.
6.3 Trolley Motor Brake 6.3.1 6.3.2 The Trolley Brake adjustment can be accomplished 2 ways: + External Method – External adjustment in the case of moderate wear or when changing the brake pre-sets. + Internal Method – Internal adjustment is required after the External method does not provide enough braking. This usually occurs when brake wear exceeds 1mm.
Figure 6-6 6.3.4 Internal Method – The internal method allows the braking to be increased as required. 1) Remove the Lock-Nut ®, Fan (D), Snap Ring (F), Pressure Washer (G), Spring (H) and all Thickness Washers (E) (see Figure 6-5 and 6-6). 2) Unscrew and remove the Hexagonal Spacers (J) and Nuts then remove the Motor Cover (P). Carefully, so as not to damage the rotor and/or the winding, slide the Rotor (N) with Brake Block (K) out of the motor completely (see Figure 6-7).
6.4 Wire Rope 6.4.1 Lubrication and Cleaning – Refer to Section 6-1. WARNING 6.4.2 Be certain that the replacement wire rope is obtained from Harrington Hoists, Inc. and is the correct wire rope for the hoist. If the wire rope is being replaced due to damage or wear out, destroy the old rope to prevent its reuse. 6.4.3 Wire Rope Removal 1) 2) 3) CAUTION The hoist must be properly powered and operational in order to perform the following procedures.
9) Remove the Dust Cover (K) by unscrewing the Dust Cover Screws (J) (see Figure 6-13). Note: Dust cover is an option and may not be present. 10) Gain access to the Rope Guide and associated components. Remove the Limit Switch Assembly (C1) removing the Screws (D1). Do not disconnect or change the setting of the Limit Switches (see Figure 6-14). 11) Remove the Screws ® and the Limit Switch Actuators (N) from the Rope Guide Ring Halves (P) and (Q) (see Figure 6-15).
12) Remove the Wire Clamping Spring (T) using the Wire Rope Guide Clamping Tool (S) and pliers to remove the Clip (U) (see Figure 6-16). 13) Unscrew the Nuts (X) remove the Screws (V) and the Springs (W) from the Rope Guide Ring Halves (P and Q), then remove the Ring Halve (Q) (see Figure 6-17). 14) Loosen the Screws (A1) of the Wire Rope Clamps (B1) and take out the Wire Rope and Ring Half (P) (see Figure 6-18).
6.4.4 1) 2) 3) Wire Rope Installation CAUTION The hoist must be properly powered and operational in order to perform the following procedures. CAUTION When replacing Wire Rope, check for wear on mating parts, i.e. Drum, Sheaves, Hook Block Sheaves and replace if necessary. WARNING ALWAYS unwind the roll of the new Wire Rope without kinks or bends (see Figure 6-20). 4) Examine the Wire Rope Guide Ring Halves (P) and (Q) and the Drum after cleaning/degreasing thoroughly.
7) Press the “UP” button on the Pendant to wind the Wire Rope onto the Drum. Use protective gloves to keep the Wire Rope constantly taut and well placed in the Drum grooves, letting the Wire Rope wind around for at least 10 times (see Figure 6-23). 8) Without loosening the tension on the Wire Rope, clamp a weight onto the Wire Rope below the Rope Guide, taking care not to damage the Wire Rope.
10) Insert the Wire Rope Clamp Runners (Z) piece by piece, into the slot on the side of the Rope Guide Ring (P) (see Figure 6-26). 11) Reinstall the Limit Switch Actuators (N) onto the Rope Guide Ring Halves (P) and (Q) and tighten the Screws (R) (see Figure 6-27). 12) Reposition the Wire Clamping Spring (T) on the Runners (Z). Use the Wire Rope Guide Clamping Tool (S), to pull the Spring taut. Couple the ends of the Clip (U) onto the Spring using the pliers (see Figure 6-28).
Optional Dust Covers Figure 6-30 6.5 6.6 Storage 6.5.1 The storage location should be clean and dry. 6.5.2 Care should be take to not damage any of the electrical power cords or fittings. Outdoor Installations 6.6.1 For trolley and hoist installations that are outdoors, the trolley and hoist should be covered and protected from the weather at all times. 6.6.2 Possibility of corrosion on components of the trolley increases for installations where salt air and high humidity are present.
7.0 Troubleshooting WARNING HAZARDOUS VOLTAGES ARE PRESENT IN THE HOIST AND IN CONNECTIONS BETWEEN COMPONENTS. Before performing ANY troubleshooting on the equipment, de-energize the supply of electricity to the equipment, and lock and tag the supply device in the de-energized position. Refer to ANSI Z244.1, “Personnel Protection Lockout/Tagout of Energy Sources.” Only Trained and competent personnel should inspect and repair this equipment.
Table 7-1 Troubleshooting Guide Symptom Cause Remedy Down circuit open Check circuit for loose connections. Check down limit switch for malfunction. Broken conductor in pendant cord Check the continuity for each conductor in the cable. If one is broken, replace entire cable. Faulty magnetic contactors Check coils for open or short circuit. Check all connections on motor circuit. Check for burned contacts. Replace as needed. Faulty switch in pendant Check electrical continuity.
Table 7-1 Troubleshooting Guide Symptom Cause Remedy Contactor contacts arcing Check for burned contacts. Replace as needed. Loose connection in circuit Check all wires and terminals for bad connections. Replace as needed. Broken conductor in Pendant Cord Check for intermittent continuity in each conductor of the Pendant Cord. Replace entire Pendant Cord if continuity is not constant. Trolley making loud noise.
8.0 Warranty Warranty explanation and terms. All products sold by Harrington Hoists, Inc.
Notes 52
9.0 Parts List When ordering Parts, please provide the Hoist code number and serial number located on the Hoist nameplate (see fig. below). Reminder: Per sections 1.1 and 3.7.1 to aid in ordering Parts and Product Support, record the Hoist code number and serial number in the space provided on the cover of this manual. RH Advantage Series Nameplate The parts list is arranged into the following sections: Section Page 9.1 Hoist Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.
10.1 Hoist Parts 1 1A 1B 1C 2 2A 2B 3 4 4A 4B 4C 4D 4E 4F 4G 4H 5 5A 5B 5C 6A hoist motor – 2 speed, 230V hoist motor – 2 speed, 460V brake shoe + brake lining fan cover connection module axial joint half joint rollers assembly reducer rope drum cover – 23 ft. lift rope drum cover – 33 ft. lift rope drum – 23 ft. lift rope drum – 33 ft. lift spacer – 23 ft. lift spacer – 33 ft. lift staybolt – 23 ft. lift staybolt – 33 ft. lift rope clamp limit switch cover – 23 ft. lift limit switch cover – 33 ft.
10.1 Hoist Parts 7 anchorage cross head assy, 23 ft. lift anchorage cross head assy, 33 ft. lift anchorage cross head, 23 ft. lift anchorage cross head, 23 ft. lift 7B lever 7C limiter pivot 7D lever pivot 7E staybolt pivot 7F terminal pivot 7G terminal 7H terminal wedge 7I wire rope clamp lever support 8 load limiter 10A electrical frame 10B cover rope – 23 ft. lift 12 rope – 33 ft.
10.
10.
10.2 Trolley Parts 14A 14B 14D 14E 14F 14G 14H 14H drive plate drive wheel assembly buffer plate buffer drive sprocket reducer trolley motor – 2 speed, 230V trolley motor – 2 speed, 460V 14H/1 motor cover 14H/2 fan 14H/3 fan cover 15 drive plate assembly 15A drive plate 15B cog wheel 16 idle plate assembly 16A idler plate 16B idle wheel assembly 17 connecting bar 18 transmission bar 19 roll pin 20 connection plate, 23 ft. lift 20 connection plate, 33 ft. lift 21A balance weight, 23 ft.
10.
10.3 Electrical Parts 1C10 1C12 1C14 1C16 2C10 2C12 2C14 0XFM05 0FU02 lift/lower rev.contactor, 230V lift/lower rev.contactor, 230V slow/fast contactor, 230V slow/fast contactor, 230V right/left contactor, 230V right/left contactor, 230V slow/fast contactor, 230V transformer, 230V fus.sec.
Notes 62
Notes 63
www.harringtonhoists.com Harrington Hoists, Inc. 401 West End Avenue Manheim, PA 17545-1703 Phone: 717-665-2000 Toll Free: 800-233-3010 Fax: 717-665-2861 Harrington Hoists – Western Division 2341 Pomona Rincon Rd.
