ZX6&ZX8
ELECTRICWIREROPEHOIST
INSTALLATION,OPERATIONAND
MAINTENANCEINSTRUCTIONS
56565656defgh StreetCraneCompanyLimitedreservestherighttoalteroramendthedetailsgiveninthispublicationwithoutpriornotification.
StreetCraneCompanyLimited2012DocumentRef:D2840rev.F
defgh Street Crane Co Ltd
III
INTRODUCTIONThismanualhasbeencarefullypreparedtoassistyou inthe installation,maintenanceandsafeoperationoftheStreetCraneequipmentasdescribedinthemanual.Itisintheinterestofallpartiesinvolvedwiththeuseofthisequipmenttoensurethatproceduresarefollowedefficientlyandsafely.Before installing,usingorstartinganymaintenanceworkon thehoiststudy thismanualcarefully. Obtainacompleteunderstandingofthehoistanditscontrolsinordertoensurethesafeandefficientuseofthehoist.Ensurethatallpersonsinvolvedintheoperationaresuitablyqualifiedandtrainedinitssafeoperation.Provided that the recommendedoperation,maintenance and lubricationprocedures are followed, youwillmaximisetheHoistslifeexpectancyandhavetroublefreeservice.Anyoneworkingwithoron theequipmentshouldalsobeawareof their relevant responsibilitiesunder theFactoriesAct,theHealthandSafetyatWorkAct1974andLiftingOperationsandLiftingEquipmentRegulations(LOLER) 1998. The user has the responsibility for ensuring that the equipment is properly inspected andmaintainedandissafetouse.NOTE:Othernationalregulationsmayapplyforothercountries.InGreat Britain codes of practice exist for the SafeUse of Cranes. This standard, BS 7121, also coversinspection,testingandexamination.Theusershouldbefamiliarwithitscontentsanditisadvisabletohaveacopyofthisstandardkeptalongsidethismanual.BS7121coversthefollowingsubjects:
Safesystemsofwork Managementoftheliftingoperation Planningoftheliftingoperation,riskassessmentsandmethodstatements Selectionanddutiesofpersonnelandtheirminimumattributes Maintenanceofcranes Inspection,TestingandExamination
In addition,management and supervisionhave an initial role toplay in any safetyprogrammebyensuringthat:
Theequipmentissuitableforthejobintended Theequipmenthasbeenthoroughlyexaminedandissafetouse Asafetyprocedureisadoptedforemergencysituationsi.e.powerfailure Asafesystemofworkisadoptedformaintenancepersonnel
Itshouldbeemphasisedthatthesafetyadviceandmaintenancedetails included inthisdocumentshouldbemadeavailablewhere theycanbemosteffective. It isyour responsibility toensure that this information ismadeavailableatTHEPLACEOFWORK.
defgh Street Crane Co Ltd
IV
THISPAGEISINTENTIONALLYBLANK
defgh Street Crane Co Ltd
V
CONTENTS1. GENERALSAFETYINSTRUCTIONS ........................................................................................................10
1.1 SYMBOLS............................................................................................................................................ 10 1.2 PERSONNELDefinitionsandAttributes ........................................................................................... 10 1.3 MAINTENANCESAFETYPROCEDURE ................................................................................................. 10 1.4 MAINTENANCEANDINSPECTIONACCESS ......................................................................................... 11 1.5 WARRANTY/REPLACEMENTPARTS .................................................................................................. 11 1.6 PERIODICTESTS.................................................................................................................................. 11 1.7 STORAGE ............................................................................................................................................ 11 1.8 TRAININGANDAFTERSALESSERVICE ............................................................................................... 11
2 DESCRIPTIONOFEQUIPMENT.............................................................................................................12 2.1 HOISTNAMEPLATE ............................................................................................................................ 14 2.2 LIMITINGDEVICES.............................................................................................................................. 14
2.2.1 Hoistingandloweringlimits.......................................................................................................... 14 2.2.2 Ratedcapacitylimiter(RCL) .......................................................................................................... 15 2.2.3 Travel/Traverselimits(optional) ................................................................................................. 15
3 INSTALLATIONANDCOMMISSIONINGINSTRUCTIONS ........................................................................16 3.1 TRAVERSEENDSTOPS........................................................................................................................ 16 3.2 RUNNING&MOUNTINGSURFACETOLERANCESANDFINISHES....................................................... 17
3.2.1 TolerancesontheInclinationoftheRunningSurface .................................................................. 17 3.2.2 TolerancesonCrabRailGauge&RailHeight................................................................................ 17 3.2.3 TolerancesonSingleGirderRunwayFlangeWidth ...................................................................... 18 3.2.4 TolerancesonMountingSurfaceforFootMountedHoists.......................................................... 18 3.2.5 Toleranceonmisalignmentofrailjoints,wheelrunningsurfacesandguidancesurfaces........... 19
3.3 HOISTWEIGHTSANDLIFTINGPOINTS............................................................................................... 19 3.3.1 LowHeadroom.............................................................................................................................. 19 3.3.2 DoubleGirderCrab ....................................................................................................................... 20 3.3.3 FootMounted ............................................................................................................................... 21
3.4 INSTALLATIONOFLOWHEAD2&4FALLSINGLEGIRDERHOIST........................................................ 22 3.4.1 SettingtheReactionRoller............................................................................................................ 24
3.5 INSTALLATIONOFLOWHEAD6&8FALLSINGLEGIRDERHOIST...................................................... 25 3.5.1 AdjustingtheCTandNonCTtrolleywidthsrunwaywidth300700mm..................................... 25 3.5.2 Installingthehoistontotherunway ............................................................................................. 28
3.6 INSTALLATIONOFFOOTMOUNTEDHOIST........................................................................................ 30 3.7 SETTINGTHEUPPERANDLOWERLIMITSWITCHESStandardEnvironment .................................. 31
3.7.1 Settingthelowerlimit................................................................................................................... 31 3.7.2 Settingtheupperlimit .................................................................................................................. 32
3.8 SETTINGTHEUPPERANDLOWERLIMITSWITCHESGalvanising/AggressiveEnvironments .......... 33 3.8.1 Settingthelowerlimit................................................................................................................... 33 3.8.2 Settingtheupperlimit .................................................................................................................. 33
3.9 ULTIMATEUPPERLIMITSWITCHROTARY(OPTIONAL) ................................................................... 34 3.9.1 Settingtheultimateupperlimit.................................................................................................... 34
3.10 ULTIMATEUPPERLIMITSWITCHHOOKBLOCKOPERATED(OPTIONAL)........................................ 36 3.10.1 Settingtheultimateupperlimit ............................................................................................... 36
3.11 LOWHEADROOMHIGHESTHOOKPOSITION2FALL&4FALL ......................................................... 37 3.12 LOWHEADROOMHIGHESTHOOKPOSITIONZX86FALL&8FALL .................................................. 38 3.13 FOOTMOUNTHIGHESTHOOKPOSITIONZX6&ZX8......................................................................... 38
defgh Street Crane Co Ltd
VI
3.14 DOUBLEGIRDERPARALLELCRABHIGHESTHOOKPOSITIONZX6&ZX8.......................................... 39 3.15 DOUBLEGIRDERPERPENDICULARCRABHIGHESTHOOKPOSITIONZX8 ......................................... 39 3.16 CHECKING/ADJUSTINGTHERATEDCAPACITYLIMITER ................................................................... 40
3.16.1 AdjustingtheRatedCapacityLimiterforProofLoading .......................................................... 40 3.17 TRAVERSELIMITS(OPTIONAL) ........................................................................................................... 41
3.17.1 Settingtraverselimits............................................................................................................... 41 3.18 CONNECTINGTHEPOWERSUPPLY .................................................................................................... 43
3.18.1 Supplycables/fuses ................................................................................................................ 43 3.18.2 Mainisolatorsupplyswitch(byothers) ................................................................................ 43 3.18.3 Connectingtothemainssupply ............................................................................................... 43 3.18.4 Electromagneticcompatibility.................................................................................................. 45 3.18.5 ConnectingthePendantcontrollerLowHeadroom.............................................................. 45
3.19 COMMISSIONINGPROCEDURE .......................................................................................................... 46 3.20 DISMANTLING/REMOVALOFTHEHOIST ......................................................................................... 46
4 OPERATINGINSTRUCTIONS ................................................................................................................47 4.1 INTENDEDUSE ................................................................................................................................... 47 4.2 DUTIESOFTHEOPERATOR/SAFEHOISTINGPRACTICES .................................................................. 47 4.3 REMOTECONTROLLEDCRANES/HOISTS.......................................................................................... 49 4.4 CONTROLSTATIONOPERATINGINSTRUCTIONS................................................................................ 50
4.4.1 LegendNomenclature................................................................................................................... 50 4.4.2 SwitchON...................................................................................................................................... 50 4.4.3 Pushbuttonoperation .................................................................................................................. 50 4.4.4 Joystickoperation ......................................................................................................................... 51 4.4.5 EmergencyStop ............................................................................................................................ 51
4.5 LEAVINGTHECRANE/HOISTUNATTENDED ..................................................................................... 52 4.6 POWERFAILURE................................................................................................................................. 52
5 INSPECTIONANDMAINTENANCEINSTRUCTIONS................................................................................53 5.1 REPORTINGOFDEFECTSANDINCIDENTS.......................................................................................... 53 5.2 SPECIALKNOWLEDGE ........................................................................................................................ 53 5.3 KEEPINGOFRECORDS........................................................................................................................ 53 5.4 DAILYPREUSEINSPECTIONS(atthestartofeachday/shift)............................................................ 53 5.5 HOISTSTHATHAVEBEENUNUSEDFORANEXTENDEDPERIOD ....................................................... 54 5.6 INSPECTIONANDMAINTENANCEINTERVALS ................................................................................... 55 5.7 LUBRICATION ..................................................................................................................................... 58
5.7.1 LubricationSchedule..................................................................................................................... 60 5.8 INSPECTIONANDMAINTENANCEWIREROPE................................................................................ 62
5.8.1 OffloadingandStorage ................................................................................................................. 62 5.8.2 ReplacingtheWireRope............................................................................................................... 62 5.8.3 FittingtheRopeGuide .................................................................................................................. 67 5.8.4 WedgeandSocketTermination.................................................................................................... 70
5.9 INSPECTIONANDMAINTENANCEHOIST/CRABFRAME ................................................................. 71 5.9.1 Sheaves ......................................................................................................................................... 71 5.9.2 SingleGirderWheels ..................................................................................................................... 72 5.9.3 DoubleGirderCrabWheels(DoubleFlange) ................................................................................ 72
5.10 INSPECTIONANDMAINTENANCEHOISTBRAKE............................................................................. 73 5.10.1 HoistBrakeComponents.......................................................................................................... 73 5.10.2 HoistBrakeData....................................................................................................................... 74
defgh Street Crane Co Ltd
VII
5.10.3 BrakeDisc(Rotor)Spline .......................................................................................................... 74 5.10.4 Checking/AdjustingtheAirGap.............................................................................................. 74 5.10.5 ChangingtheBrakeDisc(brakerotor)/Inspectingthebrakehub .......................................... 75 5.10.6 FittingtheHandRelease .......................................................................................................... 76 5.10.7 Fittingthebrakesealkit(optional) .......................................................................................... 77 5.10.8 Brakerectifier ........................................................................................................................... 77
5.11 INSPECTIONANDMAINTENANCETRAVERSEBRAKE ...................................................................... 78 5.11.1 TraverseBrakeComponents .................................................................................................... 78 5.11.2 Checking/AdjustingtheAirGap.............................................................................................. 79 5.11.3 ChangingtheBrakeDisc(brakerotor)/Inspectingthebrakehub .......................................... 79 5.11.4 FittingtheTraverseDriveHandRelease .................................................................................. 80 5.11.5 Fittingthebrakesealkit(optional) .......................................................................................... 81
5.12 INSPECTIONANDMAINTENANCEHOOKBLOCK............................................................................. 82 5.13 INSPECTIONANDMAINTENANCEHOISTDRIVECOUPLING............................................................ 84
6 FAULTFINDING ..................................................................................................................................85 6.1 GENERAL ............................................................................................................................................ 85 6.2 BRAKES............................................................................................................................................... 86 6.3 MOTORUNITS.................................................................................................................................... 87 6.4 GEARBOXES........................................................................................................................................ 88
7 TECHNICALDATA................................................................................................................................89 7.1 CONDITIONSOFUSE .......................................................................................................................... 89 7.2 PROCEDUREFORESTIMATINGREMAININGSERVICELIFE................................................................. 89 7.3 HOISTMODELCODE .......................................................................................................................... 90 7.4 NOISELEVELS ..................................................................................................................................... 93 7.5 HOISTMOTORDATA.......................................................................................................................... 94
7.5.1 ZX06HoistMotorData3:1SPEEDRATIO400V,3Ph,50Hz...................................................... 94 7.5.2 ZX08HoistMotorData4:1SPEEDRATIO400V,3Ph,50Hz...................................................... 94 7.5.3 ZX06HoistMotorData3:1SPEEDRATIO460V,3Ph,60Hz..................................................... 95 7.5.4 ZX08HoistMotorData4:1SPEEDRATIO460V,3Ph,60Hz...................................................... 95 7.5.5 ZX06HoistMotorData3:1SPEEDRATIO575V,3Ph,60Hz...................................................... 96 7.5.6 ZX08HoistMotorData4:1SPEEDRATIO575V,3Ph,60Hz...................................................... 96 7.5.7 ZX06HoistMotorData3:1SPEEDRATIO380(10%)V,3Ph,60Hz......................................... 97 7.5.8 ZX08HoistMotorData4:1SPEEDRATIO380(10%)V,3Ph,60Hz......................................... 97 7.5.9 ZXDualWoundWUTypeTraverseMotorData400V50Hz ...................................................... 98 7.5.10 ZXDualWoundWUTypeTraverseMotorData460V60Hz ................................................. 99 7.5.11 ZXDualWoundWUTypeTraverseMotorData575V60Hz ............................................... 100 7.5.12 ZXDualWoundWUTypeTraverseMotorData380V60Hz ............................................... 101 7.5.13 ZXTraverseMotorDataforusewithFrequencyInverter...................................................... 102
7.6 CABLECROSSSECTIONANDLENGTHOFSUPPLYCABLE ................................................................. 104 7.7 RESULTSOFPERIODICTESTS............................................................................................................ 105 7.8 RECORDOFREPLACEMENTPARTS(ropes,brakes,sheavesetc.) .................................................... 106
FIGURESFigure1HoistNameplateLocation.................................................................................................................... 14 Figure2SingleGirder2&4FallTraverseEndStops.......................................................................................... 16 Figure3SingleGirder6&8FallTraverseEndStops.......................................................................................... 16
defgh Street Crane Co Ltd
VIII
Figure4DoubleGirderTraverseEndStops ....................................................................................................... 17 Figure5SingleGirderRunwayTolerances......................................................................................................... 19 Figure6DoubleGirderRunwayTolerances....................................................................................................... 19 Figure7LowHeadroom2&4FallLiftingPoints ................................................................................................. 19 Figure8LowHeadroom6&8FallLiftingPoints ................................................................................................. 19 Figure9DoubleGirderCrabLiftingPoints2&4fallunits............................................................................. 20 Figure10DoubleGirderCrabLiftingPoints6&8fallunits........................................................................... 20 Figure11RemovingHoistCoveron6&8fallDoubleGirderCrabs .................................................................. 20 Figure12Lifting6&8fallDoubleGirderCrabs................................................................................................. 20 Figure13FootMountedLiftingPoints............................................................................................................... 21 Figure14InstallingtheLowHeadroomTrolley ................................................................................................. 22 Figure15WithdrawingtheReactionRoller ....................................................................................................... 22 Figure16LowHeadroomRunwayClearance .................................................................................................... 23 Figure17SettingtheLowHeadroomLegs......................................................................................................... 23 Figure18LowHeadroomHoistTransportationFeet......................................................................................... 24 Figure19ReactionRoller ................................................................................................................................... 24 Figure20CTTrolleyPlateAssemblyElectricalPanelside................................................................................. 25 Figure21CTTrolleyPlateAssemblyHoistPanelside........................................................................................ 26 Figure22TrolleyPlateAssemblyfittedfor700mmrunway.............................................................................. 26 Figure23Runwaywidthspacerpositions.......................................................................................................... 26 Figure24SafetyBarPosition ............................................................................................................................. 27 Figure25Endcaprefitted................................................................................................................................... 27 Figure26Endcapreversedandrefitted............................................................................................................. 28 Figure27Liftingthehoisttotherunway........................................................................................................... 28 Figure28Settingthetensioningscrew.............................................................................................................. 29 Figure29InstallationofFootMountedHoist .................................................................................................... 30 Figure30HoistLimitSwitchesStandardEnvironment ................................................................................... 31 Figure31HoistLimitSwitchesStandardEnvironmentRv1(seehoistnameplateforrevision) .................... 31 Figure32HoistLimitSwitchesGalvanising/AggressiveEnvironment............................................................. 33 Figure33UltimateUpperLimitSwitchRotaryType ....................................................................................... 34 Figure34SettingtheUltimateUpperLimitSwitchRotaryType................................................................... 35 Figure35UltimateUpperLimitSwitchHookBlockType................................................................................ 36 Figure36RatedCapacityLimiter ....................................................................................................................... 40 Figure37SettingtheTraverseLimitSingleGirderArrangement .................................................................... 41 Figure38TraverseLimitDoubleGirderarrangement ....................................................................................... 42 Figure39HoistElectricalConnections............................................................................................................... 43 Figure40DelayTimers....................................................................................................................................... 44 Figure41PhaseFailureRelay............................................................................................................................. 44 Figure42ControlTransformerConnections...................................................................................................... 45 Figure43StrainerWireConnections ................................................................................................................. 45 Figure44Clearancestoconsiderwhenlifting ................................................................................................... 48 Figure45RecommendedHandSignals............................................................................................................... 49 Figure46ControlPendantLegends ................................................................................................................... 50 Figure47ZX6Gearboxoilfill&levelpluglocations .......................................................................................... 58 Figure48ZX8Gearboxoilfill&levelpluglocations .......................................................................................... 59 Figure49CorrectUncoilingofWireRopes ........................................................................................................ 63 Figure50IncorrectUncoilingofWireRopes ...................................................................................................... 63 Figure51Windingofnewwireropes ................................................................................................................ 63
defgh Street Crane Co Ltd
IX
Figure52Fleetangle........................................................................................................................................... 64 Figure53ReevingDiagramsforZX6&ZX82&4FallLowHead&CrabHoists .................................................. 64 Figure54ReevingDiagramsforFootMountHoists:ZX082FTM/ZX084FTM ................................................ 65 Figure55ReevingDiagramsforFootMountHoists:ZX062FTM/ZX064FTM ................................................ 65 Figure56ReevingDiagramsforZX86&8FallLowHead&CrabHoists:.......................................................... 65 Figure57ReevingDiagramsforFootMountHoists:ZX086FTM/ZX088FTM................................................ 66 Figure58FittingTopandBottomHalvesofRopeGuideInnerBand ................................................................. 67 Figure59RopeGuideInnerBandSpringandSleeveArrangement................................................................... 67 Figure60RopeGuideInnerBandFitted ............................................................................................................ 68 Figure61FittingRopeGuideOuterBand .......................................................................................................... 68 Figure62FittingRopeGuidePlateStandardEnvironments ........................................................................... 69 Figure63FittingRopeGuideRetainerStandardEnvironmentsRv1(seehoistnameplateforrevision) ...... 69 Figure64FittingRopeGuidePlateGalvanising/AggressiveEnvironments .................................................... 69 Figure65WedgeandSocketTermination ......................................................................................................... 70 Figure66Sheavecharacteristics......................................................................................................................... 71 Figure67Sheaveandbarrelgrooveinspection.................................................................................................. 72 Figure68HoistBrakeComponents.................................................................................................................... 73 Figure69CheckingHoistBrakeAirGap............................................................................................................. 74 Figure70AdjustingtheHoistBrakeAirGap...................................................................................................... 75 Figure71InspectingtheBrakeDisc ................................................................................................................... 75 Figure72HoistBrakeHandRelease .................................................................................................................. 76 Figure73BrakeSeal ........................................................................................................................................... 77 Figure74TraverseBrakeComponents .............................................................................................................. 78 Figure75CheckingTraverseBrakeAirGap ....................................................................................................... 79 Figure76AdjustingtheTraverseBrakeAirGap ................................................................................................ 79 Figure77TraverseDriveBrakeHandRelease ................................................................................................... 80 Figure78TraverseDriveBrakeSeal................................................................................................................... 81 Figure79HookThroatAdmittance.................................................................................................................... 82 Figure804FallBottomBlock,HookNut,Grubscrew,Greasenipple................................................................ 83 Figure812,6&8FallBottomBlock,HookNut,Grubscrew,Greasenipple ..................................................... 83 Figure82SoundPressureLevels........................................................................................................................ 93
defgh StreetCraneCoLtd
Page10of112 Ref:D2840rev.F
1. GENERALSAFETYINSTRUCTIONS
1.1 SYMBOLS
1 WARNINGThissymboldrawsattentiontothepossibleinjuryorriskoflife.
2 WARNINGOFELECTRICALPOTENTIALThissymbolisfoundonelectricalenclosures.Theseshouldonlybeopenedbyqualifiedpersonsorsuitablyinstructedpersonnel.
3 WARNINGOFSUSPENDEDLOADThissymbolwarnsoftherisktolifeandlimbfromstandingunderasuspendedload.
1.2 PERSONNELDefinitionsandAttributesTheusershouldensure that thepersoncarryingoutany taskhassuchappropriatepracticaland theoreticalknowledgeandexperienceof theequipment inquestionaswillenable them toperform the tasksafelyandrecogniseanyhazardsassociatedwiththework.TheyshouldbephysicallyandmentallyfitandtrainedinSafeHoistingPracticesandtheuseofsafetyandaccessequipment. Noworkofanykindshouldbeauthorisedtopersonswhoareunder the influenceofnarcotics,alcoholormedication,whichaffects theirability to react.Hazardscanonlybeminimisedbycare,commonsenseandbeingalertatalltimes.Variouspersonnelcanbeinvolvedintheliftingoperation,installationandinspectionandmaintenanceoftheequipment,supervisors,coordinators,operators,slingers,signallers,erectorsandmaintenancepersonnel.ThedutiesofthesepersonnelandtheirminimumattributesaredefinedinBS71211:2006.Also,ISO15513givescompetencyrequirements forcranedrivers (operators),slingers,signallersandassessors. In the textof thismanualthefollowingdefinitionsapply:
Userpersonororganisationthathascontrolofboththeliftingoperationandthecraneoperatorandhasthe responsibility to ensure the equipment is properly maintained and thoroughly examined by acompetentperson.CompetentPersonpersonwhohassuchpracticalandtheoreticalknowledgeandmechanicaland/orelectricalexperienceofthecrane/hoistandtheequipmentused inthe liftingoperationwhichenablesthem to detect defects or weaknesses and to assess their importance in relation to the safety andcontinueduseoftheliftingequipment.Operatortrainedpersonwhoisoperatingthecrane/hoistforthepurposeofpositioningloads.
1.3 MAINTENANCESAFETYPROCEDUREWhenpersonnelare required toworkon the crane /hoist for inspection,maintenanceorother reasons,asystemshouldbe inoperation toensure that theyarenotendangeredbymovementof theequipmentandthat a secure working place is provided. Personnel should follow such a procedure. Where no formalprocedureexists,StreetCranerecommendsthefollowing:Oncommencinganymaintenanceworkonthecraneorhoist:
1. Obtainthenecessaryauthorisation/permittowork.2. Parkthecraneorhoistinadesignatedmaintenanceposition,clearofanypersonnel.3. Followtheappropriatehealthandsafetyregulationsandprocedures.4. Remove any loads or attachments from the hook and ensure that the bottom block is suitably
supportedtopreventaccidentalrunaway.
defgh StreetCraneCoLtd
Ref:D2840rev.F Page11of112
5. Disconnectthemainsswitchandsafeguardagainstunauthorisedpoweringup,byplacinglocksandwarningnoticesintheappropriatepositions.
1 Somemaintenanceproceduresaremoreeffectivelyperformedwithpowertotheequipment.Ifworkhastobecarriedoutonliveparts,anadditionalcompetentpersonmustbeavailabletoactuatethepowerisolatingswitchinanemergency.Ensurethatthereisaneffectivemannerofcommunicationbetweenpersonnel.
6. Toavoidinjuries,useonlyinsulatedtoolsandequipment.7. Oncompletionofanymaintenancework,ensureall fixings,guards,covers,drip trays,etc.
arereplaced.1.4 MAINTENANCEANDINSPECTIONACCESSThe equipment itselfmayhavenoprovision formaintenance accessor itmaybe fittedwith fullorpartialmaintenanceaccessplatforms.Wherenooronlypartialaccesshasbeenprovidedontheequipment,separateor additional access equipmentwill be required to service some of the components. These componentsshould be accessed via a secure, mobile or temporary structure e.g. tower scaffold, selfstanding stairplatforms, scissorliftor cherrypicker. Allaccessequipment shouldbeassembledandoperatedby trainedpersonnel in accordance with the manufacturers instructions following the appropriate health and safetyregulationsandprocedures.The following should be considered when choosing the most appropriate type of maintenance accessequipment. Floorspaceavailablefortheaccessequipment. Workingheightabovefloorlevel. Numberofpersonnelwhorequireaccessathighlevel. Totalweightofanypartstoberemoved/replaced. Provisionofsafetyharnessanchorpoints
1.5 WARRANTY/REPLACEMENTPARTSThewarrantywillbecome invalid if the instructions for installation,operationandmaintenance instructionscontainedinthismanualarenotfollowed.WherereplacementcomponentsarerequireduseonlygenuineStreetCraneparts.Modificationstothecraneoranyof itsmechanismsshouldnotbecarriedoutwithout theapprovalofStreetCraneCompanyLimited.Failuretoadopttheserecommendationswillinvalidatethewarrantyandcouldresultinanunsafecondition.Pleasedisposeofelectricalandelectronicequipmentinanapprovedandenvironmentallyfriendlymanner.1.6 PERIODICTESTSThehoistmustbeinspectedbyacompetentpersonatleastonceayear.Thecompetentpersonmayconsidershorterperiodstobemoreappropriatedependingonthedutyofthehoist.Arecordoftheresultsofthetestshouldbekept inthehoist logbook,section7.7. Aspartoftheannualtesttheremainingservice lifeofthehoistshouldbeestablished,seesection7.2.1.7 STORAGEIfthehoististobeplacedinstorageforanyperiodoftimeensurethat: Thehoistiscoveredandstoredindoorsinaheatedbuilding. Packthehoistclearofthefloor.Raisethebottomblocktoitstoppositionandensurethatthereareno
kinksinthewirerope. EnsureallelectricalswitchesareturnedtotheOFFposition. Alwaysfullyinspectthehoistbeforeinstallingandputtingintoservice.
1.8 TRAININGANDAFTERSALESSERVICEIf required,StreetCraneCompanyareable toprovide trainedservice technicians toassist in inspectionandmaintenanceproceduresandprovideoperatortraining.
defgh StreetCraneCoLtd
Page12of112 Ref:D2840rev.F
2 DESCRIPTIONOFEQUIPMENT
The ZX series hoist is of the electrically driven wire rope type. The hoist has a maximum load that it ispermittedtolift.ThisisreferredtoastheRatedCapacityorSafeWorkingLoad(SWL).Theratedcapacityisclearlymarkedonthehoistnameplateandthebottomblock.
1.Hoistmotor 6.Controlpanel 11.Upperlevellimitswitch2.Hoistbrake 7.Traveldrive 12.Lowerlevellimitswitch3.Wirerope 8.Reactionroller(LHonly) 13.Ropeguide4.Bottomblock 9.Travelwheels 14.Ropeclamps5.Hoistgearbox 10.Ratedcapacitylimiter 15.Sheaveassembly
defgh StreetCraneCoLtd
Ref:D2840rev.F Page13of112
defgh StreetCraneCoLtd
Page14of112 Ref:D2840rev.F
2.1 HOISTNAMEPLATEThehoistnameplateislocatedonthehoistendframeandcontainsthefollowinginformation: Thehoistmodelcode. Themanufacturersname. Theserialnumber. Theyearofmanufacture. Hoistclassification. Mechanismclassifications.
The information on this nameplate will be required when ordering replacement parts and whenassessingtheremainingservicelifeofthehoist.Furtherinformationonthehoistmodelcodecanbefoundinsection7.3.
Figure1HoistNameplateLocation
2.2 LIMITINGDEVICESEachhoistisfittedwithupperandlowerlimitsandaratedcapacitylimiter(RCL).Theseareessentialitemsforthe safe operation of thehoist. Additional limiting devicesmaybe fitted ifdeemed necessaryby the riskassessment.2.2.1 HoistingandloweringlimitsHoisting and lowering limit switches are fitted to all hoists to prevent the hook from going too high anddamagingthehoistandfromgoingtoolowsoastoallowtheropestogoslack.ThesearesafetydevicesandshouldNOTbeusedasanormalmethodofstoppingthehoist. Movement intheoppositedirection,atthespeedselectedbytheoperator(sloworfast)isstillpossibleafterthenormallimithasbeentriggered.
defgh StreetCraneCoLtd
Ref:D2840rev.F Page15of112
1 Certaincraneconfigurationsallowtheupperhookpositiontobesetatahigherlevelthantheundersideof thebridgegirders (doublegirder cranes). In such instances theoperatormusttakeextremecarewhen liftingtoensurethatadequateclearance ismaintainedbetweentheloadorliftingattachmentandthehoistorcranestructure.
Anoptionalsecondhoistupperlimitorultimatelimitmayalsobefittedifdeemednecessarybytheuserriskassessment.Theultimatelimitisanemergencylimitemployedonlyifthenormalupperlimitfails.Oncetripped,thelimitmustbemanuallyresetbyserviceormaintenancepersonnelandwillrequirethehookblocktobe loweredmanuallyandthelimitreset.Ifthesecondhoistupperlimitoperates,thehoistshouldbetakenoutofserviceuntilthereasonforthenormalupperlimitswitchfailurehasbeeninvestigated.Thefailureshouldberectifiedbeforeputtingthehoistbackintoservice.Thesecondhoistupperlimit,whentripped,willpreventmovementfromallhoistandtraversemotions.Thetravelmotion(longtravel)willremainfullyoperable.Aredwarninglightonthebaseofthecontrolpanelwillilluminatetoindicatewhenthesecondultimatelimithasbeenactivated.2.2.2 Ratedcapacitylimiter(RCL)Allhoistunitsarefittedwitharatedcapacitylimiter(RCL)topreventtheliftingofloadsbeyondthecapacityofthehoist/crane.IftheRCListrippedthehoistmotionwillstopanditwillthenonlybepossibletomoveinthelowerdirection.2.2.3 Travel/Traverselimits(optional)Limitswitchesattheextremesoflongandcrosstravelareoptionalbasedontheusersriskassessment.Therearethreetypes:
1. Onreachingthelimitthecraneorhoisttravelmotionwillstopaltogether.2. On reaching the limit the craneorhoistwill change from fast to slow speedandproceedat slow
speeduntiltheendstopisreached.3. Ifa twostage limit is fitted,on reaching the firststage themotionwill reduce toslowspeed. On
reachingthesecondstagethemotionwillstop.Operationofthelimitdoesnothaveanyeffectonothercranemotions.Movementintheoppositedirection,atthespeedselectedbytheoperator(sloworfast)isstillpossibleafterthelimithasbeentriggered.
defgh StreetCraneCoLtd
Page16of112 Ref:D2840rev.F
3 INSTALLATIONANDCOMMISSIONINGINSTRUCTIONS
Installationandcommissioningof thehoistmustbecarriedoutbyacompetentperson(s). We recommendthatinstallationandcommissioningarecarriedoutbyStreetCraneCompanyortheirapprovedagents.Immediately reportanydamagewhichmayhaveoccurredduring transit. Consultwith themanufacturer /supplierandrepairtheequipmentbefore installation. Donot installdamagedequipment. UseonlyoriginalStreetCranesparepartsforrepairs.Donotcarryoutanyalterationsormodificationstothehoisteitherpriortoorduringinstallation.Ifthehoistislocatedoutdoorswerecommendthatasmallcover(roof)isfittedtotherunwaybeamtoprotectthehoistatitsparkingposition.
3.1 TRAVERSEENDSTOPSSinglegirder2&4 fall lowheadhoists requireend stops tobemountedoneitherendof the runwayandincluderubberbuffersasshown.WeldonendstopscanbeprovidedbyStreetCrane.(PartNo.27031).
Figure2SingleGirder2&4FallTraverseEndStops
Singlegirder6&8fall lowheadhoistsaresuppliedfittedwithrubberbuffers. Suitableendstopsshouldbepositionedateitherend,centralontheundersideoftherunway.WeldonendstopscanbeprovidedbyStreetCrane.(PartNo.2720061).
Figure3SingleGirder6&8FallTraverseEndStops
defgh StreetCraneCoLtd
Ref:D2840rev.F Page17of112
Doublegirdercrabunitsaresupplied fittedwithrubberbuffers. Suitableendstopsshouldbepositionedateitherendofthecrabrails.WeldonendstopscanbeprovidedbyStreetCrane.(PartNo.2720061).
Figure4DoubleGirderTraverseEndStops
3.2 RUNNING&MOUNTINGSURFACETOLERANCESANDFINISHES
3.2.1 TolerancesontheInclinationoftheRunningSurfaceTheangleofinclinationoftherunningsurfaceforthehoistshouldnotexceedthevaluesshown.
3.2.2 TolerancesonCrabRailGauge&RailHeightThegaugeshallnotdeviatefromthenominalbymorethan3mm.Thedifferenceinrailheightshallnotexceed3mmforgaugesuptoandincluding2000mmor5mmforgaugesgreaterthan2000mm.Railheightshouldbeaminimumof30mm.
defgh StreetCraneCoLtd
Page18of112 Ref:D2840rev.F
3.2.3 TolerancesonSingleGirderRunwayFlangeWidthThe variation in thewidthof a single girder runway flange shouldbeno greater than3mmover its entirelength.
3.2.4 TolerancesonMountingSurfaceforFootMountedHoistsTheverticalmisalignmentbetweenallmountingholesshallnotexceed1mm.
defgh StreetCraneCoLtd
Ref:D2840rev.F Page19of112
3.2.5 Toleranceonmisalignmentofrailjoints,wheelrunningsurfacesandguidancesurfacesThe running surface for the hoist wheels and guide rollers (single girder hoist only) should be free fromobstructionsandleftunpainted.Thesesurfacesshouldalsobefreefromdamage,pitting,weldbeadsorothersurfacedefects.Surfacesshouldbealignedtoprovideasmoothtransitionpathforthewheelsbetweentracksections. Gapsinanyjoints(J)shouldbenogreaterthan2mm. Thereshouldbenostepintherunningorguidancesurface(h)greaterthan0.5mm. Lateralmisalignmentindoublegirderrailjoints(L1)shouldnotexceed1mm.
NOTE: Runway joint splice plates on the bottom flange are not possiblewith ZX6& ZX8 single girder lowheadroomhoistsbecauseofthehoistreactionroller.
Figure5SingleGirderRunwayTolerances Figure6DoubleGirderRunwayTolerances
3.3 HOISTWEIGHTSANDLIFTINGPOINTS
3.3.1 LowHeadroom
Figure7LowHeadroom2&4FallLiftingPoints Figure8LowHeadroom6&8FallLiftingPoints
3.3.1.1 TableofweightsLowHeadHoists 2Fall 4Fall 6Fall 8Fall NB LB ELB VLB NB LB ELB VLB NB LB ELB LB ELB
ZX6 329 362 410 350 386 439 ZX8 861 983 1255 1385 928 1011 1190 1376 1867 2104 2328 2244 2453
Weightsshownforeachmodelinkgdonotincludeanyoptionalextras
1 TheliftinglugsfittedtothehoistunitaredesignedforliftingthemassofthehoistunitONLY(includinganytransportationfeet).
defgh StreetCraneCoLtd
Page20of112 Ref:D2840rev.F
3.3.2 DoubleGirderCrab
Figure9DoubleGirderCrabLiftingPoints2&4fallunits
Figure10DoubleGirderCrabLiftingPoints6&8fallunits
Doublegirdercrabunitshaving2or4fallsshouldbeliftedusingtheliftingpointsfittedtothehoistendframeseeFigure9. Crabunitswith6or8fallsshouldbe liftedusingtheeyeboltsfittedtoeachcornerofthecrabframeseeFigure10.Beforethe6and8fallunitscanbelifted,thetopsectionofthehoistcovershouldberemovedtoallowliftingchainstoaccesstotheeyebolt.RemovethefourM8setscrewsandwashersseeFigure11.
Figure11RemovingHoistCoveron6&8fallDoubleGirderCrabs
LegofliftingchaincannowpassthroughapertureinendframesideplateseeFigure12
Figure12Lifting6&8fallDoubleGirderCrabs
Afterliftingiscompleted,refitthehoistcovertopsectionandtightensetscrewsto15Nm.
defgh StreetCraneCoLtd
Ref:D2840rev.F Page21of112
3.3.2.1 TableofweightsDoubleGirderCrab 2Fall 4Fall 6Fall 8Fall NB LB ELB NB LB ELB NB LB ELB NB LB ELB
ZX6 423 477 566 446 502 596
ZX8 PARALLELARRANGEMENT(CRB)1400GAUGE 1002 1104 1329 1078 1185 1419 1292 1410 1669 1496 1753
ZX8 PERPENDICULARARRANGEMENT(CRE)1400GAUGE 1002 1078 1219
2000GAUGE 1039 1123 1398 1116 1204 1398 1234 1300 1406
2600GAUGE 1076 1161 1346 1153 1241 1436 1284 1350 1494 1555 1665
Weightsshownforeachmodelinkgdonotincludeanyoptionalextras3.3.3 FootMounted
Figure13FootMountedLiftingPoints
3.3.3.1 TableofweightsFootMounted
2Fall 4Fall 6Fall 8Fall NB LB ELB NB LB ELB LB ELB LB ELB
ZX6 267 304 355 289 327 384 ZX8 637 716 889 722 809 998 889 1063 941 1114
Weightsshownforeachmodelinkgdonotincludeanyoptionalextras
1 TheliftinglugsfittedtothehoistunitaredesignedforliftingthemassofthehoistunitONLY.
defgh StreetCraneCoLtd
Page22of112 Ref:D2840rev.F
3.4 INSTALLATIONOFLOWHEAD2&4FALLSINGLEGIRDERHOIST Measuretherunwayflangewidth. Whilstthehoist isonthefloorandstoodonthepackingfeet,slackenthe4M12 lockinggrubscrews
thatsecurethepanelsidetrolleyframetothelegs(donotreleaseanyfixingsonthehoistbarrelside). Openthetrolleyframeuntilthegapbetweentheendsofthewheelaxlesisatleast20mmwiderthan
thewidthoftherunwayflange(seeFigure14).Donotremovethecirclipsontheendsofthelegs.
Figure14InstallingtheLowHeadroomTrolley
Disconnect the reaction roller assembly from thewheel support castingby removing the circlip andwasherontheendofthepin.
Withdrawthereactionrollerassemblyfromthewheelsupportcasting(seeFigure15).
Figure15WithdrawingtheReactionRoller
Raisethehoisttorunwaylevel,usetheliftinglugsprovidedseeFigure7. Pushthebarrelsidetrolleyontotherunwayflangeuntilthehoistsideguiderollerstouchthetoeofthe
runway. Secure thebarrel side frameagainstmoving. Ensure that the reaction roller isheld in thecorrectorientationwiththespringpointingoutwards,horizontally.
Pushthepanelsidetrolleyontotherunway(tapwithrubber/nylonmalletasnecessary)untilthegapbetweenguiderollerandtoeofflangeisbetween3and5mm(seeFigure16).Checkthatthegapisthesameatbothends.
defgh StreetCraneCoLtd
Ref:D2840rev.F Page23of112
Figure16LowHeadroomRunwayClearance
Lower the hoist unit so that the wheels are touching the beam flange ensuring that the 35mmclearancegapismaintained.
1 Donotremovethehoistliftingtackleuntilthehoistisfullysecuredontherunway. RemoveeachofthefourM12lockinggrubscrewsfromthepanelsidetrolleycastings. Usingthesingleconepointsetscrew,screwintoeachholeinturnandtightenuntilacentrepopindent
ismadeinthehoistlegs. Usinga10mmdiameterdrill,drilla fullconeof10mmdiameter intoboth legsat fourpositions (see
Figure17). Removeanyswarffromtheholesusingamagnet. Replaceconepointsetscrewinitsstorageposition,securingwiththelocknut.
Figure17SettingtheLowHeadroomLegs
ReplaceeachofthefourM12 lockinggrubscrewsandtightento40Nm. Secureeachgrubscrewwithlocknuttightenedto40Nm.
Replacethereactionrollerassemblyonthewheelsupportcasting.Setthereactionrolleraspersection3.4.1.
Removethefourbluetransportationfeetfromthehoistlegs(Figure18).
defgh StreetCraneCoLtd
Page24of112 Ref:D2840rev.F
Figure18LowHeadroomHoistTransportationFeet
3.4.1 SettingtheReactionRollerBefore setting the reaction rollerensure that the sideguide rollerson thepanel side trolley frame, i.e. theguiderollersonthesamesideasthereactionrollerassembly,areincontactwiththetoeoftherunwaybeamflange.Forthesettingoperationtheclearancebetweenthesideguiderollersandtherunwayflangemustbeonthebarrelside(notethisisontheoppositesidetothatshowninFigure16).Thereactionrollerfittedtolowheadroomhoistunitsrunsontheundersideoftherunwaybeamdirectlybelowthetraversedrivewheel.Iftherollerassemblyhasnotbeenreplaced,rotatetheassemblyuntilthelocationpinalignswiththeholeinthebodycasting(redadjustingspringfacinghorizontallyoutwards).Pushthepinintotheholeandattachthewasherandcirclip,thewashersitsdirectlybehindthecirclip.
Figure19ReactionRoller
Ensure that the travel drive wheel is in contact with the runway flange. Turn the reaction roller
adjustingnutuntiltherollerjusttouchestheundersideoftherunway. Turntheadjustingnutanadditionalfive(5)fullturnsandthenlockinpositionusingthelocknut.Hold
theadjustingnutandtightenthelocknutto81Nm.
1 Fivefullturnsoftheadjustingnutisimportanttoachievecorrectcompressiononthereactionrollerspring.
defgh StreetCraneCoLtd
Ref:D2840rev.F Page25of112
3.5 INSTALLATIONOFLOWHEAD6&8FALLSINGLEGIRDERHOIST3.5.1 AdjustingtheCTandNonCTtrolleywidthsrunwaywidth300700mm3.5.1.1 DisassemblyoftheCT&NonCTTrolleyPlateAssemblies
Measuretherunwayflangewidth. Iftherunwayis300mm,adjustmentoftheTrolleyPlateAssembliesisnotrequired,see3.5.2. Whilstthehoist isonthe floorandstoodon itsdelivery feet, identifyM16Hexscrews (3)andM20
SocketCapscrew(1)(viewthroughaccesshole),onCTtrolleyandnonCTtrolleysonElectricalPanelSideonly(seeFigure20).
Usinga17mmAFAllenkeyensureM20SocketCapscrew (1) is fullyscrewed in,turningthescrewclockwise.
Figure20CTTrolleyPlateAssemblyElectricalPanelside
1 To adjust the CT andNon CT trolley assemblies for 350700mm runways removal of the CTmotorsandTrolleyPlateassembliesisrequired,suitableliftingequipmentisnecessary.
RemovebothCTmotors,loosenandremoveM8FlangedHexscrews(4).Placeasideontoasuitablesurface,takingcarenottostraintheelectricalcable.
RemovetheEndcapElectricalPanelSide,loosenandremoveM16Hexscrews(3),seeFigure20. Removethe50mmspacers(3)and25mmspacers(2)fromtheaxleandplaceaside. Remove/slidetheTrolleyPlateAssemblyofffromtheaxle,seeFigure20.
UsetheDshackleholestoattachsuitableliftingequipment(70kg),placeaside. Remove/slidethecompleteTrolleyPlateAssemblyHoistSide,SeeFigure21,includingtheaxleand
spacersfromthehoist.Placeasideontoasuitablesurface.UsetheDshackleholesforsuitableliftingequipment(150kg),placeaside.
1 It is important that the Hoist Side M16 Hex screws(3) are NOT adjusted or loosened,See Figure 21, this ensures correct assembly when the Trolley Plate Assemblies are reassembled.
M20SocketCapscrew(1)(inside end cap viewthroughaccesshole)
EndCap(ElectricalPanelSide)
(300mmRunwayshown)50mmSpacers(3) 25mmSpacers(2)
Axle
M16Hexscrews(3)
M8 Flanged Hex screws(4)
DShacklehole
TrolleyPlateAssembly
defgh StreetCraneCoLtd
Page26of112 Ref:D2840rev.F
Figure21CTTrolleyPlateAssemblyHoistPanelside
3.5.1.2 AdjustingtheTrolleyplate,spacerandsafetybarspositions
Figure22TrolleyPlateAssemblyfittedfor700mmrunway
HoldingtheTrolleyPlateAssemblyHoistside,pushtheaxlethroughandremovethe50mm(3)and
25mm(2)spacers,seeFigure21. Iftherunwayis700mmrefittheTrolleyPlateAssemblyuptotheendcap,andfitthespacersonthe
inside,seeFigure22. ForotherrunwaywidthsseethebelowtableforpositionsofthespacersFigure23.
RunwayWidth(mm) SpacersuptoEndcap Spacersontheinside300 50mm(3)25mm(2) None350 50mm(3)25mm(1) 25mm(1)400 50mm(3) 25mm(2)450 50mm(2)25mm(1) 50mm(1)25mm(1)500 50mm(2) 50mm(1)25mm(2)550 50mm(1)25mm(1) 50mm(2)25mm(1)600 50mm(1) 50mm(2)25mm(2)650 25mm(1) 50mm(3)25mm(1)700 None 50mm(3)25mm(2)
Figure23Runwaywidthspacerpositions
M16Hexscrews(3)DONOTADJUSTORLOOSEN
TrolleyPlateAssembly50mmspacers(3)25mmspacers(2)
Axle
Endcap
For700mmrunwayTrolleyplateisfitteduptotheendcap,allspacers50mm(3)and25mm(2)arefiitedontheinside.
M16Hexscrews(3)HoistSideDONOTADJUST
DShacklehole
defgh StreetCraneCoLtd
Ref:D2840rev.F Page27of112
AdjustallthetrolleysafetybarsfortherunwayflangewidthasFigure24below.ThesafetybaristogivesupporttotheTrolleyPlateAssemblyuponfittingtothehoist.
Figure24SafetyBarPosition
3.5.1.3 RefittingtheTrolleyPlateAssembliestothehoist
RefitthecompleteTrolleyPlateAssemblyHoistSideincludingtheaxleandspacers(seeFigure22)intothehoistbeam,useDshackleholeforsuitableliftingequipment(Weight150kg).
Ensurethesafetybars(seeFigure25)areincontactwiththetopofthebeamandrelease. Refit the Trolley Plate Assembly Electrical Panel Side and spacers onto the axle, mirroring the
positionsonthehoistside,refertoFigure23forthecorrectpositions.
1 Itisveryimportantthatthepositionsofthetrolleyplateassembliesandspacersaremirroredexactly,ensuringthebeamiscentral,seeFigure25.
RefittheEndcapElectricalPanelSide,fitandtightenM16HexScrews(3)to20Nm.RefittheCTmotors,andtightenM8FlangedHexscrews(4)to24Nm,seeFigure25.
(700mmshown)
Figure25Endcaprefitted
RunwayWidth(mm)
DimX(mm)
300400 140450550 90600700 30
Refitendcap
RefitCTmotor RefitCTmotor
DimX
M16Hexnuts
defgh StreetCraneCoLtd
Page28of112 Ref:D2840rev.F
3.5.2 Installingthehoistontotherunway3.5.2.1 Liftingthehoisttotherunway
RemovetheEndcapElectricalPanelSide,loosenandremovetheM16Hexscrews(3) RefittheEndcapbutinreverse,seeFigure26below,tightentheM16Hexscrews(3),torque20Nm.
ThisgivesspaceontheaxletoallowtheTrolleyPlatestobepositionedwiderthanthebeamflange.
1 ItisveryimportantthattheHoistSideM16Hexscrews(3)areNOTadjustedorloosened.
Figure26Endcapreversedandrefitted
SeeFigure27fitsuitableliftingchainhooktoliftingpointholes.1 Fit suitable liftingequipment to the liftingpointholesensuring that the includedanglebetween chainsdoesnotexceed60andliftthehoistuptotherunwaylevel,ensuringthewidthofthetrolleys issufficienttoclearthebeamrunwaywidth.
3.5.2.2 SettingtheTrolleyPlatesandwheelsontotherunway
Position thehoistensuring theTrolleyPlateAssembly Hoist side and trolleywheels areover therunwayandthatthesiderollersareincontactwiththesideofthebeamflange.
Figure27Liftingthehoisttotherunway
1 For6Fallhoists toallow the fittingof thehoistcover, rotate midspan liftingstrapby90andsecurewith1offM16fastener(the2ndM16fasteneristoberetainedintheunusedholeforfutureliftingrequirements)Figure27.
EndcapReversedElectricalPanelSide
M16Hexscrews(3)HoistsideDONOTADJUST
defgh StreetCraneCoLtd
Ref:D2840rev.F Page29of112
Supporting theTrolleyPlateAssembly Hoistside,push theTrolleyPlateAssembly Electricalpanelsidetrolleysovertherunwayflange.Ensurethetrolleyplate is incontactwiththe insidespacersandthatthesiderollersare incontactwiththesideofthebeamflange.
RemovethereversedEndcapElectricalPanelSide,loosentheM16Hexscrews(3). Replace any removed spacers and refit the Endcap Electrical Panel Side, tighten the M16 Hex
screws(3)to20Nm. ToallowtheTrolleyPlateAssembliestopivot,thetensioningscrewrequiresadjustment,
seeFigure28.Usinga17mmAFAllenkeyunscrewtheM20SocketCaphead(counterclockwise)untilitmakescontactwiththeendcap.
Usingasuitabletorquewrenchwitha17mmAFAllenkeySocketapply100Nmoftorque(counterclockwise)totheM20SocketCaphead,seeFigure28.
Testthepivotofthetrolleyassembliesusinghandforceonly.
Figure28Settingthetensioningscrew
Lowerthehoistontorunwayflanges,ensuringthatallthewheelsareincontactwiththebeam. Remove thesafetybars (8) fromboth trolleyplateassemblies, releaseM16nutsandunscrew,see
Figure24. Removethetransportationfeetfromthehoist. For6Fallhoiststheliftingstrapsrequireremovalandfittingintothestorageposition,seeFigure27,
toallowthefittingofthehoisttopcover,refitthehoistcover.
M20SocketCapscrewtensioningscrew.Adjustbyturningcounterclockwiseto100Nm.
Endcap
defgh StreetCraneCoLtd
Page30of112 Ref:D2840rev.F
3.6 INSTALLATIONOFFOOTMOUNTEDHOIST
1 TheZX6&ZX8footmountedhoistunitsaredesignedformountinghorizontallywiththefeetatthebottomoftheunit.Thehoistsarenotsuitableformountingsuspendedupsidedownorinanyotherorientationotherthanasshown.
Figure29InstallationofFootMountedHoist
Footmountedhoistunitsaresuppliedwithfourmountingfeet.On2&4fallunitseachfoothasasingle18mmdiameterhole.TheyshouldbesecuredtoasuitablesupportingstructureusingfourM16fixingswithminimumgradeof8.8.On6&8fallunitseachfoothasasingle22mmdiameterhole.TheyshouldbesecuredtoasuitablesupportingstructureusingfourM20fixingswithminimumgradeof8.8.
1 Thesupportingstructureshouldbesuitablydesignedtosupportboththemassofthehoistunittogetherwith its rated capacity plus dynamic effects. Tolerances on themounting surfaceshouldbeinaccordancewith3.2.4.
defgh StreetCraneCoLtd
Ref:D2840rev.F Page31of112
3.7 SETTINGTHEUPPERANDLOWERLIMITSWITCHESStandardEnvironmentEachhoistisfittedwithanupperandlowerlevelhoistlimitswitch.Thelimitswitchesareactivatedbycontactwiththetravellingropeguidebush/retainer.Thesearesafetyswitchesandshouldnotbeusedasthenormalmethod forstopping thehoist. Whenactivated,eachswitchwillonlyallow travel in theoppositedirection.Removethehoistcovertogainaccesstothelimitswitches.NOTE:Thelimitspacertubesaredesignedtopreventtheswitchesfrombeingplacedoutsidethenormalrangeofoperation.Donotremoveormodifythesetubes.
1 Incorrect settingof the limit switchesmay cause seriousaccidentsanddamage to thehoistunit.
Figure30HoistLimitSwitchesStandardEnvironment
Figure31HoistLimitSwitchesStandardEnvironmentRv1(seehoistnameplateforrevision)
3.7.1 Settingthelowerlimit Releasethegrubscrewsthatsecuretheholdingarmtothelimitbarsandslidetheswitchtowardsthe
endofthehoist. Lowerthehooktothedesiredlowestoperatingposition.Donotletthehooktouchthefloorsuchthat
itwouldcausetheropestogoslack.
defgh StreetCraneCoLtd
Page32of112 Ref:D2840rev.F
NOTE:Theclearancebetweentheropeguideandtheropeclampsshouldnotbelessthan10mmwhenthehookisatitslowestposition.
Slidethelimitswitchuptotheropeguidebush/retaineruntiltheswitchisactivated.Tightenthegrubscrewsholdingthearmtothelimitbar.
Test that the limit operates satisfactorily firstly at slow speed and then at fast speed. Readjust ifnecessary.Whentheadjustmentsarecomplete,replacethehoistcover.
3.7.2 Settingtheupperlimit Releasethegrubscrewsthatsecuretheholdingarmtothelimitbarsandslidetheswitchtowardsthe
endofthehoist. Raisethehooktothecorrectoperatingposition.
1 Theupperhook levelfor lowheadroomhoistsvarywiththerunwayflangewidth. Thehoistwillbeseriouslydamagedifthehookissethigherthanthevaluesindicatedinsection3.11.
Slidethelimitswitchuptotheropeguidebush/retaineruntiltheswitchisactivated.Tightenthegrubscrewsholdingthearmtothelimitbar.
Test that the limitoperatessatisfactorily firstlyatslowspeedand thenat fastspeed,stoppingat thecorrectdistance fromtheundersideofthebeam. Readjust ifnecessary. Whentheadjustmentsarecomplete,replacethehoistcover.
defgh StreetCraneCoLtd
Ref:D2840rev.F Page33of112
3.8 SETTINGTHEUPPERANDLOWERLIMITSWITCHESGalvanising/AggressiveEnvironmentsEachhoistisfittedwithanupperandlowerlevelhoistlimitswitch.Thelimitswitchesareactivatedbycontactwith the travelling rope guide follower. These are safety switches and shouldnotbeused as thenormalmethod forstopping thehoist. Whenactivated,eachswitchwillonlyallow travel in theoppositedirection.Removethehoistcovertogainaccesstothelimitswitches.NOTE:Theguiderailhasastop tabateachendwhichensures that the limitswitchbracketsarenotplacedoutsidethenormalrangeofoperationoftheswitchesDonotremoveormodifythesestoptabs.
1 Incorrect settingof the limit switchesmay cause seriousaccidentsanddamage to thehoistunit.
Figure32HoistLimitSwitchesGalvanising/AggressiveEnvironment
3.8.1 Settingthelowerlimit RemovetheM6fastenersthatsecurethelimitswitchbrackettotheguiderailandpositiontheswitch
towardstheendofthehoist. Lowerthehooktothedesiredlowestoperatingposition.Donotletthehooktouchthefloorsuchthat
itwouldcausetheropestogoslack. NOTE:Theclearancebetweentheropeguideandtheropeclampsshouldnotbelessthan10mmwhen
thehookisatitslowestposition. Positionthelimitswitchbracketsuchthatthelimitswitchisactivatedbytheropeguidefollower.Refit
andtightentheM6fastenerssecuringthebrackettotheguiderail. Test that the limit operates satisfactorily firstly at slow speed and then at fast speed. Readjust if
necessary.Whentheadjustmentsarecomplete,replacethehoistcover.3.8.2 Settingtheupperlimit RemovetheM6fastenersthatsecurethelimitswitchbrackettotheguiderailandpositiontheswitch
towardstheendofthehoist. Raisethehooktothecorrectoperatingposition.
1 Theupperhook levelfor lowheadroomhoistsvarywiththerunwayflangewidth. Thehoistwillbeseriouslydamagedifthehookissethigherthanthevaluesindicatedinsection3.11.
PositionthelimitswitchbracketsuchthatthelimitswitchisactivatedbytheropeguidefollowerRefitandtightentheM6fastenerssecuringthebrackettotheguiderail..
Test that the limitoperatessatisfactorily firstlyatslowspeedand thenat fastspeed,stoppingat thecorrectdistance fromtheundersideofthebeam. Readjust ifnecessary. Whentheadjustmentsarecomplete,replacethehoistcover.
defgh StreetCraneCoLtd
Page34of112 Ref:D2840rev.F
3.9 ULTIMATEUPPERLIMITSWITCHROTARY(OPTIONAL)When specified, anultimateupper limitmaybe fitted to thehoistunit toprevent thebottomblock fromdamagingthehoistshouldthenormalupper limitswitch fail. Itshouldbesettoactivateattheupper levelgiven in section3.11. Thenormal limit should thenbe set toactivateapproximately75100mmbelow theultimatelimit.Aredwarninglightonthebaseofthecontrolpanelwillilluminatetoindicatewhenthesecondultimatelimithasbeenactivated.
Figure33UltimateUpperLimitSwitchRotaryType
3.9.1 Settingtheultimateupperlimit
1 Extremecaremustbeexercisedwhentestingtheultimatelimitswitchasitisnecessarytobypassthenormalupperlimit.
Repositionthenormalupperlimitsuchthattheultimatelimitisthefirsttooperate. Raise the hook to the desired operating position at slow speedwith no load attached allowing an
additional50mmforafastspeedapproach.
1 Theupperhook levelfor lowheadroomhoistsvarywiththerunwayflangewidth. Thehoistwillbeseriouslydamagedifthehookissethigherthanthevaluesindicatedinsection3.11.
Removethelidfromthesecondupperlimitandloosenthecentralclampscrew(seeFigure34). Turncamno.2adjustmentscrewuntilcamno.2ispositionedjustbeforeitoperatesthemicroswitch. Retightenthecentralclampscrew. Test the operating position in slow speed at first repeating the test in fast speed adjusting the trip
positionwherenecessary.Replacelimitswitchlid. Checkthattheredwarninglightinthebaseofthecontrolpanelilluminates. Setthenormalupperlimitsothatitoperatesapproximately75100mmbelowtheultimateupperlimit
(see3.7.2/3.8.2).
defgh StreetCraneCoLtd
Ref:D2840rev.F Page35of112
Figure34SettingtheUltimateUpperLimitSwitchRotaryType
defgh StreetCraneCoLtd
Page36of112 Ref:D2840rev.F
3.10 ULTIMATEUPPERLIMITSWITCHHOOKBLOCKOPERATED(OPTIONAL)When specified, anultimateupper limitmaybe fitted to thehoistunit toprevent thebottomblock fromdamagingthehoistshouldthenormalupper limitswitch fail. Itshouldbesettoactivateattheupper levelgiven in section3.11. Thenormal limit should thenbe set toactivateapproximately75100mmbelow theultimatelimit.Aredwarninglightonthebaseofthecontrolpanelwillilluminatetoindicatewhenthesecondultimatelimithasbeenactivated.
Figure35UltimateUpperLimitSwitchHookBlockType
3.10.1 Settingtheultimateupperlimit
1 Extremecaremustbeexercisedwhentestingtheultimate limitswitchas itnecessarytobypassthenormalupperlimit.
Repositionthenormalupperlimitsuchthattheultimatelimitisthefirsttooperate. Raise the hook to the desired operating position at slow speedwith no load attached allowing an
additional50mmforafastspeedapproach.
1 Theupperhook levelfor lowheadroomhoistsvarywiththerunwayflangewidth. Thehoistwillbeseriouslydamagedifthehookissethigherthanthevaluesindicatedinsection3.11.
Removethebottomblocktriggerfixingssuchthatthebottomblocktriggercanbesplitintwo. Positionthebottomblocktriggeraroundthehoistrope.
1 The bottom block trigger must be positioned around the fixed rope on the reevingarrangementi.e.theropewhichterminatesatthewedgeandsocketseeFigure35.
Replaceblocktriggerfixings. Adjustthelengthofthestrainerwireandpositionofthebottomblocktriggersuchthatthelimitswitch
operates Testtheoperatingpositioninslowspeedatfirstrepeatingthetestinfastspeedraising/loweringthe
bottomblocktriggerwherenecessary. Trimorsecureanyexcessstrainerwire. Checkthattheredwarninglightinthebaseofthecontrolpanelilluminates. Setthenormalupperlimitsothatitoperatesapproximately75100mmbelowtheultimateupperlimit
(see3.7.2/3.8.2).
defgh StreetCraneCoLtd
Ref:D2840rev.F Page37of112
3.11 LOWHEADROOMHIGHESTHOOKPOSITION2FALL&4FALL
ZX6 ZX8
ZX62FALL
ZX82FALL
ZX64FALL
ZX84FALL
1 Topreventaccidentaldamagetothehoistunit,alllowheadroomhoistsaredespatchedfromStreetCranewithupperandlowerlimitswitchessettosuita500mmrunwayflange.Aspartofthe commissioning procedure, the upper and lower limit switches should be adjusted toachievetheoptimumCDIMENSIONfortherunwayflangewidth(see3.7/3.8).
defgh StreetCraneCoLtd
Page38of112 Ref:D2840rev.F
3.12 LOWHEADROOMHIGHESTHOOKPOSITIONZX86FALL&8FALL
ZX8LOWHEADROOM6&8FALLS
HOIST FALLSRUNWAY
WIDTH(mm) BARREL'C'DIMENSION
(mm) DATASHEETZX8 6 300700 NB,LB,ELB 1175 DZX1109ZX8 8 300700 LB,ELB 1282 DZX1110
3.13 FOOTMOUNTHIGHESTHOOKPOSITIONZX6&ZX8
ZX6FOOTMOUNT
HOIST FALLS BARREL'C'DIMENSION
(mm) DATASHEETZX6 2 NB,LB,ELB 526 DZX1051ZX6 4 NB,LB,ELB 495 DZX1054
ZX8FOOTMOUNT
HOIST FALLS BARREL'C'DIMENSION
(mm) DATASHEETZX8 2 NB,LB,ELB 585 DZX1151ZX8 4 NB,LB,ELB 550 DZX1154ZX8 6 LB,ELB 645 DZX1157ZX8 8 LB,ELB 637 DZX1160
defgh StreetCraneCoLtd
Ref:D2840rev.F Page39of112
3.14 DOUBLEGIRDERPARALLELCRABHIGHESTHOOKPOSITIONZX6&ZX8
ZX6DOUBLEGIRDERPARALLELCRAB900mmGAUGE
HOIST FALLS BARREL'C'DIMENSION
(mm) DATASHEETZX6 2 NB,LB,ELB 104 DZX1016ZX6 4 NB,LB,ELB 71 DZX1019
ZX8DOUBLEGIRDERPARALLELCRAB1400mmGAUGE
HOIST FALLS BARREL'C'DIMENSION
(mm) DATASHEETZX8 2 NB,LB,ELB 295 DZX1116ZX8 4 NB,LB,ELB 260 DZX1122ZX8 6 NB,LB,ELB 372 DZX1128ZX8 8 LB,ELB 421 DZX1134
3.15 DOUBLEGIRDERPERPENDICULARCRABHIGHESTHOOKPOSITIONZX8
ZX8DOUBLEGIRDERPERPENDICULARCRAB14002600mmGAUGE
HOIST FALLS BARREL'C'DIMENSION
(mm) DATASHEETZX8 2 NB,LB,ELB 295 DZX1119ZX8 4 NB,LB,ELB 260 DZX1125ZX8 6 NB,LB,ELB 555 DZX1131ZX8 8 LB,ELB 547 DZX1137
defgh StreetCraneCoLtd
Page40of112 Ref:D2840rev.F
3.16 CHECKING/ADJUSTINGTHERATEDCAPACITYLIMITERTheratedcapacity limiter isusedtopreventthehoistfrom liftinga load inexcessoftheratedcapacity(safeworking load). Ifthehoist isoverloaded,the limitswitchwilltripandtheUPdirectionwillbecome inactive.The hoist will be allowed to lower only. Once the load has been removed then the limit switch willautomaticallyresetandallmotionswillbecomeactiveagain.Theratedcapacitylimiterispresetatthefactorypriordespatchandissettoratedcapacity+7.5%.Checkingof the ratedcapacity limiterwill requirecalibrated testweightsequal to the ratedcapacityof thehoistandratedcapacityplus10%,(SWLandSWL+10%).Lifttheloadjustclearofthefloorwiththetestloadattached.The limitdoesnotrequireanyadjustment if thehoistpicksup itsratedcapacity (SWL)butdoesnot lift theratedcapacity+10%(SWL+10%).Ifthelimittripseitherbeloworabovetheselimits,adjustthelimitbyturningthegrubscrew.3.16.1 AdjustingtheRatedCapacityLimiterforProofLoadingForproofloadtestingofahoistorcraneataloadgreaterthantheratedcapacity,proceedasfollows: Releasethegrubscrewbyapproximatelyhalfaturn. Carryouttheproofloadtestsonthehoist/craneasrequired. Attachacalibratedtestloadtothehookof(RatedCapacity+10%).Lifttheloadjustclearofthefloor
andtightenthegrubscrewuntilthelimitswitchjustoperates. Lowertheloadtothefloorandrepeattheliftseveraltimesatslowhoistingspeedmakingsurethatthe
limitertripseachtime. Repeatthetestatratedcapacity,thistimeensuringthatthe limiterdoesnotactivate.
Figure36RatedCapacityLimiter
defgh StreetCraneCoLtd
Ref:D2840rev.F Page41of112
3.17 TRAVERSELIMITS(OPTIONAL)Thetraverselimitarrangementemployseitheraoneortwostagecruciformswitchdependingonthetypeofstoppingarrangement.Besureofthetypethatisfittedtoyourhoist. Asinglestagelimitswitch(typePF33710100)isemployedtostopthemotioncompletelywhenthelimit
isreachedortoallowthehoisttoproceedatslowspeedonlyuntiltheendstopisreached.Thesinglestagelimitemploysoneactuatingarmateachendoftravel.
The two stage switch (typePF26755100) isemployed to firstly slow the speed from fast to slowandthen tostop themotioncompletelyon reaching thesecondstage. The twostage limitemploys twoactuatingarmsateachendoftravel.
NOTE:Oneachoftheabove,whenthelimitistripped,normaloperationisavailableintheoppositedirection.Reversingawayfromthestopisatthespeedselectedbytheoperator(sloworfast).3.17.1 SettingtraverselimitsToensurereliableoperationoftheswitch,theactuatingarmshouldbepositionedtostrikethe limitbarasshowninFigure37.Thearmshouldbepositionedsothattheswitchrotatesthrough90eachtimeitpassesanarm.Theshortbarontheswitchoccupiesthemid(0)positionwhentheswitchisbetweenthetwoactuatingarms.Thebarontheswitchwillthenrotatethrough90clockwiseoranticlockwiseeachtimeitpassesanactuatingarm.
1 Failuretosettheswitchandactuatingarms,asshown,willresultinpermanentdamagetotheswitch.
Figure37SettingtheTraverseLimitSingleGirderArrangement
defgh StreetCraneCoLtd
Page42of112 Ref:D2840rev.F
Figure38TraverseLimitDoubleGirderarrangement(SeeFigure37forsettingdimensions)
Whensettingthepointofoperationforthe limitswitch,accountshouldbetakenofthehoistspeedandthestoppingdistance.Thepointofoperationshouldbesettoallowafullyloadedcrane/hoisttostopfromfastspeedbeforereachingtherequiredposition.
defgh StreetCraneCoLtd
Ref:D2840rev.F Page43of112
3.18 CONNECTINGTHEPOWERSUPPLY
1 Connectionofthepowersupplymustbecarriedoutbyacompetentperson.Ensurethatthesupply to the hoist matches the information in the hoist technical data and on the hoistnameplate.Alsoensurethatthesupplyhasbeencorrectlyinstalledandprotected,i.e.voltage,phase,frequency,fusesize,cable/conductorsize.Checkthatthevoltageatthepointofsupplyiswithinthetoleranceof5%andthenominalfrequencyiswithinthetoleranceof1%oftheratedvalues.
3.18.1 Supplycables/fusesThe size of the supply cables to the hoist must be selected in accordance with the table in section 7.6.Terminalsmustbeofa sizeappropriate to the cable sizeand securely fixed. Selectionofa suitable sizeofmainsfuseisgiveninsection7.5.FusesofclassgL/gGshouldbeused(ortypeJforCSAinstallations).3.18.2 Mainisolatorsupplyswitch(byothers)Themainisolator(supplyswitch)mustdisconnectallphasesofthesupplytothehoist,mustbeclearlymarkedandlocatedinaneasilyaccessibleposition.TheswitchshouldbecapableofbeinglockedintheOFFpositionwhilstanymaintenanceworkisbeingcarriedout.Themainisolator,ifreasonablyaccessible,mayalsobeusedfor emergency stop or emergency off purposes. NOTE a separate emergency stop is located on the hoistcontrollersee4.4.5.3.18.3 ConnectingtothemainssupplyConnectthecablesinaccordancewiththecircuitdiagramsviatheplugandsocketlocatedonthesideofthehoistcontrolpanel.
Figure39HoistElectricalConnections
Check the settingofboth the Traverse Fast to Slow and theHoist Slow to Fast speeddelay timers.
TheseshouldcorrespondwiththesettingsinFigure40. CheckthesettingsonthePhaseFailureRelaycorrespondwithFigure41. Checkthattheconnectionstothecontroltransformermatchthesupplyvoltage(seeFigure42). Before switching the power on carry out Earth continuity and insulation resistance tests on the
completedinstallation.
defgh StreetCraneCoLtd
Page44of112 Ref:D2840rev.F
Figure40DelayTimers
Figure41PhaseFailureRelay
POTENTIOMETERSETTINGSSupply H1 H2
380V50Hz 12.5% 12.5%380V60Hz 15% 15%400V50Hz 12.5% 12.5%415V50Hz 12.5% 12.5%440V50Hz 12.5% 12.5%460V60Hz 12.5% 12.5%575V60Hz 12.5% 12.5%
defgh StreetCraneCoLtd
Ref:D2840rev.F Page45of112
Figure42ControlTransformerConnections
3.18.4 ElectromagneticcompatibilityThehoist itselfcomplieswith the requirementsofBSEN6100062/4with regard toEMC. Theusershouldtakecaretoensurethattheremainderoftheinstallationmeetstheserequirements.3.18.5 ConnectingthePendantcontrollerLowHeadroomWhereacontrolpendantistobeattacheddirectlytoalowheadroomhoist,itmustbesupportedbythetwostrainerwiresoneithersideofthependantcable.Theelectricalcableorterminalsmustnotsupportanyload.ConnectthetwopendantstrainerwirestotheM6screwsonthesuspensionbracketasshown.TightentheM6fixingsto9Nm.Connecttheplugontheendofthependantcabletothesocketonthesideonthehoistcontrolpanel.
Figure43StrainerWireConnections
defgh StreetCraneCoLtd
Page46of112 Ref:D2840rev.F
3.19 COMMISSIONINGPROCEDURE
1 Checkstobecarriedoutbeforeswitchingonthepowersupply. Checkthatthehoistinstallationiscompleteandallfixingscrewsaresecure. Checkthatthecorrectendstopsareinplace. Check that theelectrical installation iscompleteand installedas section3.18. Ensure that theEarth
continuityandinsulationresistancetestsweresatisfactorilycarriedout.
1 Oncepowersupplyisconnected: Checkthattheemergencystopfunctionscorrectly. Check eachmotionby firstmoving at SLOW speed andmoving theminimumpossibledistance also
ensuringthatthedirectionofmovementscorrespondtothelegendsonthecontroller. Double girder Travel the crab unit the full length of the crane to ensure that there is sufficient
clearancebetweenthewheelflangesandtherail. SinglegirderTravelhoistfulllengthofrunwaytoensurethatadequateclearanceexistsbetweenguide
rollersandrunway.Checkthattheclearancedoesnotbecomeexcessive.Checkthatthereactionrolleroperatessatisfactorily.
Checkthattherunwayendstopsfunctioncorrectly. Setandchecktheupperandlowerlimits(section3.7). Settheultimateupperlimit(rotarytypeseesection3.9,blockoperatedtypesee3.10)andthetraverse
limit(section3.17)iffitted. Checkandadjust,ifnecessary,theratedcapacitylimiter(seesection3.12).Ifthehoististobesubject
toaproofloadtestaspartofacraneorrunwayinstallation,seetheinstructionsforbypassoftheRCLinsection3.16.1.
Runthehoistseveraltimesunder light load(approx10%ofSWL)andatslowspeedtoallowthewireropetobeddownand improve itsservice life. Aftertherunning inperiod,checkthatthewedgeandropehasseatedcorrectlyinthesocket.Removeanytwistimpartedintheropeduringinstallation,seesection5.8.2.4.
Thehoistisnowreadyforproofloadandperformancetestingasrequired.Confirmthatcommissioninghasbeendulycarriedoutandcompletethetestlogbookinsection7.7.
3.20 DISMANTLING/REMOVALOFTHEHOISTThefollowinghoistdismantlingandremovalprocedureassumesthatthehoist isstill in itsoriginalconditionandworkinginthesameenvironment.Ifthehoisthasbeenmodifiedsuchthatitnolongerresemblestheoriginalinstallation,thecompetentpersonmaydecideonanalternativemethodofremovalanddismantling. Raise the hook to its upper level. Alternatively the hook and rope may be removed if required.
See5.8.2.1 Electricallyisolatethecrane,disconnectallelectricalcables. Removeanyattachmentssuchaslimitbrackets,cabletowingarms,pendantetc. Supporttheweightofthehoistatitsappropriateliftingpoints.See3.3 DoubleGirderCrabscanbeloweredtotheground. ForFootMountedHoistsremovethefootboltsandcheckthereisnoadhesionofthefootplatesbefore
loweringtotheground. For2&4FallLowHeadHoists: Releasethereactionroller.See3.4.1 Removethelockinggrubscrews.See3.4 Openthelowheadtrolleyframeuntilthewheelscleartherunwayflange. Lowertothefloor. For6&8FallLowHeadHoists: Removetrolleyspacers.See3.5 Openthelowheadtrolleyframeuntilthewheelscleartherunwayflange. Lowertothefloor. Ifthehoistisnottobereused,disposeofinanenvironmentallyfriendlymanner.
defgh StreetCraneCoLtd
Ref:D2840rev.F Page47of112
4 OPERATINGINSTRUCTIONS
4.1 INTENDEDUSEThecrane/hoistisdesignedforlifting,movingandloweringloads,uptotheratedcapacityoftheequipment,bymeans of a hook or other similar load handling device. The equipment should not bemodified or anyadditionsmadewithouttheapprovalofStreetCraneCoLtd. Theequipmentisnotintendedfortransportinganypersonseithersuspendedinabasketfromthehoist
orforpersonstravellingonthecranebridge. Thecrane/hoistisnotintendedforpullingloadsatanangleandnotfortowingordraggingloadsalong
thefloor.Thehoistisdesignedforliftingaloadinaverticalpathonly. Ensurethatthehoistisalwaysoperatedwithinitsratedcapacity(SWL).Theweightofanyliftinggear
shouldbetaken intoaccountwhenassessingthe loadonthehoist. Itmayalsobenecessarytoallowforanyadhesionbetweentheloadanditssupports.
1 Overloadingcanleadtoapossiblefailureofsomeoftheloadcarryingparts.Overloadingthecrane/hoistmaystartadefect,whichcouldleadtofuturefailureevenatlessthantheratedcapacity.
Donotuse thecrane/hoist forpulling loads loose, i.e.pullingcomponents frommouldsandalwaysmakenecessaryallowancesforanyadhesionbetweentheloadanditssupports.
The end of travel limits, (hoist or travel), are not intended to be a regularmethod of stopping themotion.Theyaresafetydevicesandtheyshouldbeapproachedwithcaution.
Thehoistisnotintendedtooperatewithaslackrope.4.2 DUTIESOFTHEOPERATOR/SAFEHOISTINGPRACTICESAtthestartofeachworkingdayorshift,carryoutthedailypreusechecksseesection5.4.Donotworkwithanycraneorhoistifanydefectsarefoundwhichmaycompromisesafety.Thefollowing informationservesasaguideforsafehoistingpracticesandanoperatoradheringtothesewillquicklyfindthathe/sheisabletoworkbothsmoothlyandquickly,withoutprejudicingsafetyandequipment.
1. Knowwherethesafety,fireandfirstaidequipmentislocatedandhowtouseit.2. Ensurethatnooneisworkingonthecranetrack,craneplatform(iffitted)orwheretheycouldbe
struckbythecrane/hoist.3. Beforeusing thecrane/hoistmakea fullvisual inspection toascertain that theequipment is in
good working order, paying particular attention to the rope and hook. See 5.4 Daily preuseinspections.
4. Donotusethecraneforanythingotherthanitsintendedpurpose.5. Ensurethecrane isproperlymaintainedandthatallthenecessaryexaminationandmaintenance
recordsareuptodate.6. Allrelevantaccidentprevention,safeliftingandslingingproceduresshouldbeobeyed.7. Constantlymonitorallcraneandhoistmovementsandbe ready toactivate theemergency stop
shouldanyabnormalcircumstancesarise.Beespeciallyawareofinstanceswherethecrane/hoistmay fail to stop when the push button/joystick is released or if the crane / hoist movesunexpectedly.
8. Alwaysoperatethecranewithcareandconsideration.Careshouldbetakentoavoidtheswingingofloads.
9. EnsurethattheSWLdataplatesareclearlyvisibletotheoperatoratalltimes.10. Centre thehoistover the loadbefore lifting. Donot sidepullas this candamage thehoistand
endangertheoperator.11. Donotlowerthehook/bottomblocksofarastoallowthehoistropestobecomeslack.
1 Ifthisdoeshappen,theoperatorshouldsatisfyhimselfthattheropeiscorrectlyreevedonthesystemofsheaves&hoistbarrelbeforecontinuingtooperatethecrane.
12. Donotliftaloadunlessyoucanseeitissecurelyslungwithsuitableliftingtackle.
defgh StreetCraneCoLtd
Page48of112 Ref:D2840rev.F
1 LiftingtackleshouldonlybedeemedsuitableifinaccordancewithLOLER98.(Othernationalregulationsmayapply).
13. Alwaysgentlyinchthehoistintotheload.
1 Running intothe loadat fullhoistspeed imposesexcessiveoverloadsonthehoistandcouldresultinfailureofpartsand/orsupportingstructure.
14. Donotinchthehoistunnecessarily.Excessivestoppingandstartingcauseshightemperaturesinthemotorandbrakeandmayresult inoverheatingorburnoutofthecomponent ifcontinuedtoexcess.
15. Donottryandmoveintheoppositedirectionuntilthecrane/hoisthascometoacompletestop.
3 Donotstandbelowasuspendedloadorallowanyotherpersonneltodoso.16. Prior to operating the travel or traversemotion, the operator shouldmake personnel aware of
approachingloadsusingaudiblewarningswherenecessary.
3 Donotmovetheloadsovertheheadsofotherpersonnel.17. Donotrunthehoistorcraneintothetravelstopsatfullspeed.Ensurethattherubberbufferisin
placeandnotdamaged.18. Ensurethatadequateclearanceismaintainedbetweentheloadorliftingattachmentandthehoist
orcranestructure.SeeFigure44.
Figure44Clearancestoconsiderwhenlifting
19. Ensurethatyoucanseethehookorloadclearlyatalltimesorarereceivingsignalsfromsomeone
who can. Ensure thatbothparties know the fullmeaningof thehand signals foroperating thecrane/hoist.SeeFigure45forrecommendedhandsignals.
20. Do not continue to travel or traverse once the crane or hoist has come to a stop against theendstops.Thiswillcauselocaliseddamagetotherailorrunwaybeam.
21. Neverleavealoadsuspendedintheairunsupervised.22. Donotparkthecraneoverfumes,steamordangerousprocesses.Foroutdoorcranes/hoists,park
inashelteredareawherepossible.23. Do not leave outdoor cranes/hoists unattended for long periods without applying the storm
anchors.
defgh StreetCraneCoLtd
Ref:D2840rev.F Page49of112
Figure45RecommendedHandSignals
4.3 REMOTECONTROLLEDCRANES/HOISTSTopreventunauthoriseduse,theoperatorshouldeitherretainthetransmitter intheirpossessionorremovethekeyfromitskeylockswitchand,forshortperiods,retainthekeyintheirpossession.Forlongerperiods,orwhenthecraneisnotinuse,thetransmittershouldbedepositedinadesignatedsafestorageplace.When the transmitter is fittedwith a belt or harness, the operator should bewearing the harness beforeswitching the transmitteron. Thiswillpreventaccidentaloperationof the crane /hoistwhilst fitting. Thetransmittershouldalsobeswitchedoffbeforeremovingtheharness.
defgh StreetCraneCoLtd
Page50of112 Ref:D2840rev.F
Ensure that the identification tagon the radio securitykeymatches the identificationnumberon the radiotransmitterandtheidentificationnumberonthecrane.4.4 CONTROLSTATIONOPERATINGINSTRUCTIONSThecontrolstationmaybefittedwitheitherpushbuttonsorjoysticks.Pendantswillbepushbuttonoperated,remotecontrolstationsmaybeeitherpushbuttonorjoystick.Inallcasesthepushbuttonorjoystickisspringapplied,which,whenreleased,willreturntotheneutralposition,themotionwillstopandtherelevantbrakewillautomaticallyapply.4.4.1 LegendNomenclatureAlegendcorrespondingtothedirectionofmotionislocatednexttoeachofthecontroldevices,(pushbuttonorjoystick).ThelegendplatesmaybeineitherEnglish(words)orInternationalsymbols.
Figure46ControlPendantLegends
Toimprovesafetyinoperation,therearedirectionalidentificationlegendsonthecranethatcorrespondtothelegendsonthecontroller.4.4.2 SwitchON
Establish power supply to the conductors via themain isolator (thismay be located on awall orsupportingcolumn).
Releasetheemergencystopbuttononthecontroller. Momentarilydepress theONpushbutton. Thiswillenergise the crane /hoistmain contactorand
allowsubsequentmotionstotakeplace.4.4.3 Pushbuttonoperation
1. Theoperatingcontrols(pushbutton)mustneverbemechanicallyblockedinanONposition.2. All opposing functions aremechanically interlocked e.g. hoist function cannot be operated at the
sametimeasthelowerfunction.3. Allcontrolpendantsarefittedwithdualpressure,twostage,pushbuttonstocontrolhoistandcrane
motions. Remote control stationsmay be fittedwith either push buttons or joysticks. For pushbutton operation depress the required pushbutton and the crane / hoist will move in thecorrespondingdirection. Selectthedirectionofmotionrequired. SlowSpeed.Tooperateslowspeedofadualspeedmotion,pressthebuttonintothefirststage. FastSpeed. Tooperatefastspeedofadualspeedmotion,pressthebuttonfully in(i.e.tothe
secondstage).
defgh StreetCraneCoLtd
Ref:D2840rev.F Page51of112
Change Speed from Slow to Fast. To change from slow speed to fast speed depress thepushbuttonfullyintothesecondstage.
ChangeSpeedfromFasttoSlowtravel/traversemotions.Tochangefromfastspeedtoslowspeed,reducepressureonpushbuttonandallowittocomeouttothefirststage. SwitchgearcontrolledThemotionwillfirststopandthencontinueatslowspeed. InvertercontrolledThemotionwilldeceleratetoslowspeed.
Change Speed from Fast to Slow Hoist. To change from fast speed to slow speed, removepressureonpushbuttoncompletelyandthenengageslowspeed.
SingleSpeed.Forcranes/hoiststhatareonlysinglespeed,pressthebuttontoeitherthefirstorsecondpressure.
4. Tomaintaintheselectedmotionthepushbuttonmustbehelddepressed.Releasingthepushbuttonwillstopthemotion.
5. PresstheEMERGENCYSTOPpushbuttonifnofurtheractionsaretobetaken.4.4.4 Joystickoperation
1. Theoperatingcontrols(joystick)mustneverbemechanicallyblockedinanONposition.2. All opposing functions aremechanically interlocked e.g. hoist function cannot be operated at the
sametimeasthelowerfunction.3. Control joysticksnormallyhave two stages to control thehoist and cranemotions, the first stage
being slow speed and the second stage fast speed. However, three or four stage units may besuppliedasanoption. Move the required joystick forwardand the crane /hoistwillmove in thecorrespondingdirection.Thespeedofthemotionwillbeproportionaltothestageselected. Selectthedirectionofmotionrequired. SlowSpeed.Tooperateslowspeedofadualspeedmotion,movethejoysticktothefirststage. Fast Speed. Tooperate fast speedof adual speedmotion,move the joystickdirectly to the
secondstage. ChangeSpeedfromSlowtoFast. Tochange fromslowspeedto fastspeed,movethe joystick
fromthefirststagetothesecondstage. ChangeSpeedfromFasttoSlowtravel/traversemotions.Tochangefromfastspeedtoslow
speed,returnthejoysticktothefirststage. SwitchgearcontrolledThecranewillfirststopandthencontinueatslowspeed. InvertercontrolledThecranewilldeceleratetoslowspeed.
Change Speed from Fast to Slow Hoist. To change from fast speed to slow speed, releasejoystickcompletelyandthenengageslowspeed.
SingleSpeed. For cranes /hoists that areonly single speed,move the joystick to anyof thejoystickstages.
4. Tomaintain the selectedmotion the joystickmustbeheld in the selectedposition. Releasing thejoystickwillstopthemotion.
5. PresstheEMERGENCYSTOPpushbuttonifnofurtheractionsaretobetaken.4.4.5 EmergencyStop
1 Before startingwork it is imperative to check the correct operation of the emergency stopbutton.Itisimportantthattheoperatorisconstantlyawareandmonitoringallcraneandhoistmovements and ready to activate the emergency stop should any abnormal circumstancesariseorsituationsoccurthatmayendangerthesafetyofpersonnelworkinginthevicinity.Beespeciallyawareofinstanceswherethecrane/hoistmayfailtostopwhenthepushbutton/joystickisreleasedorthecrane/hoiststartsormovesunexpectedly.
1. DepressingtheEMERGENCYSTOPpushbuttonwillcauseallmotionstostopandallbrakestoengage.2. Theemergencystopwilllockallcontrolsintheoffposition.3. Ifthebuttonisusedinanemergencystopsituation,ensurethatanyfaultsarereportedandrectified
beforereestablishingthepowersupply.4. Twist to release theEMERGENCYSTOPbutton. No functionswillbeoperativeuntil theemergency
stopisunlatchedandtheONpushbuttonoperat
Top Related