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MAINTENANCE MANUAL

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MAINTENANCE MANUALMAIN

    MAINTENANCE INSTRUCTIONS

1. PLACING THE HOIST IN SERVICE 1.7 LOAD TEST

1.1 CONNECTION TO THE MAINS SUPPLY A load test is required.

    1.8. EARTH LEAKAGE TEST Please check whether the voltage stamped on

    the data plate corresponds to that of the

    mains supply. The wiring diagram contained in After extended periods of storage or stoppage,

    this book gives the necessary information for an earth leakage test is required to check for

    connecting the electrical hoist to the mains ingress of moisture.

    supply.

    2. GENERAL DESCRIPTION

    1.2 EARTHING CONDUCTOR

    2.1 HOIST BRAKE ASSEMBLY

    The earthing conductor marked green / yellow

    in the supply line must be connected to the The brake is a direct current brake consisting

    earth terminal. of a rectifier, a DC magnet, single or double

     brake discs and linings mounted on a spline. 1.3 CHECKING THE PHASE CONNECTIONS This arrangement eliminates any axial

     pressure on the motor bearing. As the motor

    When the push-button on the pendant control is energized, the DC magnet is activated and

    station is pressed for lifting, the load must rise. the pressure plate is pulled against the springs,

    If it goes down, switch off the current supply thus releasing the brake. The brake is applied

    and reverse two phases on the supply. Note by multiple springs when the magnet is de-

    that hoist was left with about one diameter turn energized. As the brake is electrically

    before cutting the top limit for this purpose. connected with the motor circuit, it is switched

     with the motor; thus in the event of power 1.4 FINAL SETTING OF LIMIT SWITCH failure, the brake engages automatically (fail to

     safety).

    After checking the earth conductor, mains

    2.2 HOIST MOTOR supply and phase connections, the hook

    should be brought to the top position until the

    limit switch stops the hoisting movement. The hoist motor is a standard frame size,

    Correct adjustment of the switch is important three-phase squirrel-cage induction motor with

    before a hoist is put into service as accidents a special hoisting duty winding. The totally

    may occur otherwise. The limits in the limit enclosed fan-cooled motor employs Class „B‟

    switch enclosure are adjusted to operate in or „F‟ insulation. The motor is fully insulated

    accordance with the longest possible hook and can withstand high temperatures. The

    travel. The limits must be readjusted to suit starting torque is more than 200% of the

    the local requirements. normal torque. The normal rating is 180 starts

     per hour; 40% ED.

    1.5 START-UP CHECK AND LUBRICATION

    2.3 HOIST GEARS

     1.5.1 If supply, erection and commissioning are

    done by Condra, all lubricant points will be All gears are made of high-quality steel and

    adequately greased and the gearbox assembly designed for oil bath lubrication in a totally

    filled with oil. The rope and rope drum are enclosed gearbox. Provision has been made

    lubricated with special grease. for long service life.

1.5.2 When crane components and individual hoists

    are supplied, please refer to our maintenance

    check and lubricant specifications contained in

    this book.

1.6 CLEARANCE CHECK

    Check all end positions of the hoist or crane for

    possible obstructions in the crane and hoist

    operating area.

    MAINTENANCE INSTRUCTIONS

    Page 1 2.4 HOIST ROPE, DRUM AND ROPE GUIDE brake disc pressure plate and brake spline. ASSEMBLY The brake linings are renewable. The brake is

     spring-applied and magnetically released by The rope is of the normal right-hand lay with a means of the DC magnet. As the brake is fibre core, a 6 x 36 construction. For lifts in mechanically and electrically connected to the excess of 10 m, a non-spin rope with a steel motor, it is switched with the motor. Thus, in core and a 7 x 36 construction is to be used. the event of a power failure, the brake The rope drum is manufactured from mild steel engages automatically (fail to safety). with machined grooves taking the total length

    2.9 HOIST ASSEMBLY of rope. The standard drum diameter is

    approximately 19 times the diameter of the

    rope. The rope guide is a solid, cast bronze All hoist operations are controlled by push-ring, precision-machined to suit the drum button switches on the pendant control. All grooves. It can be removed from the end of controls are effected through magnetic the drum and refitted. contactors and an auxiliary circuit for positive

     reliability. An electromagnetic brake retains

    2.5 BOTTOM BLOCK the load safety in case of emergency or when

     the power supply is switched off. A limit switch The cast-iron rope sheaves have a minimum stops overwinding and overlowering. 110 (volts) diameter of 20 times larger than the wire rope is used for the control circuits, unless diameter and are fitted with anti-friction otherwise requested. All components of the bearings. The stamp forged annealed steel hoist are unitized, simplifying dismantling and hook is tested to 200% of the safe working re-assembly during maintenance. load and is mounted with a thrust bearing,

    3. MAINTENANCE INSTRUCTIONS enabling it to revolve with the load.

    2.6 ROPE PULLEYS 3.1.1 SERVICE INTERVALS

    3.1.2 For class 1 am duty (normal workshop duty up All the pulleys in the bottom and top blocks are

    fitted with sealed ball-bearings and are to a maximum of 4 hours per day, under the lubricated for life. load spectrum of 1) the cranes and / or hoists

     should be serviced / inspected every two

    2.7 LIMIT SWITCH AND GUIDE TUBE months.

    ASSEMBLY

    3.1.3 For class 3m duty (up to a maximum of 16

    A limit switch is mounted in the hoist in order to hours per day, under the load spectrum of 1) limit the hoisting and lowering motion. The cranes and / or hoists should be serviced switch, of the self-resetting type, automatically /inspected every month.

    cuts out the hoisting motor after the rope guide

    NOTE 1. These intervals do not apply to cranes has reached its end position on the rope drum.

    It offers protection against inadvertent and hoists placed in special conditions operation of the hoist. The limit switch also such as foundries (over furnaces) or activates in case of phase reversal, thus chemical plants, etc. Advice on service preventing damage to the hoist when phase intervals for cranes and hoists used in rotation is changed accidentally. In case of a these conditions should be obtained phase reversal, the limit switch is activated and from our service department. neither the hoisting or lowering modes can be

     2. Please note also that whenever the operated.

     hoist is used to install heavy machinery We advise that a technician be called in from in new buildings, this cannot be our nearest branch to repair or replace the regarded as normal working conditions service limit switch. and a shorter interval between services /

     inspections should be considered. The collars are adjusted only if the rope is

    changed.

    2.8 CROSS-TRAVEL AND LONG-TRAVEL

    DRIVE UNITS AND BRAKE

The brake is a direct current disc brake,

    consisting of a rectifier, a DC magnet, single

    Page 2

    MAINTENANCE INSTRUCTIONS

    3.2 SAFETY WARNINGS d) Insert the feeler guage between the

     magnet and the pressure plate as shown 3.2.1 Always make certain that the power supply to in Figure 1.

    the crane or hoist is switched off and the e) Use the feeler gauge to ensure that the

    isolating switch is locked. A warning note must gap is uniform all the way around.

    be attached to the switch to guard against the f) Re-lock the adjusting screws by fastening the

    power supply being switched on while lock-nuts.

    maintenance work is in progress. g) Re-check the gap after re-locking the

     adjusting screws and readjust if necessary. 3.2.2 Check that all tools and/or equipment used h) Replace the cover and fasten the four

    during erection, installation or service and screws.

    repair have been removed from the crane /

    hoist before operating it.

3.3 SAFETY PRECAUTIONS

3.3.1 Maintenance work on the crane, hoist and

    crawl must not start before the load has been

    removed and the power supply to the crane,

    hoist and crawl has been switched off.

3.3.2 For the maintenance and operation of all

    equipment, all relevant official regulations and

    accident prevention regulation must be

    adhered to.

3.3.3 Tests and checks must be carried out as listed in the check-list and also as stated in our 3.4.3 Renewal of lining Lubrication Schedule. a. Remove the brake cover. 3.4 HOIST BRAKE ASSEMBLY b. Remove the fan by removing the tension pin or circlip. 3.4.1 Adjustment for Lining wear c. Loosen the lock-nuts on all three adjusting screws and remove the bolts. The wear on the brake linings has to be d. Remove the disc(s) and linings. checked regularly in accordance with the e. Check the brake discs for distortion and instructions that follow and at the intervals wear. The discs should be parallel specified in paragraph 3.1. The lining wear is within +- 0.02 mm. checked between the magnet and the pressure plate after the cover has been removed. When IMPORTANT new, the gap is adjusted to 0,6 mm for single discs and 0,8 mm for double discs. Allowance Both the brake disc(s) and pressure plate must has been made for a maximum gap of 1,6 mm, move freely on the spline and guide pins. after which the load will induce progressive slipping of the linings. Recheck the brake adjustment after 2 hours of continuous operation. 3.4.2 Readjustment of brakes 3.4.4 Weather covers (where applicable) If the wear on the brake has reduced the brake lining to 5 mm, renew the linings (refer to Weather covers, where applicable, must be paragraph 3.4.3). Check the distance between replaced as soon as possible to prevent the pressure plates as follows: damage due to rain or water. a) Remove the cover by removing the four 3.4.5 Brake rectifier protection fuses screws. b) Loosen the locknuts on the three adjusting Only „ultra rapid‟ type fuses should be used. screws. Contact Condra Service Department for c) Using a feeler guage, adjust the gap as information and/or the supply of spare fuses. specified (0,6mmfor single discs and Do not run open circuit. 0,8mm for double discs). Page 3

    MAINTENANCE INSTRUCTIONS

    3.4.6 Replacement of hoist brake coil 3.5 DRUM, COVER AND ROPE GUIDE

    ASSEMBLY

    a. Follow the procedure set out in

    3.5.1 Rope and rope guide paragraph 3.4.3. a. d.

    b. Disconnect the power supply to the DC

    magnet in the motor connection box. Regular greasing will increase the life of the c. Remove the four nuts holding the rope and the rope guide. Use graphite grease

    magnet and the motor. only. Rope dressing must not be used. In d. Lightly tap against the back of the very dusty and gritty environments, the rope

    magnet to release the tight fit of the drum and rope guide should be cleaned

    spigot. thoroughly to remove all dirt before new e. The magnet can now be pulled off graphite grease is applied.

    without removing the pinion.

    3.5.2 Replacement of wire rope

    3.4.7 Replacement of hoist stator

     The wire rope must be replaced if there is any a. Switch off the main power supply. sign of wear, tear, broken strands, corrosion or b. Disconnect the wires supplying the permanent deformation such as kinks, bends,

    motor and brake magnet. bruises, etc.

    c. Remove the fan cover.

    3.5.3 Removal of wire rope d. Remove the brake fan.

    e. Remove the brake plates and linings.

    f. Remove the nuts and spring washers a. Lower the bottom block as far as the

    from the motor studs. limit switch allows.

    g. Remove the brake magnet and studs. b. Move the limit switch striker collar to the h. Remove the stator, taking care not to outermost position and operate the hoist

    touch the rotor and shaft. in lowering mode until the drum nut is i. Fit the new stator, again taking care not within 10mm of the rope clamps.

    to touch the rotor and shaft. c. Ensure that the correct reeving method j. Refit the brake magnet (NOTE: The is noted before removing the existing

    brake cable side to be the same as the rope. This will avoid confusion when

    motor connections). fitting the new rope.

    k. Refit the nuts and spring-washers to the d. Undo the rope clamps on the drum and

    motor studs. Tighten evenly all round. on the fixed point.

    l. Refit the brake plates and linings (do not e. Unreeve the rope from the top and

    forget the springs). bottom blocks.

    m. Reset the brake gap.

    3.5.4 Fitting of new wire rope n. Refit the brake fan.

    o. Reconnect the brake magnet and motor

    connections. This procedure should be carried out by p. Switch on the mains and carefully check experienced personnel only.

    the direction of the motor. If the

    direction is incorrect, change the two a. Lay the total length of rope on the floor

    phases. Note that for two-speed motors to eliminate twist.

    the winding with higher resistance b. Feed the rope into the drum and tighten

    belongs to the slow speed. the rope clamp on the drum.

    While checking the motor direction, c. Rotate the drum in lifting mode until the

    check that the brake plates and linings grooves of the rope are wound onto the

    move freely. drum.

    q. Refit the brake fan cover. Retest the d. Lower enough rope to allow reeving of

    motor. the top and bottom blocks. Drive the

     bottom blocks into the top limit and fix

    NOTE: When the hoist motor is the end of the rope so that a clearance

    removed it is possible that the hoist rope of about a sheave diameter remains

    will unwind down to the limit switch between the bottom block and the drum.

    bottom position. This will put the switch e. Secure the loose end of the rope to the

    in the off position. In this event, bridge rope anchor.

    out switch to activate the motor. f. Set the lower limit switch striker.

    Remember to remove the bridge

    immediately after use.

    Page 4

    MAINTENANCE INSTRUCTIONS

    3.6 LIMIT SWITCH 4. AFTER SALES SERVICE DIVISION

    4.1 CRANE AND HOISTS SERVICES & Correct adjustment of the switch is important,

    INSPECTION REPAIRS AND LOAD TESTS as accidents may occur otherwise. Please

    AS PER OHA ACT (85/1993) consult the limit switch adjustment instructions.

    The limit switch must be adjusted to suit the

    local requirements. Condra (Pty) Ltd has an After Sales Service

     Division to cater for all your Crane and Hoist 3.7 CROSS-TRAVEL AND LONG-TRAVEL requirements after commissioning. A 24 hour DRIVE UNITS AND BRAKE service is provided to contracted clients and

    3.7.1 Adjustment of lining wear we recommend this approach to all of our

     clients. The Service Manager can be The wear on the brake linings has to be contacted for further information at the checked periodically in accordance with the numbers listed below.

    following instructions and at intervals specified

    4.2 SPARE PARTS in the maintenance instructions. The wear can

    be checked between the magnet and the

    pressure plate. When new, the gap is adjusted For our clients who have their own to 0,5mm and allowance has been made for a maintenance staff, spare parts can be ordered maximum cap of 1,5mm. through our AFTER SALES SERVICE

     DIVISION or directly through our To adjust the brake, loosen the Allen-head cap MANUFACTURING DIVISION at the numbers screws and remove one shim from each of the listed below.

    three screws. Tighten the screws again and

    4.3 WHEN ORDERING PLEASE STATE: check the gap by means of a feeler gauge. If

    the wear on the brake has reduced the

    thickness of the brake lining to 5mm, renew The Crane or Hoist W/O number. the lining. A description of the part and part number

     which you can obtain from this parts list. We 3.7.2 Renewal of lining recommend that you have your Cranes and

     Hoists inspected at least once a year by our a. Remove all three Allen-head cap screws.Service Division, even if you do have your own

     maintenance staff.

    b. Remove the brake magnet, together

    with the pressure plate. HEAD OFFICE (011) 873-9800 tel c. Slide the brake lining off the centre HEAD OFFICE (011) 873-9807 fax

    spline. SERVICE DIVISION (011) 822-2463 tel d. For re-assembly with the new brake SERVICE DIVISION (011) 822-2469 fax

    lining, follow the reverse order of the

    above steps.

    e. Ensure that all the spacers and shims

    are fitted to give an equal gap of 0,5mm.

    The brake will not operate otherwise.

3.7.3 Weather covers (where applicable)

     Weather covers, where applicable, must be

     replaced as soon as possible to prevent

     damage due to rain or water.

3.7.4 Brake rectifier protection fuses

     Only „ultra rapid‟ type fuses should be used.

     Contact Condra Service Department for

     information and/or the supply of spare fuses.

3.7.5 Replacement of coil

     The operation is carried out in the same

    manner as the renewal of the lining.

    Page 5

    MAINTENANCE INSTRUCTIONS

5. LUBRICATION INTERVALS

     CLASS 1M DUTY CLASS 2M DUTY CLASS 3M DUTY

    3 60 6 30 1 20 LUBRICATION INTERVALS MONTHS MONTHS WEEKS MONTHS MONTH MONTHS

    1. Grease rope guide and rope drum X X X

    2. Check oil level in all gearboxes and

    refill as necessary X X X

    3. Change oil in hoist gearbox X X X

    4. Change grease in travel gearboxes X X X

    5. Grease plummer blocks X X X

    6. Grease open reduction X X X

6. LUBRICATION SPECIFICATIONS

     PETROLMARK APPLICATION SPECIFICATION BP SHELL MOBIL

     Regular gear oil Gear oil BP hypogear Shell spirex Mobilube Hoist unit Grade SAE EP 90 GL 5 GL 5 EP 90 MB SAE 90 HD75W-90

     Lithium soap Energrease Energrease Shell grease Mobilux Drive gearboxes Grease N?. 3 FG 00 EP FG 00 EP S 3655 EP 004

     Molybdenised Grone grease - - Mobil Open gears Lithium soap EP Special X OGL 007

     Lithium soap Super BP energrease Shell alvania Mobilux Wheels Grease N?. 2 WB 3 EP LS 3 R 3 EP 3

     Grease 904 Energrease Energrease Barbatia Mobilarma Rope guide Graphite grease GP 2 G GP 2 G Grease 2 798

     Read this schedule in conjunction with the maintenance instructions.

     GEARBOX OIL LEVEL

     When filling with oil, do not fill above level plug, as this can cause damage to motor.

     Approximate quantities of oil required for changes :

     Hoist unit __________

     Cross travel gearboxes __________

     Long travel gearboxes __________

     Slewing gearboxes __________

    Page 6

    MAINTENANCE INSTRUCTIONS

    CRANE / HOIST SERVICE CHECK LIST

    1 2 3 4 5 6

    Check crane structure Steelwork Check cabin fixing and glass Check service platforms and hand railing Check condition of gantry Check end stops / buffers Check gantry rails Check crab rails Check monorail

    Check isolator / ACB / fuses Downshop supply Check collector brackets Check collectors, brushes Check condition of downshop in general

    Check fitting and doors (covers) Panel and connection boxes Check all contactors, relays and overloads Check transformers Check fuse carriers, fuses and ACB‟s Check wiring (tight / loose wires) Check hoist, cross and long travel rectifiers Check cable glands and earth connections

    Check enclosures Pendant & pushbutton / controllers Check buttons, controllers and labels Check pendant cable Check pushbutton Check cable loop and pushbutton box Check key & selector switches (if applicable)

    Check all lights fittings and globes Lights and hooter (where applicable) Check light switches and transformers Check hooter and foot switch

    Check connections, terminals and cables Hoist Check magnets and connections Check the limit switch operating rod Check terminals and connections Check operation of limit switch up and down Check ultimate limit switch (if applicable) Check rope guide Check rope and securing device Check drum and rope guide nut (see note) Check and adjust brakes Report on condition of linings Check for oil leaks & level of oil in gearbox Replace oil in gearbox (see lubrication instructions)

    NOTE : Please check “Lubrication Instructions” – intervals of oil and grease changes before greasing rope and

     rope guide nut. Remove impurities from these parts prior to lubrication.

    Date : ____________________ Checked by :

     Signature :

    Page 7

    MAINTENANCE INSTRUCTIONS

    CRANE / HOIST SERVICE CHECK LIST (continued)

    1 2 3 4 5 6

    Check oil breathing plugs Hoist

    Check tight fit of all supporting screws / bolts

    Check load hooks for cracks cold deformation

    Check condition of safety catch

    Check sheaves

    Check crab travel gears Cross travel (crab)

    Check tight fit of all supporting screws / bolts

    Check and adjust brake

    Check connections, terminals and cables

    Check smooth running of motor and gearbox

    Check cross travel limit switch (if applicable)

    Replace grease in gearbox

    (see lubrication instructions)

    Check and grease pinions and gears Long travel

    Check wheels

    Check tight fit of all supporting screws / bolts

    Check oil breathing plugs

    Check and adjust brake

    Check connections, terminals and cables

    Check smooth running of motor and gearbox

    Check long travel limit switch (if applicable)

    Replace grease in gearbox

    (see lubrication instructions)

    NOTE : Please check “Lubrication Instructions” – intervals of oil and grease changes before greasing rope and

     rope guide nut. Remove impurities from these parts prior to lubrication.

    Date : ____________________ Checked by : Signature :

    Page 8

    MAINTENANCE INSTRUCTIONS

    STANDARD CRANE ELECTRICAL CIRCUIT DIAGRAM

    NOTE: FOR HOIST AND CRAWL UNITS LONG TRAVEL DOESN’T APPLY’

     FOR NON-STANDARD CRANES SEE SPECIALLY DESIGNED DIAGRAMS.

    On a STANDARD CRANE the supply & long travel switch gear are housed in one control panel placed on the end

    carriage and the hoist & cross travel switchgear are housed in another control panel on the back of the hoist

    Page 9

SERVICE REGISTER

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