English 7.9.2007 SERVICE MANUAL FOR HOIST - DOCTNI16-0.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 ! Read the instructions supplied with the product before installation and commissioning. # Keep the instructions in a safe place for future reference. Table of content 5.9.1 Service ...........................................................32 1 Major update history (only in English) ........ 5 2 Introduction ................................................... 7 2.1 Instructions ..........
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.22 Inverter for travel....................................... 56 5.23 Rope drum ................................................ 58 6.6.2 6.6.3 5.23.1 Service, drum size φ 243/303/355/406 mm ...58 5.23.2 Service, drum size φ 608 mm ........................59 5.23.3 Drum wear inspection ....................................59 6.7.1 5.24 Rope guide ..........................................
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 8.4 General Overhaul, GO............................ 126 8.5 Recommended tightening torques.......... 126 9 Lubricants .................................................. 128 9.1 Lubricant types ....................................... 128 9.2 Lubricant quantities................................. 129 9.2.1 9.2.2 9.2.3 Lubricant volumes, hoisting gears ...............
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 1 Major update history (only in English) Section Hook operated control limit switch Second brake Description Construction of hook operated control limit switch added. Construction and service of second brake, brake release and manual crank added. Rope guide Construction of rope guide added (ø 608 mm). Lubricant volumes, travel Lubricant volumes for larger trolley gears added.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 2 Introduction 2.1 Instructions The instructions for safe and effective installation, operation and maintenance of the hoist are included in the hoist delivery. The hoist itself is also provided with labels and markings. The instructions are issued on paper and/or on CD-ROM. The instructions for using digital CD-ROMs are printed on the packaging.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 3 Safe operation 3.1 Intended use of the hoist and ambient conditions The hoist is intended for lifting and moving goods. The hoist may not be used for lifting and moving people. The hoist is intended for indoor use or for use in outdoor premises when specially equipped for the purpose. The ambient temperature should be -10 ... +40ºC (14…104ºF), with explosive proof hoists 20 ...
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 3.3.3 Determining the operating group of the hoist When the load spectrum and the average daily operating time of the hoist are identified, the hoist's operating group is obtained from the table below. Load spectrum Average daily operating time (hours per day) ISO/FEM ≤ 0.5 ≤1 M3 1Bm M4 1Am M3 1Bm M4 1Am M5 2m LIGHT MEDIUM HEAVY VERY HEAVY 3.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 c_hopb1d A. Markings in compliance with FEM and DIN standards B. Markings in compliance with SEN standard C. Markings in compliance with SFS standard D. Markings in compliance with ANSI standard 1. Up/Down pushbutton 2. Right/Left pushbutton for trolley 3. Forwards/Backwards pushbutton for bridge of crane 4. Hoist selection pushbutton (only if the pushbutton controls several hoists) 5.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 3.5.1 Using the pushbuttons (two steps, contactor control) c_cots2a A. Position of pushbutton (0, 1 and 2) B. Speed The position of the pushbutton affects the speed as follows: • Position 0: Neutral position. Motion stops. • Position 1: Slow speed. • Position 2: High speed. ! A skilled operator always uses the low speed (step 1) when starting to hoist.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 the crane operator variable speeds to minimize swing, reducing the slowdown ramp time to stop, providing safer and productive operation. • ! ! ! Position 2: Accelerate to high (maximum) speed Inverter Drives provide state of the art control in the hoist, bridge and trolley motions of industrial cranes. A skilled operator can benefit from this type of control system.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 4 Hoist manufacturer 4.1 Hoist identification data The type marking and serial number of the hoist are shown on the rating plate attached to the hoist and in the inspection records supplied with the hoist. # Always state the serial number of the hoist when ordering spare parts or service. 4.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 4.3.1 Spare parts Spare parts for the hoist are specified in the separate spare parts catalogue delivered with the hoist. Always state the serial number marked on the rating plate of the hoist when ordering spare parts. Always use genuine spare parts and lubricants approved by the manufacturer of the hoist. R&M reserves the right to revoke warranty terms when non original parts are used.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5 Construction 5.1 Low Headroom Trolley Hoist The low headroom hoist trolley is a hoist model that is installed on the bottom flange of the main beam. The low headroom hoist allows maximum effective use of the available lifting height. Drum size ø 243 mm 1 7 4 c_zlatr01c 5 2 3 6 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5. Electric cubicle 6.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Drum size φ 303/355 mm c_r1latr1d 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5. Electric cubicle 6. Hook-block 7. Travelling machinery Drum size φ 303 mm, low profile c_jtrol1c 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5. Electric cubicle 6. Hook-block 7. Travelling machinery 16/130 R&M Materials Handling, Inc.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Drum size φ 406 mm c_r2latr1c 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5. Electric cubicle 6. Hook-block 7. Travelling machinery 5.2 Double-girder Trolley Hoist Double-girder trolleys are available in numerous versions, where the available height above the main girders determines the construction.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Drum size φ 303/355 mm c_datr1eb 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5. Electric cubicle 6. Hook-block 7. Travelling machinery Drum size φ 406 mm c_datr1eb 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5. Electric cubicle 6. Hook-block 7. Travelling machinery 18/130 R&M Materials Handling, Inc.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Drum size φ 608 mm c_datr5b 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5. Electric cubicle 6. Hook-block 7. Travelling machinery Drum size φ 608 mm (two hoisting motors) c_datr6b 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5. Electric cubicle 6. Hook-block 7. Travelling machinery 19/130 R&M Materials Handling, Inc.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.3 Normal Headroom Trolley Hoist The normal headroom trolley hoist hangs under a single beam. Normal headroom trolleys can be used with straight or curved beams. Drum size φ 303/355 mm c_r1natr1d 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5. Electric cubicle 6. Hook-block 7. Travelling machinery 20/130 R&M Materials Handling, Inc.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Drum size φ 406 mm c_qcntr_e000760 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5. Electric cubicle 6. Hook-block 7. Travelling machinery 5.4 Fixed Hoist Fixed hoists do not have any trolley and are used in applications where horizontal movement is not needed. 21/130 R&M Materials Handling, Inc.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Drum size φ 303/355 mm c_r1fatr1b 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5. Electric cubicle 6. Hook-block Drum size φ 406 mm c_qcfldlelflg_d000610 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5. Electric cubicle 6. Hook-block 22/130 R&M Materials Handling, Inc.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Drum size φ 608 mm c_datr7a 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5. Electric cubicle 6. Hook-block Drum size φ 608 mm (two motors) c_datr8a 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5. Electric cubicle 6. Hook-block 23/130 R&M Materials Handling, Inc.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.5 Machinery Hoist A machinery hoist does not include a hook or travelling machinery. Machinery hoists are used in applications where only lifting or pulling is required. Machinery hoists can be mounted in different positions according to the required lifting or pulling angle. Drum size φ 303/355/406 mm c_hmv1c 1. Hoisting motor and brake 2. Hoisting gear 3. Connection box 4. Rope drum 5.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.6 Trolley buffers The hoisting trolley is provided with rubber buffers. Some models are equipped with buffer extensions. 5.6.1 • • 5.7 Service Check that the buffers and runway end stops are in good condition. Replace broken buffers. Check that the hoist buffers bump into the runway end stops or buffers of other trolley.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5. Cover of rim gear 6. Rim gear 7. End flanges of hoisting machinery A, B, C, D Fixing screws for hoisting machinery Disassembly: • Lower the hook to the ground. Switch OFF the power supply to the hoist. • Remove the protective cover of the hoisting machinery. • Lock the rope drum with i.e. a wooden wedge, to prevent it from rotating.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 ! • • • • Handle the motor-gearbox subassembly with care. Avoid damaging the inner dust-ring and the rim gear cover. Remove the fixing screws of the brake and remove the brake (3), brake disc (4) and friction plate (6). Carefully guide the connection wires and plug through the hole in the gearbox. Remove the fixing screws for the motor. Extract the motor from the gearbox.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 - Drive pinion of the gear fits correctly into the gear-rim of the drum. Rotate the motor’s shaft on the brake-end side to guide the pinion into the gear-rim and to check the right fitting. • • • • • • • • • Fasten the bolts B & D. Remove the thread bars and fasten the bolts A & C. Tighten the bolts to the correct torque. Re-assemble the hoist limit switch.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 9. Hoisting motor 10. Fixing screws for motor 11. Friction plate. 12. Brake disc. 13.Hoisting brake 14. Fixing screws for hoisting brake 15. Fan. 16. Fan cover. Disassembly: • Lower the hook to the ground. Switch OFF the power supply to the hoist. • Remove the protective cover of the hoisting machinery. • Lock the rope drum with i.e. a wooden wedge, to prevent it from rotating.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • • • • • • • ! 5.8 Assemble the friction plate (11). Text "REIBSEITE" must be against the friction disc (12) (if applicable). Assemble the brake disc (12) and the brake (13). Tighten the fixing screws (14) for the brake. Re-assemble the fan (15) and the fan cover (16). Reconnect the motor wires and close the connection box. Remove the drum-locking device (wooden wedge).
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Drum size φ 608 mm c_r3gebo1a 1. Breather plug 2. Fixing screws for hoisting motor 3. Fixing screws for gearbox cover 4. Gearbox cover 5. Fixing screws for gearbox 6. Fixing plate for gearbox 7. Gearbox plug 8. Coupling 5.8.1 Service • • • • Check the gearbox visually for leakage.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.9 Hoisting motor and brake Standard hoists are equipped with two-speed squirrel-cage motors, which are especially designed and manufactured for hoisting duty. The motors incorporate a cylindrical rotor and class F insulation, and are conform to the protection standard IP54/DIN40050. Optionally, the hoist can be equipped with a inverter and specially designed motors for this duty.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.9.1.2 Brake c_brda1b 1. Fan cover 2. Fan 3. Brake 4. Inside of the brake 5. Brake disc 6. Friction plate 7. Anchor plate 8. Fixing screws • • • ! • Lower the hook to the ground. Switch OFF the power supply to the hoist. Remove the protective cover of the hoisting machinery. Lock the rope drum with i.e. a wooden wedge, to prevent it from rotating.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • • • • • Brake type and size Original thickness of the brake disc [mm] Minimum thickness of the brake disc [mm] Tightening torque for brake fixing screws [Nm] / [lbf.ft] Tightening torque for anchor plate screws [Nm] / [lbf.ft] NM38741NR# NM38751NR# NM38753NR# 11.15 14.00 14.00 10.4 13.2 13.6 22 / 16.2 22 / 16.2 22 / 16.2 5.0 / 3.7 11.0 / 8.1 11,0 / 8.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Brake type and size Original thickness of the brake disc [mm] Minimum thickness of the brake disc [mm] Tightening torque for brake fixing screws [Nm] / [lbf.ft] NM39340NR# NM39351NR# 11.15 14.00 10.4 13.2 22 / 16.2 22 / 16.2 5.11 Manual brake release for hoisting motor (for brake type NM387**) ! ! ! ! ! ! The manual brake release is allowed to use only in case of emergency.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.11.2 Brake release usage instructions ! ! ! ! Secure the area under and around the hoist. Warn the personnel on the shop floor and the supervisors about the intended action Make sure the area under the hoist is free of obstacles. Beware that the motor rotational speed does not exceed the rated rotational speed.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.12.1 Assembling the manual crank • • • • • Switch OFF the power supply to the hoist Remove fan cover (1) Remove retainer ring and fan (2) Install the crank (4) onto shaft gearing and tighten with bolt (3) to the shaft's centre thread. Screw the lever arm (5) into fork lever.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.13 Hoisting limit switch Drum size φ 243 mm The roller lever limit switch unit for hoisting is located under the drum cover, on the limit switch fixing plate. 5.13.1 Service • • • Check the proper tripping point of lower limit function. Check that the locking screws (3) are tight. Check the wiring for loose connections. Assembly 4 1 3 2 c_zlowli01c 1. Hoist limit switch 2.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Adjustment • Lower the hook to approx. 100mm above the floor. • Loosen the fixing screws (3). • Move limit switch along the fixing plate until the limit roller lever switch is just activated. • Tighten the fixing screws and test the operation. The downwards motion must stop at the described distance. • Repeat step 1…4 until the correct setting is achieved.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.14.2 Assembly 1. Hoist limit switch 2. Connection-box cover 3. Fixing screws limit switch Disassembly: • Switch OFF the power supply to the hoist. • Remove the connection-box cover (2). • Remove the wires from the limit switch. • Remove the fixing screws (3). • Extract the limit switch (1).
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.14.3 Adjustment c_holi2b S1. Measurement for phase sequence supervision limit S2. Measurement for upper limit of hoisting S3. Measurement for slowdown limit of hoisting S4. Measurement for lower limit of hoisting C. Minimum distance of hook from bearing surface of hoist travel wheel H. Maximum lifting height • • • • • • • • • • Lower the hook to approx. 100mm above the floor.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • Turn the screw “S1” so that it will activate just after “S2” (in upwards direction). c_holiad1b • Close the connection-box. 5.14.4 Fine adjustment If maximum height of lift is needed, fine-tune the upper and lower limit of hoisting.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.15 Hoisting limit switch (old, black) The rotary hoist limit switch contains four contacts, with the below described default functions. The rotary limit switch unit for hoisting is located in the connection box on the hoisting gearbox. c_holi1c S1. Supervision limit for phase sequence of hoisting (or hoisting safety limit). S2. Upper limit of hoisting. S3.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.15.2 Assembly c_holi4a 1. Hoist limit switch 2. Connection-box cover 3. Fixing screws limit switch Disassembly: • Switch OFF the power supply to the hoist. • Remove the connection-box cover (2). • Remove the wires from the limit switch. • Remove the fixing screws (3). • Extract the limit switch (1).
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.15.3 Adjustment c_holi2b S1. Measurement for phase sequence supervision limit S2. Measurement for upper limit of hoisting S3. Measurement for slowdown limit of hoisting S4. Measurement for lower limit of hoisting C. Minimum distance of hook from bearing surface of hoist travel wheel H. Maximum lifting height • • • • • • • • • • • • • • • Lower the hook to approx. 100mm above the floor.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • • • Raise the hook to the upmost position, until the motion is stopped by the upper limit switch “S2”. Loosen the locking screw (5) Turn the screw “S1” so that it will activate just after “S2” (in upwards direction). • Tighten the locking screw and close the connection-box.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 B [mm] 100 Min. C [mm] 350 120-240 300 340 380 350 415 400 450 450 480 490 510 Rope reeving 02 (Standard hook with RSN1 hook forging), nominal load 2500kg B [mm] 100-253 300 Min. C [mm] 435 465 350 500 400 530 450 560 500 595 550 625 600 660 650 690 690 715 Rope reeving 04 (Standard hook with HBC2.5 hook forging), nominal load 5000kg B [mm] 100 Min.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.16.1 Service • • • Check the proper tripping point of upper limit function. Test safety limit switch function manually monthly. Check the wiring for loose connections. 5.17 Hook operated control limit switch (ø 303, 355, 406, 608 mm) Hook operated limit switch trips hoisting movement when hook reaches the adjustable lever.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 c_hopbnw1b 1. Movement pushbuttons 2. Hoist selection pushbutton (only if pushbutton controls several hoists) 3. On pushbutton and warning signal 4. Emergency stop pushbutton 5. Display (optional) c_hopbol1a 1. Movement pushbuttons 2. Hoist selection pushbutton (only if pushbutton controls several hoists) 3. On pushbutton and warning signal 4. Emergency stop pushbutton 5.18.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • • • • • • • • Check the wires for loose connection. Check that the switch-elements are in good condition and not loose. Check the pushbutton rubbers, emergency stop button and other eventual selector switches are in good condition. Check the cable entry and the plug (if applicable) are tight and in good condition. Close the pushbutton controller.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Double girder trolleys, drum size φ 303/355/406 mm c_tmqde2a 1. Gear 2. Motor 3. Gearbox fixing screws. 4. Junction box 5. Junction box fixing screws 6. Motor fixing screws 7. Securing nuts 8. Coupling Double girder trolleys, drum size φ 608 mm c_tmqde1a 1. Gear 2. Motor 3. Gearbox fixing screws. 4. Junction box 5. Junction box fixing screws 6.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.19.1 Service 5.19.1.1 • • • Check that the traveling motor operates properly when loaded. Check for any excessive noise, vibration and/or heat. Clean the cooling-ribs surface when needed. 5.19.1.2 • • • • Traveling motor Traveling gearbox Check the gearbox visually for leakage.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.20 MF06 Travelling motor with Compact- / DC-brake 10 11 12 DC 9 8 CB 7 6 5 4 3 2 1 c_MF06b1 DC. DC-brake CB. Compact brake 1. Fixing screws for travelling gear 2. Travelling motor 3. Friction disc 4. Brake discs 5. Aluminium ring 6. Adjustment nut for brake air gap (self-locking) 7. Motor cover 8. Power supply plug 9. Rectifier (DC brake motor) 10. Brake (DC brake motor) 11.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • • • • Unscrew the adjustment nut (6) for the brake air gap. Extract the brake parts. If the thickness of the friction material is less than 5 mm, replace all the brake parts. Re-assemble in the reverse sequence. Adjust the brake air gap. Refer to the section 'Adjustment of Compact-brake air gap’. 5.20.3 Removing DC-brake and inspection of brake friction disc c_trmobr3b 1.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • • Detach the motor from the gearbox. Re-assemble in the reverse sequence. 5.21 MF07 and MF10 Travelling motor 7 1 2 8 3 4 5 6 1. Fan cover 2. Fan / Flywheel 3. Fixing screws for motor 4. Brake 5. Brake disc 6. Friction plate 7. Rectifier 8. Power supply plug 5.21.1 Removing DC-brake and inspection of brake friction disc • • • • • • • ! Ensure there is no danger of live voltage.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.21.2 Dismounting the travelling motor • • • • • Ensure there is no danger of live voltage. Remove the power supply plug (8) for the travelling machinery. Unscrew the fixing screws (3) for the motor. Detach the motor from the gearbox. Re-assemble in the reverse sequence 5.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 4 kW inverter c_dmcs0401a 1. Connectors 2. Signal LEDs 3. Parameter switches 57/130 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.23 Rope drum Drum size ø 243/303/355/406 mm c_r1rd1d 1. Rope drum 2. Bearing strips for rope drum 3. Bearing frame 4. Sealing 5. Connector rods for end flanges of rope drum 6. Rim gear cover and inspection hole 7. Rim gear 8. Drum axial locking part A. Lubrication point for drum bearing B. Lubrication point for drum bearing 5.23.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 ! • Only lubricate the greasing points A OR B, but not both. During lubrication, the drum MUST rotate at least two complete rounds. Do not use excessive grease, as that may damage the bearings. Approximately two pumps of grease will suffice. Lubricate the gear-rim (7) through the inspection hole (6) Drum size φ 608 mm c_r3rd1a 1. Rope drum 2. Bearing 3. Bearing frame 4. Sealing 5.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • The maximum difference in groove depth between reference area and worn area is 20% of the nominal groove depth. 5.24 Rope guide The rope guide ensures that the wire rope winds on the drum correctly and prevents the wire rope from jumping into the wrong groove. Rope guide, drum size ø 243 mm c_r1rq4D 1. Fixing screws 2. Bearing housing 3. Intermediate beam 4. Sleeve half 5. Rope guide 6.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Disassembly • Loosen fixing screws (1). • Remove bearing housing and second half of sleeve on both ends of rope guide. • Remove first halves of sleeves • Remove rope guide # Note that 1 of 3 screws is longer, this should be located closest to the drum. Rope guide, drum size ø 303, 355, 406 mm c_r1rq1f 1. Rope guide 2. Rope press roll spring 3. Rope press roll axle 4. Rope press roll 5.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Rope guide, drum size φ 608 mm 3 2 1 c_qderogu3a 1. Connector rod for end flanges of hoisting machinery 2. Rope guide 3. Rotation support Rope guide assembly, drum size ø 608 mm 5 4 2 1 6 7 3 8 c_qderoqu2a 1. Rim, front half 2. Rim, rear half 3. Rope slot locking bar 4. Rotation support 5. Rim spacer 6. Locking bar fixing screws 7. Rim fixing screws 8.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Replacing an old style rope guide with a heavy-duty rope guide When replacing an old style rope guide with a new style rope guide in true vertial lift hoist or machinery hoist, the hoisting limit switch setting for the hook’s lower position may need re-adjusting to ensure safe operation. See the drawing below to identify the type of rope guide you have on the hoisting unit.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 min.15 mm (0.6”) 1 3 2 c_qderogu6a 1. Rope fixing clamps 2. Rope 3. Rope guide Assembly • Dismount one intermediate shaft from the hoisting unit. It is recommended to remove the shaft that is at the top corner, opposite to the side where the rope leaves the drum.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Disassembly • Remove the rotation support (4) on the rope guide. • Remove one intermediate shaft from the hoisting unit. It is recommended to remove the shaft that is at the top corner, opposite to the side where the rope leaves the drum. • Remove the rope slot locking bar (3) and screws (6) • Remove the rope guide rim fixing screws (7).
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • • Pass the ends of the rim (1) through the sleeves (5) and press the sleeves into the sockets in the frame halves. Fix the rim in place with the two M10 Nyloc nuts (6). Follow the adjustment instructions to get the nuts to the proper tightness. Rope guide initial adjustment • Tighten the two Nyloc nuts (6) until the rope guide is snug against the rope drum.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.25 Rope clamps The rope is fixed to the rope drum with rope clamps. The number of rope clamps varies with the type of hoist. # Intheaddition to the clamps on the rope ends, there must always be at least two full turns of rope on drum when the hook is at its lowest position in order to provide friction. c_rdrc1a 1. Rope 2. Rope drum 3. Rope clamps 4. Friction turns 5.25.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 ! The drum brake must always be kept clean. The braking torque reduces strongly if any grease or oil penetrates to the friction surfaces. 5.26.1 Holding Brake The holding brake acts as a second brake and mechanically locks the drum when the hoisting or lowering motion has stopped.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.26.3 Adjusting holding brake 1. Brake rim 2. Detent arm 4. Shaft of the detent arm 15. Holding brake limit switch 16. Solenoid 1.Assemble the brake rims (1) together with disc springs (24, 10 pcs) and screws (25). All the disc springs must be placed so that the concave sides are facing in to the brake rim. 2.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 found and repaired. The drum brake components must be checked for wear and damage and then adjusted per instructions. ! After the drum brake has been activated do not jumper any controls to lower the load using the hoist. 15 21 2 4 1 3 20 c_db03a 1. Brake rim 2. Detent arm 3. Cam wheel 4. Follower 15. Micro switch 20. Rope drum 21. Adjustment spring 5.26.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 - Check that the positioning of the limit switch is correct and will be contacted by the follower roll. The gap between the follower roll and limit switch is to be 0.5 mm measured on the cam wheel’s highest point. Refer to the Drum Brake Adjusting instructions.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 - Replace if deformations, cracks, broken welding seams, etc. are found around the hoisting unit fixing places. 5.26.5.6 Other components inspection after overspeed • Check the fixing of counterweights - No deformations, cracks, etc.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.26.6 Adjusting overspeed brake 15 21 2 1 4 3 20 c_db03a 15 M 7 3 2 1 1 24 25 21 ~3 ~0 .5 ~5 c_db02a 6 27 4 1 26 c_db01a 3 1. Brake rim 2. Detent arm 74/130 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 3. Cam wheel 4. Follower roll 6. Roll for limit switch 7. Shaft of detent arm 15. Over speed limit switch 21. Helical spring 24. Disc springs 25. Screw 26.Marking point 27. Only in models with drum diameter 608 mm with 2 hoisting motors 1. Assemble the brake rims (1) together with disc springs (24, 10 pcs) and screws (25).
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.27 Sheave support and rope anchorage support 5.27.1 Service (R2 and R4 reevings) L. Locking plate W Locking washer OW Old type washer L+S Locking plate + locking screw • • L. Locking plate OL. Old type locking plate NL. New type locking plate W.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 A 2 3 4 1 C_rowh2b 1. Rope 2. Rope anchorage 3. Wedge 4. Rope clamp A. Rope drum φ 243 mm 5.28.1 Service 04.2004 - 01.2005 01.2005 1 A H L1 L2 L4 6xd A H L1 1xd 04.2004 D A L2 L4 D c_rowh3c D 1.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 13-14 15-16 • • • • • 25 30 194 220 65 65 23 25 M10 M12 15 18 Check that the rope clamp-nuts are tight. Ensure that the rope has not slipped in the rope anchorage by comparing the measures with the stated measures in the table. Make sure the rope end protrudes from the rope anchorage as specified on table. Check the condition of the rope at point “A”.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Re-assembly: • Insert the rope into the rope anchorage ! • • • ! Make sure the rope enters the anchorage in the correct direction. See section: “Rope Anchorage, Service” for details Insert the wedge into the rope anchorage, making sure that a length of at least six times the rope diameter protrudes from the anchorage.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • • • Switch ON the power supply to the hoist. Raise the hook carefully to the upmost position. Constantly watch the rope on the drum and make sure that the movement stops before the rope guide reaches the end of the drum. Adjust the hoist limit switch when needed. See section: “Hoisting limit switch, Assembly, Adjustment” for details. 5.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 2-fall, 1-rope reeving, drum size φ 608 mm c_hbresh02v2a 1. Hook forging 2. Safety-catch 3. Rope sheave 4-fall, 1-rope reeving, drum size φ 303/355/406 mm c_hbresh04v1a 1. Hook forging 2. Safety-catch 3. Rope sheave 4. Return sheave 5. Return sheave shaft 6. Support frame 7. Support frame shaft 81/130 R&M Materials Handling, Inc.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 4-fall, 1-rope reeving, drum size φ 608 mm c_hbresh04v2a 1. Hook forging 2. Safety-catch 3. Rope sheave 4. Return sheave 5. Return sheave shaft 6. Support frame 7. Support frame shaft 6-fall, 1-rope reeving, drum size φ 355/406/608 mm c_hbresh06v1a 1. Hook forging 2. Safety-catch 3. Rope sheave 4. Return sheave 5. Return sheave shaft 6. Support frame 7.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 8-fall, 1-rope reeving, drum size φ 355/406/608 mm c_hbresh08v1a 1. Hook forging 2. Safety-catch 3. Rope sheave 4. Return sheave 5. Return sheave shaft 6. Support frame 7. Support frame shaft 10-fall, 1-rope reeving, drum size φ 608 mm c_hbresh10v1a 1. Hook forging 2. Safety-catch 3. Rope sheave 4. Return sheave 5. Return sheave shaft 6. Support frame 7.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 1-fall, 2-rope reeving, drum size φ 355 mm c_hbresh21v1a 1. Hook forging 2. Safety-catch 2-fall, 2-rope reeving, drum size φ 406/608 mm c_hbresh22v1a 1. Hook forging 2. Safety-catch 3. Rope sheave 84/130 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 4-fall, 2-rope reeving, drum size φ 406/608 mm c_hbresh24v1b 1. Hook forging 2. Safety-catch 3. Rope sheave 4. Return sheave 5. Return sheave shaft 6. Support frame 7. Support frame shaft 6-fall, 2-rope reeving, drum size φ 406/608 mm 1. Hook forging 2. Safety-catch 3. Rope sheave 4. Return sheave 5. Return sheave shaft 6. Support frame 7.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 8-fall, 2-rope reeving, drum size φ 406/608 mm c_hbresh28v1b 1. Hook forging 2. Safety-catch 3. Rope sheave 4. Return sheave 5. Return sheave shaft 6. Support frame 7. Support frame shaft 10-fall, 2-rope reeving, drum size φ 608 mm c_hbresh20v1b 1. Hook forging 2. Safety-catch 3. Rope sheave 4. Return sheave 5. Return sheave shaft 6. Support frame 7.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.29.1 Service • • • • • • Check that the sheaves (3 and 4) rotate freely. Check the sheaves for wear and damage. Check the side-plates of the hook block are tight and not damaged. Check that the hook rotates freely. Check that the safety catch functions properly. Check the hook forging for wear, burrs, deformation and cracks.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Note: Safety latch on HBC forging decreases dimension a2 about 5 mm and about 15mm on RSN forging. Hook forging standard Dimension standard Material standard RSN DIN 15401 DIN 15400 HBC Oversized DIN 15401 DIN 15400 5.29.2 Hook block assembly Hook block 2-fall, 1-rope reeving c_hb02as2b_005170_004725 2. Safety latch set 3. Hook forging. 4. Bearing set 5. Thrust bearing 6. Locking set 7.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • • • • • Remove the hook-block fixing parts (13). Remove the side plates (11). Remove the sheave cover screws and remove the sheave cover plate (9). Remove the cover plate (7), locking set (8) and thrust bearing (5). Extract the hook (3) from the bearing set (4). Re-assembly: • Lubricate the thrust bearing and the hook shaft.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 4. Hook bearing set 5. Thrust bearing 6. Locking ring 7. Bearing housing 8. Side plate 9. Sheave bearing set 10. Rope sheave 12. Shaft locking 13. Rope sheave set 15. Sleeve Disassembly: • Lower the hook onto a stable working-platform. Pull with a gloved hand some extra rope down from the drum, so that the hook-block is free. If needed, adjust the lower limit switch.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Hook block, all other models c_hb20as1b_004723 Note: The actual hook block outlook may vary, depending on the size! 2. Safety latch set 3. Hook forging. 4. Hook bearing set 5. Thrust bearing 6. *) Locking ring or nut 7. Cover 8. Shaft & shaft locking screws 9. Sheave cover 10. Rope sheave 11. Side plate & side plate locking screws 12.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • • • • • • • Switch OFF the power supply to the crane. Remove the shaft locking parts (8). Remove the side plate fixing parts (11) Extract the rope sheaves (10), sheave covers (9) and side plates (11). Remove the cover plate (7) Remove the locking ring (or nut) (6) and thrust bearing (5). Extract the hook (3) from the bearing set (4).
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Disassembly: • Lower the hook onto a stable working-platform. Pull with a gloved hand some extra rope down from the drum, so that the hook-block is free. If needed, adjust the lower limit switch. • Switch OFF the power supply to the crane. • Remove the shaft locking parts (5). • Extract the shaft (5) and the rope sheave (4) from the shaft support (3).
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Disassembly: • Lower the hook onto a stable working-platform. Pull with a gloved hand some extra rope down from the drum, so that the hook-block is free. If needed, adjust the lower limit switch. • Switch OFF the power supply to the crane. • Remove the shaft locking parts (5). • Extract the shaft (5) from the support frame (3).
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Rotation resistant ropes have more outer strands than standard ropes. Outer strands have left hand lay, while inner strands are in right hand lay. 5.30.2 Service • • ! Inspect the rope. Regular rope inspection and maintenance shall be carried out according to the guideline instructions below and according to international standard ISO 4309:2004. Lubricate the rope with suitable lubrication.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Rotation Resistant Ropes Rope diam. Mm Rope construction 6.7 17 x 7 8 – 8.5 24 x 7 11 – 11.5 28x 7 15 28 x7 Detected length mm 40 200 50 250 70 350 90 450 Maximum wire breaks Duty class M4 Duty class M5, M6 2 4 4 8 2 4 4 8 2 4 4 8 2 4 4 8 Local reduction of rope diameter Rope diameter can decrease due to external or internal wear or damage.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Protrusion of rope parts Rope with rise up of core, strand or group of wires shall be changed immediately. Loose outer strands The outer strands of the ropes shall be tight, when the rope is not loaded. In standard and heavy duty ropes the outer strands can have small, visible gap under load. If the gap does not close when the load is released, the rope shall be changed.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.30.3 Assembly Disassembly: • Adjust (or by-pass) the lower limit switch so that the rope can be fully unwound from the drum • Lower the hook onto a stable working-platform. • Remove the rope guide, see section “Rope guide, Assembly” for details. • Pull, with a gloved hand, the rope down from the drum, until the last turn. • Switch OFF the power supply to the crane.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 # Inaretwo-rope systems (True Vertical Lift), replace both ropes simultaneously. Ensure that both ropes exactly identical except right/left hand lay. # Inin length two-rope systems (True Vertical Lift), ensure that both rope are of equal length. A small variation may cause the hook block and the balancing beam to tilt.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Overload protection, mechanical switch c_odme1b 1. Rope anchorage 2. Lever mechanism 3. Set of plate springs 4. Mechanical limit switch 5. Adjustment screw for mechanical limit switch Overload protection, load sensor c_odme1b 1. Rope anchorage 2. Lever mechanism 3. Load sensor 4.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 ! • Safety limit switch is not adjustable! Lubricate the pivot joint of the lever mechanism, the suspension support of the rope anchorage and the rocker bushings of the support beam with suitable thin oil. # Regulations in certain countries require that the operating point of overload protection is checked annually by conducting an overload test.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 SWM c_SWM01a 1. Digital display 2. Indicator LEDs 3. Programming buttons Condition monitoring unit c_cid01a 1. Digital display 2. Indicator LEDs 3. Programming buttons 5.32.1 Service Consult with the service manual of the respective condition-monitoring unit for details. • Check that non of the fault-indicating LEDs are lit up, and that the display does not show an error message.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 5.33 Load signal amplifier The load signal amplifier amplifies the signal coming from the load sensor. The amplified signal is fed into the condition-monitoring unit. The LED’s indicate the load, in percentage of the rated load of the hoist.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 ! Setup the condition monitoring unit always after load sensor amplifier adjustment! Refer to separate service manual for condition monitoring unit.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 6 Installation Familiarize yourself with the installation instructions delivered with the hoist before commencing. Pay attention to the instructions on safe operation of the hoist. 6.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Low headroom trolley, drum size φ 243 mm 6.2 Clearance between the wheel flange and the main girder flange (measure X) must be 3…5 mm. Ensure that the clearance is equal on both ends of the trolley. 5 c_qztr01c 2 1 3 6 4 1. 2. 3. 4. 5. 6. • ! • • ! Locking washers Fixing nuts Plain washers Adjusting nuts Lifting mounts Screw rods Remove the temporary transport supports.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 6.3 Low headroom trolley When installing a low headroom trolley, the wheel gauge has to be adjusted properly. Clearance between the wheel flange and the main girder flange (measure X) must be 3…5 mm. Ensure that the clearance is equal on both ends of the trolley. c_lab1b A X B X B Drum size φ 303mm c_bmla1a 1. Locking screw and nut 2. Fixing screws for fixing bracket 3.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 ! • Tighten the lowest fixing screws (2) for the fixing brackets of the trolley on both sides to the correct tightening torque. Refer to the section “Recommended tightening torques”. Tighten the locking screws (1) for trolley adjustment on both sides. Drum size φ 355/406mm and φ 303 for low profile c_r2bmla1c 1. Adjusting bar 2. Locking screws 3. Frame tube 4.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 6.4 Double-girder trolley c_dab1a 1. Travel wheel 2. Rail • • • • • • Remove the temporary transport supports. Take the hoist out of the packing and move it to the installation site. Lift the hoist using the lifting lugs provided. Check that the rail centers (B) on the main beam are suitable for the hoist trolley.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 6.5 Normal headroom trolley 6.5.1 Straight beam c_nab1c 1. Adjusting bar 2. Adjusting nuts for flange width 3. Trolley positioning nuts 4. Frame tube 5. Trolley side plate • • • • • Remove the temporary transport supports. Take the hoist out of the packing and move it to the installation site. Lift the hoist using the lifting lugs provided.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 ! Tighten the nuts (2)/(6) and (3) to the correct tightening torque. Refer to the section 'Recommended tightening torques'. c_nab2b B A 0,1-0,2 mm 0,1-0,2 mm 6.5.2 Curved beam, when two trolleys c_nab3a 2. Adjusting nuts for flange width 3. Trolley positioning nuts 4. Frame tube 5. Trolley side plate • • • Remove the temporary transport supports.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 • • ! Adjust the side plate (5) of the trolley inwards by turning the screws (3) until there is a gap of approximately 3…5mm between the flange of the travel wheels and the flange of the beam. Adjust the position of the trolley so that the hook is hanging below the centerline of the beam. Lock the position by tighten the nuts (2).
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 6.6 Normal headroom trolley, drum diameter 608 mm 6.6.1 Straight beam B 6 A L4 L2 L3 L1 c_nab3a 1. Adjusting bar for trolley position 2. Adjusting nuts for flange width 3. Trolley positioning nuts 4. Frame tube 5. Trolley side plate 6. Adjusting bar for flange width • • • • • Remove the temporary transport supports.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 # Adjust the position of the trolley so that the hook is hanging below the centerline of the beam. Select L-dimensions according to rope reeving and beam flange from table below. ! Tighten the nuts (2) and (3) to the correct tightening torque. Refer to the section 'Recommended tightening torques'. 6.6.1.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 6.6.2 Curved beam B A ø 608 mm c_nab4b 2 5 3 L2 L1 2. Adjusting nuts for flange width 3. Trolley positioning nuts 5. Trolley side plate • • • • • Remove the temporary transport supports. Take the hoist out of the packing and move it to the installation site. Lift the hoist using the lifting points marked on the hoist. Loosen the adjusting nuts for flange width (2).
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 6.6.2.1 Standard reeving (1 rope from drum) Falling ropes 2 4 6 L1 (mm.) 0 18 40 L2 Inch 0 0,71 1,57 (mm.) 97 146 146 Inch 3,82 5,75 5,75 6.6.2.2 Standard reeving (2 ropes from drum) Falling ropes 2 4 6 8 L1 (mm.) 21 0 6 12 L2 Inch 0,82 0 0,23 0,47 (mm.) 97 146 146 146 Inch 3,82 5,75 5,75 5,75 6.6.3 Outfitting the hoist • • • 6.7 Install the power supply.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 6.7.1 Outfitting the hoist • • • 6.8 Install the power supply. Refer to the section “Connecting the to mains network”. Adjust the limit switch for hoisting. Refer to the section “Adjusting hoisting limit switch”. Carry out the commissioning inspection and complete the commissioning log. Refer to the section “Commissioning”.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 6.9 Connecting to the mains network An electrical wiring diagram is delivered with the hoist. Carry out the following procedures before connecting the hoist to the mains network: • Check that the rated voltages correspond to the main voltage. The voltages and frequencies marked on the rating plate of motors driven by inverter can deviate from the values on the rating plate for the hoist.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 7 Commissioning Before handing over the hoist, at least the inspections and adjustments listed below should be carried out. In some cases it is appropriate to carry out a more thorough inspection. The scope of the inspection depends on the operating range and application. 7.1 Inspections without load. 7.1.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 ! For safety reasons the hoisting limit switch must always be adjusted before the commissioning tests are continued. 7.1.5 Inspection and adjustment of the limit switch for travel (not in all models) • ! Adjust the triggering locations of the limit switch. Check the operation of the limit switch by running the hoist to the triggering locations.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 The current should be in balance in all phases and may not exceed the ratings for the motor. Check the current at both hoisting speeds. 7.2.2 Inspection of running temperature. If the thermal protection halts hoisting prematurely, identify the reason for overheating before continuing the commissioning tests. 7.2.3 Inspection of travelling machinery. • • 7.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 8 Maintenance The lifetime of the hoist is divided into Safe Working Periods (SWPs). At the beginning of the Safe Working Period, a new hoist has an SWP% of 100. A Safe Working Period ends when the SWP% of the hoist is zero.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 8.2 Periodical inspections and servicing The servicing intervals for the hoist are defined as SWP% periods. The actual operation of the hoist is taken into account in SWP%. If the hoist is provided with a condition monitoring unit, the SWP value can be read from the SWP-data counter display of the unit.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Items for inspection and servicing Interval SWP% reduction 1) 2) 10% 40% 80% Hoist classification all M5/M6 M3/M4 Calendar period.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 8.3.1 STEP 1: Operating hours per inspection interval, Ti 2 ∗ H ∗ N ∗T ∗ J Ti = V ∗ 60 - H = average hoisting height [m] N = number of work cycles per hour [cycles/h] T = daily working time [h] V = hoisting speed [m/min] J = working days during inspection interval [days] 8.3.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 8.3.5 STEP 5: SWP% and remaining service life SWP% and estimated remaining service life can be obtained from table below.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 Tightening torque Size M12 M14 M16 M18 M20 M22 M24 M27 M30 Strength 8.8 [Nm] 77 125 190 275 385 530 660 980 1350 [Ft lb] 56.6 92 140 202 283 390 485 721 993 [Nm] 115 180 280 390 550 750 950 1400 1900 Strength 10.9 [Ft lb] 84.6 132 206 287 404 552 699 1030 1398 # Itlocking is recommended that the self locking nut (Nyloc nut) is replaced always when removed.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 9 Lubricants 9.1 ! Lubricant types Use of a low-grade or incompatible lubricant can damage the gearing or bearings. Use only the original lubricants recommended by the manufacturer.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 9.2 Lubricant quantities 9.2.1 Lubricant volumes, hoisting gears Drum size φ 243 mm Gear type GEN0 300 ml Volume 10.6 fl.oz (Imperial) φ 303 mm GEN1 600 ml 21.1 fl.oz (Imperial) φ 355 mm GEN2 900 ml 31.7 fl.oz (Imperial) φ 406 mm GEN3 1400 ml 49.3 fl.oz (Imperial) φ 608 mm GEN4 2500 ml 88.0 fl.oz (Imperial) 9.2.
R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502 P.: (937) 328-5100 FAX: (937) 325-5319 10Troubleshooting The table below lists some of the faults and malfunctions that may occur in the hoist, their causes and the corrective actions needed to eliminate them. # Ifauthorized you are unable to identify and eliminate the fault using this table, contact a service agent by the manufacturer. Fault The hoist is not operative. Probable cause Main supply power is not connected.
