PH_Balanced_Design_Maintenance_Manual_(3) 1 .docx

BULLETIN T-100-S

ELECTRIC HOISTS

BALANCED DESIGN

HEVI- LIFT HOISTS•

CARE AND OPERATION MANUAL

REVISED 4/ 80

Harnischfeger milwaukee, wisconsin. 53201IP&H.I

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• TABLE OF CONTENTS

TABLE OF CONTENTS

SECTION NUMBER

II

SECTION TITLE

GENERAL DESCRIPTION

General. . . . . . . . . . . . . . . . . . . . . . .. Description of Operation . . . . . . . . . . ............. . Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . ....... . Safety

INSTALLATION

Initial Operating Check Checking Mechanical Load Brake

PAGE

1-1 1 1 1-1 1·1 1·1

2-1 2 1 2 1 2-2 2-2 2-3 2-5

Ill

IV

v

VI VII

COMPONENT DESCRIPTION

General Hoist Drive. . . . . . ............. . Mechanical Load Brake. . . . . . . . . . . . . . . . . . . . ..... Motor Brake Limit Switches .

Control ..

SAFE OPERATING PRACTICES

MAINTENANCE.

Wire Rope Replacement . Control Maintenance .... Conductor and Collector Systems ..

WIRING DIAGRAMS

3 1 3 1 3-1 3-2 3-2 3-2 3-4

4 1 4-1 4 1 4 1 4-2 4-3 4-4

5-1 5 1 5·5 5-8 5-11 5-11 5-12 5-18 5-18 5-19 5-24 5-29 5-29 5-33

7 1

DESCRIPTION SECTION I

SECTION I GENERAL DESCRIPTION

GENERAL

This manual describes the installation, adjustment, opera tion and general maintenance procedures necessary for the most efficient operation of P&H Balanced Design Hevi-Lift Hoists.•

An outline for a preventive maintenance program is also included.

DESCRIPTION OF OPERATION

The wire rope drum is driven by an electric motor through a three reduction gear case. Two timed drum pinions are meshed with the drum gear to provide equal distribution of load as well as positive control of the drum movement at all times. A reversing contactor, with mechanical interlock, completes the power supply to the hoist motor only when either the RAISE or LOWER control circuits are completed through the push buttons. For optional control, such as two speed and variable speed, additional contactors, relays and resistors are required.

A direct acting DC magnetic brake provides instantenous release and braking action for the motor. As the brake coil is energized it pulls an armature against the face of a spring loaded brake pot, releasing the rotating friction discs. De energizing the coil releases the armature from the brake pot by means of the compression spring, thus applying re quired braking forces to the friction discs. Because the friction discs are coupled directly to the motor pinion shaft through a splined disc hub, the motion stops.•

A mechanical load brake, included in the gear case, will pre vent the load from lowering itself. In some cases, an electric load brake (optional) or a D.C. dynamic lowering control (optional) is used to accomplish this.

A plugging type limit switch (standard equipment) prevents the bottom block from accidently being raised too high and inflicting damage to the drum and wire rope. An adjustable geared limit switch (optional) can be pre-set to open the cir cuit when the bottom block reaches the upper and lower safe limits of travel.

All this equipment is fully described and illustrated in the OPE RATION section of this manual (Section Ill).

WARRANTY

The terms under which this hoist is are clearly defined under the warranty which accompanies every P&H product. This warranty will be voided if the hoist is operated with loads in excess of its rated capacity, under unsafe con ditions or practices, or with accessories or attachments not designed or furnished and approved by the Harhischfeger Corporation. Modifications on the hoist which affect safe operation or capacity will void the warranty.

SAFETY

Section IV of this manual has been devoted to safe operating practices. It is most import<:mt that the persons operating the hoist be familiar with these beiom operating the hoist, both for their own orotection and for the protection of other workmen

1-1

SECTION II INSTALLATION

INSTALLATION

SECTION II

GENER.Al•

Prior to installing the hoist, carefully inspect if for possible shipping damage.

Before installing a trolley mounted hoist, make certain that the trolley wheel contour is correct for the type of beam the trolley will run on, and that the trolley wheel spacing is correct for the beam flange width (refer to the topic, "mounting", in this section). There are three basic wheel con tours used on four types of beams as illustrated in Figure 21. These are the crown tapered wheel for standard 1-beam, the flat crowned wheel for wide flanged 1-beam, ttie flat crowned wheel for wide flanqed 1-bc:am and the flat tread wheel for either a patented monorail beam or a T-rail instal Ia· tion.

MOUNTING

Balanced Design Hevi-Lift Hoists are either lug mounted standard headroom or low headroom units, or they are fixed mounted (base, ceiling, deck, wall). The lug mounted hoists are usually equipped with either a plain trolley, hand chain geared trolley, single speed motor trolley or a variable speed motor trolley. These are illustrated in Figures 2-2, 2-3, 2-4 and 2 5.

All four types of trolleys utilize spacers between the drurn hanger and the truck sides to adjust for the width of the beam they operate on. For straight track standard !-beams and straight track wide flange l·bearns, the distance between

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D FLAT TRUl.D WHEFL fORT fl!

\IL INS'! fl.LLATION

2-1. Wheel Contours

2-2. Plain

2-1

INSTAlLATION the wheel flanges should be approximately 1/4 to 3/8 inch more than the nominal beam flange width. For straight• track patented monorail beams, the distance between the 0 wheel flanges should be approximately 1/16 to 1/8 inch more than the nominal beam flange width. For straight track T-rail installations, the distance between wheel flanges should be approximately 1/4 to 3/8 inch more than the width between the outside edges of the T-rail. If additional spacers are required to adjust wheel flange spacing, punch washers may be used on all but motor driven trolleys. Special factory-built spacers are required for motor driven trolleys.

F Gc<Jred Trolley

IJOI

10 \i_

NOTE

When trolleys run on curved track beams, the dis tance between trolley wheel flanges must be slightly more than for straight track of the same nominal beam flange width. The increased spacing depends upon the radius of the curved track. Generally, the hoist is built for a particular application and the proper spacing is provided at the factory. If your application for the hoist changes, contact your regional sales or service office of Harnischfeger Corporation giving complete details of type of beam, curve radii and hoist serial number.•

INITIAL LUBRICATION

Refer to the lubrication instructions in the MAINTENANCE section to lubricate the hoist prior to start up.

1: :]

Figure 2-4. Speed Motor Trolley

2-5. Variable Speed Motor Trolley

All Balanced Design Hevi-Lift hoists are shipped with the gear case filled to the proper level. If the hoist is equipped with a motor geared trolley, the trolley gear case is also filled with gear oil prior to shipment. However, to avoid the possibility of seriously damaging the hoist, these oil levels must be checked and gear oi I added if necessary, prior to operating the hoist. Geared trolley wheels are not lubricated at the factory because abrasives will contaminate the grease during shipment and must be lubricated prior to start up.

ELECTRICAL CONNECTIONS

1 :]•

Be sure that the power supply is the same as indicated on the P&H nameplate. If the hoist is operated on incorrect voltage or frequency, serious damage to the motor and the control could result.

2-2

A wiring diagram for each hoist is secured to the inside of the control cabinet cover. Before energizing the hoist power supply, check that connections are made as indicated on the wiring diagrams furnished with the hoist. Also check all electrical connections (at contactors, terminal boards, etc.) for tightness.t

To properly connect and check a three phase power connection, refer to the INITIAL OPERATING CHECK portion of this section.

CONDUCTORS AND COLLECTORS

CONDUCTOR TYPES. Bare wire conductors, either round or figure 8 are most commonly used. However, flat bar, angle, T bar or insulated bar may be advantageous in some applications where corrosive, moist or dusty conditions are present.

CONDUCTOR INSTALLATION. Wire conductors require the use of end support and strain insulator at each end of the system (see Figure 2-6). Proper wire tension can be adjusted with the adjusting nuts located on the strain in sulator threaded studs.

The required number of intermediate supports will vary with the type of conductor. A general guide to determine the number required is shown below.t

ADJUSTING NUT

Figure 2-6. Wire Stretcher

Figure 2-7. Spring Wheel Collector

BRI\CKET

Type of Conductor

Distance Between Supports (Feet)

Straight Section Curved Section

Round copper wire, No.4 "Figure 8" wire, No. 0 Flat bar T-bar Angle

40 ·(Max. overal length l)

Not used c

The location of the conductors in relation to the 1-beam will vary with type of trolley, lift, hoist size and type of conductor. Refer to the clearance drawing prepared for your_particular hoist.

Conductor contact surfaces should be cleaned and polished for most efficient operation.•

COLLECTORS. For round or figure 8 wire conductors the standard spring wheel collector is used (Figure 2-7). The standard spring shoe collector is used with open steel cur rent conductors of tee, angle or bar shaped section (Figure 2-8). The spring loaded arm holds the wheel or shoe firmly

Figure 2-8. Shoe Collector against the conductor. Slide the collector assembly to a centralized position with respect to the conductor, taking into consideration the trolley wheel float. To adjust the collector, loosen the bracket cap and slide the collector to the proper position on the collector support bar.

INITIAL OPERATING CHECK

GENERAL. The P&H Balanced Design Hevi-Lift Hoist is tested under load and adjusted for proper operation prior to leaving the factory. Before the unit is placed in service, there are several items that must be checked to insure cor rect installation and avoid serious trouble.

CHECKING DIRECTION OF ROTATION. Since direction of rotation of three phase AC motors can be reversed by reversing any two of the three line wires, it is important that the motion travel is in correct relationship with the button being depressed.

GEl Do not attempt to correct hook travel by changing reversing contactor coil connection or push button wiring. This can only be done at the main power source, load side of reversing contactor or individ ual motor junction box.

If travel relationship does not correspond to the push button being depressed, do not allow the bottom block to come into contact with the limit switch. Carefully check this as follows:

1. Temporarily connect the three phase power leads to the conductor system.

2. inch the RAISE or UP button and note the direction of bottom block travel.

INSTAllATION

CHECKING OPERATION OF UPPER LIMIT SWITCH.•

With the hoist properly connected to the correct power supply, check the operation of the upper limit switch. Raise ' the bottom block without a load to within 6 inches of con tact with the limit switch counterweight or paddle. Proceed with caution by inching or at slow speed raise the bottom block until the limit switch is tripped. This should open the hoisting circuit and set the motor brake stopping the hoist motion. With the hoist limit switch in the tripped position and control in either the raise or off position, manually operate the limit switch further in the raise position to establish the plugging circuit. Only maintain this position

3. If the bottom block travel is upward when the RAISE or UP button is depressed, proper phasing has been attained and the temporary connections may now be secured per manently.

4. If the bottom block travels downward when the RAISE or UP button is depressed, proper phasing has not been attained. To correct this, reverse any two of the power line leads at the power source. Again, do not attempt to corltlct a phase reversal by interchanging the reversing contactor or push button connections, because interchanging these con nections will not provide upper limit switch protection.

To correct the direction of travel in DC operation, inter change the two armature leads.

If bottom block travel direction is correct, trolley travel direction should also be correct. However, trolley travel direction should be checked with the push button markings. If the direction is reversed, correct this by reversing any two of the three power lead connections at the trolley con tactor only.

2-4

Figure 2-9. Upper Limit Switch Counterweight

Figure 2-10. Typical Upper Limit Switch Paddle

1098 •

OPERATION

SECTION Ill for a sufficient time to insure plugging and that bottom block lowers. If the limit switch does not operate in this manner, refer to the maintenance section of this manual for adjustment procedures.'

CHECKING OPERATION OF GEARED LIMIT SWITCH. If the hoist is equipped with a geared limit switch (Figure 2-11) to stop the bottom block at both the upper and lower limits of travel, check it for proper operation as follows:

1. Operate the hoist to raise the bottom block without a load until it is approximately two feet from the hoist drum.

SWITCH CAMS

HOIST DRUM

Figure 2-11. Geared Limit Switch'

2. Operate the hoist by inching or slow speed until the bottom block raises high enough to actuate the geared limit switch which opens the RAISE circuit and applies the magnetic brake. The switch must actuate when the bottom block is a safe distance from the drum (approximately six inches).

3. If the geared limit switch is equipped with plugging con tacts, disconnect one lead from the upper limit switch element and then slowly raise the hook block past the upper limit. The plugging contacts should close at a point just above the upper travel limit, and the hoist motor should automatically reverse direction to lower the hook block off the plugging contacts. Release the RAISE or UP button and reconnect the lead to the upper limit switch element.

4. Operate the hoist to lower the bottom block until the bottom block has reached the desired lower limit. The geared limit switch should now actuate to open the LOWER circuit and apply the motor brake.

: A=:l A minimum of one full wrap of cable must remain on the drum when the hook block is at the lower limit.

5. If the geared limit switch does not operate properly, refer to the MAINTENANCE section of this manual for adjustment procedures.

CHECKING OPERATION OF ELECTRIC BRAKE. Operate the hoist in the lowering direction with no load on the hook. With the hoist lowering at full speed for a single or variable speed hoist, and slow speed for a two speed hoist, release the DOWN or LOWER push button. The downward movement will stop, except for the allowable drift. The hook will drift approximately one inch for every 10 FPM (Feet Per Minute) of hook travel speed. This distance should be measured from the time the push button is re leased to the time the hook comes to rest. As an example, a hoist with a rated speed of 20 FPM will drive approx imately 2 inches, when operated at full speed. test the raising direction in the same manner. It should be noted that when the hoist has a full load on the hook the drift will be less than 1 inch for each 10 FPM of hook speed.

If there is excessive drift, refer to the MAINTENANCE section of this manual.

I WARNING--)

Never operate the hoist unless the brakes are operating properly.

CHECKING MECHANICAL LOAD BRAKE

Attach a near capacity load to the bottom block. Raise and lower the hoist several feet to determine if the mechanical load brake is operating correctly. The mechanical load brake will control the descent of the load in the lowering direction when the DOWN or LOWER push button is depressed. Also, it should prevent the load from to lower, except for allowable drift, when the DOWN or LOWER push button is released.

t

2-5

COMPONENT DESCRIPTION

GENERAL HOIST DRIVE

The operation and function of each sub-assembly in the Balanced Design Hevi-Lift Hoist is described in this section. The size and capacity of a unit will not vary the function of these components.'

Some of the sub-assemblies listed are optional equipment and may not apply to your particular hoist.

The drum is driven by the hoist motor through a three reduction gear case, as illustrated in Figure 3-1. Normally, a mechanical load brake is included as part of the reduc tion. The exceptions to this are the use of either an electric load brake (Magnetorque), de dynamic lowering control or countertorque control. The drum shaft is joined to the motor shaft and the motor pinion shaft in the gear case by

RIGHT DRIVE GEAR

\- LEFT DRIVE GEAR

MECHANICAL LOAD BRAKE ASSEMBLY

Figure 3-1. Balanced Design Hevi-Lift Hoist Drive

3-'1 splincd couplings. The motor pinion drives the drum pinion shaft assemblies through the mechanical load brake, or through the intermediate shaft assembly when a mechanical

MOTOR BRAKE

load brake is not used. The two drum pinions drive the drum gear, causing the drum to revolve.

MECHANICAL LOAD BRAKE

The functions of the mechanical load brake are to control the lowering speed of the load and to prevent the load from dropping due to failure of the electric motor. The mech anical load brake consists of an ACME (left hand) threaded shaft with a fixed flange, a motor gear with an ACME (left hand) threaded bore, a ratchet with friction linings riveted to each side, and a spring controlled pawl mounted in the gearcase. During the raising cycle, the motor gear is driven countc:rclockwise and the ACME thread causes the motor gear to compress the ratchet between itself and the fixed flange on the shaft. The spring loaded pawl is thrown away from the ratchet and therefore no braking action takes place. During the lowering cycle, the motor gear is driven clockwise. The load on the hook tends to keep the brake closed. The pawl engages the ratchet and forces the ratchet to slip between the motor gear and flange thereby creating the braking torque.

Whenever the hoist motor is energized, the DC magnetic motor brake is energized to pull the armature against the brake compression spring and free the disc type brake linings (see Figure 3-3). When the hoist motor is de-energized, the motor brake is also de-energized and releases the arma ture, allowing the compression spring to exert force on the disc type brake linings, which in turn apply braking torque to the motor pinion shaft.

These brakes are designed for de operation. When the hoist power supply is ac, a rectifier assembly is used to provide a de power supply to the brake.

LIMIT SWITCHES

WEIGHT TYPE UPPER LIMIT SWITCH (Figure 34). When the bottom block is in a normal operating position (below the preset upper limit), the re-set weight winds up the spring, positions the limit switch sheave against a stop. The cams are clear of the contact fingers (position 1) so that the hoist circuit contacts (A) are closed and plugging contacts (B) are open. When the bottom block approaches ·

HOIST

DRUM

RATCHET WHEEL FRICTION LININGS

MOTOR PINION DOWN

MOTOR GEAR ROTATION AND PAWL POSITION

DURING DOWN CYCLE

HOIST MOTOR

) MOTOR

-f-I -BRAKE

MOTOR GEAR

Figure 3-2. Principle of Mechanical Load Brake

1303 •

3-2

SUFFICIENT CLEARANCE ALLOWING FREE ROTATION•

BRAKE POT

POWER ON BRAKE RELEASED

POWER OFF BRAKE SET

DISC HUB

FRICTION DISCS

ENERGIZED

ARMATURE Pl. ATE

DE- ENfRGIZED

Figure 3-3. Magnetic Motor Brake

SPRING

CORD SHEAVE•

STATIONARY CABLE END

POSITION 1 POSITION 2 POSITION

B

PLUGGING CAM

A HOISTING CIRCUIT CONTACTS

B --PLUGGING CIRCUIT CONTACTS

POSITION 3

PLUGGICNIGRC(RUIETVERSE).- -- i--_-··

-LEVEL OF WEIGHT : )

POSITION 1

CLOSED ClRC

0:::

Cl J -

LEVEL OF WEIGHT

Figure 3-4. Weight Type Upper Limit Switch its preset upper limit it contacts the re-set weight, raising it to permit spring tension to rotate the switch cams until the hoist circuit cam opens the hoisting circuit contacts (A) to stop the motor and apply the motor brake (position-

2). If the bottom block drifts beyond this preset limit, the re-set weight continues to rise and the switch cams rotate still farther until the plugging cam closes the re verse circuit contacts (B) (position 3). This reverses the hoist motor and returns the bottom block to its upper limit pos1t10n. Should the cord break, the sprin l will rotate the sheave and cams to a stop where both the hoist contacts (A) and plugging contacts (B) are open.

Under normal operation the hoist motion should stop when the hoisting contacts (A) open as in position 2. The plugging contacts (B) should only close (position 3) if the motor brake malfunctions, causing excessive drift. For brake adjustment see the MAINTENANCE section of this manual.

3-3

PADDLE TYPE UPPER LIMIT SWITCHES

idcn tical to that used for weight type limit switch but no

P.L\DDLE MOUNTED ON SHAFT. Switch construction is

HOIST DRUM

Figure 3-6. Geared Limit Switch

GEARED LIMIT SWITCH. The adjustable geared limit switch opens the RAISE circuit when the bottom block reaches a preset upper limit and opens the LOWER circuit when the bottom block reaches a preset lower limit. The geared limit switch is driven by the drum gear (see Figure 3-6) and actuates after a predetermined number of drum revolutions.

LOAD LIMIT DEVICE (OPTIONAL EQUIPMENT). The load limit device is preset at the factory to open the hoist ing circuit when a lift exceeding rated capacity is attempted. If it is not operating properly, contac• t the P&H Regional

Office nearest you.

CONTROL

PUSH BUTTON STATION. Normally, hoist control is actuated through the use of a weather-proof push button station suspended from the control cabinet. The number of push button elements in the station is determined by the number of motions to be controlled from the push button station.

Figure 3-5. Paddle Type Upper Limit Switches

Three types of push button elements are used, depending on the type of control. For single speed control only one speed can be obtained in either direction.

For two speed control, a three contact element is used. By partially depressing the button, motion, direction and slow speed will operate. By completely depressing the button, slow speed drops out and high speed will operate.

PADDLE MOUNTED ON DRUM HANGER. The spring tension on the sheave is reversed from that on the weight type limit switch. As the bottom block engages the paddle in an upward direction, (Figure 3-51ower), the cord rotates the sheave which in turn rotates the switch cams until the hoist circuit cam opens the hoisting circuit contacts. If the bottom block drifts beyond this preset limit, the switch cams rotate still farther until the plugging cam closes the plugging circuit contacts. This reverses the hoist motor and returns the bottom block to its upper limit position.

3-4

For the five step variable speed control, a five step element button is used. Contact with the directional and five speed points is made by progressively depressing the button in increments of approximately one-eigth inch. As the button is depressed additional contact segments are engaged. These contacts actuate contactors which in turn vary the re sistance in the motor circuit. As the button is depressed contactors are closed, shorting resistance out of the motor circuit and increasing the motor speed.•

. Also, with variable speed push button control, timers can be added to the circuitry to provide timed acceleration.•

When required we normally recommend timers for the last two steps of acceleration (optional).

The wiring between the push button station and the con trols is a rubber or plastic covered multiconductor control cable. The push button station is suspended from the con trol cabinet by a chain which removes the strain from the control cable. Individual wires in the control cable are color coded.

CONTROL PANELS. The control panel is mounted directly on the hoist frame, except when otherwise specified. Figures 3-7, 3-8 and 3-9 illustrate typical control panels for ac operation of hoist and trolley motions.

REVERSING CONTACTOR. The reversing contactor com pletes the power supply to the motor only when directional control circuits are completed through use of the push button station. The contactor incorporates a mechanical

BRAKE RECTIFIER

0 0 interlock to prevent more than one directional control cir cuit from being operated at the same time. Individual reversing contactors are used for the hoist motion and trolley motion.

Thermal overload protection on the contactor protects the motor. These thermal overloads are manual reset, except when the automatic reset type are specified and used.

Four pole reversing contactors are used up to 10 HP at 230 volts and up to 20 HP at 460 volts. For larger motors, three pole contactors are used, in which case a separate relav is used to energize the brake coil.

ACCELERATING CONTACTORS. As the six contact points in the push button are engaged, circuits through the reversing and accelerating contactor are actuated accord ingly. Each circuit through thf! accelerating contactors shorts out additional resistance from the motor circuit and increases the motor speed.

HOIST REVERSING CONTACTOR

BRAKE TRANSFORMER

CONTROl.

1RANSFORMER

UPPER

• LIMIT SWITCH

TERMINAL BOARD0

Figure 3-7. Typical AC Single Speed Hoist Control Only

Nm

HEVEHSING CON lACTOH HOIST SPEED

PLUGGING RELAY

REVERSING CONTACTOR HOIST DlrCTIONM r-r--rGJi tr:J=-wIt""":::::J r1,....,::l""MI rt I e;J ! r;:::)' l r::1 N f\ECTIFI

CONTROL TRANSFORMEQR

6l €j Jl

0 . 6l

BRAK TRANSFORMER

UPPER

TEHMINAL BOARD

L.IMIT SWITCH TROLLEY REVERSING CON TACTO R

Figure 3-8. Typical AC Two Speed Hoist :md Single Speed Trolley Control

REVERSING CONTACTOR HOIST

!.ALSO INCLUDES SET OF RESISTORS· NOT SHOWN)

HOIST ACCELERATING CONTACTOR

CONTROL TRANSFORMER TROLLEY REVERSING CONTACTOR

RECTIFIER

p

UPPER TERMINAL BOARD•

LIMIT SWITCH

Figure 3-9. Typical AC Variable Speed Hoist and Single Speed Trolley Control Pilnel

3-6

SECTION IV

SAFE OPERATING PRACTICES

When control requirements do not exceed NEMA size 1 contactor (approximately 30 amps), a four gang single unit contactor is used. For N EMA size 2 and larger con tactors, four individual contactors are used to control the motor speed.•

TRANSFORMERS. The control circuit transformer is con nected to two of the three power supply terminals on 3 phase units. A control may be provided with either one or two transformers, depending upon a customer's require ments. Standard control voltages are 24 and 110 volts.

RECTIFIER. The magnetic brake is designed to operate on direct current. A rectifier is used in all ac control cir cuits to rectify the current to DC for proper operation of the magnetic brake coiL

PLUGGING RELAY. A plugging relay is used in every two speed hoist control. At the time the weight or paddle operated upper limit switch is engaged, the plugging relay energizes only the low speed windings of the motor and prevents plugging (reversal) in high speed.

3-7

GENERAL

Most accidents involving hoists are the result of violating a safety rule in operation or of improper maintenance.•

The purpose of this section is to assist users of P&H electric wire rope hoists in establishing safety rules for hoist opera tors and in setting up a proper preventive maintenance program.

The Harnischfeger Corporation recognizes that most companies who use hoists have a safety pro gram in force in their plants. In the event that some conflict exists between a rule set forth in this publication and a similar rule already set by an individual company, the more stringent of the two should take precedence.

Reference should also be made to ANSI 830.16, published by the American Society of Mechanical Engineers, and to HM 1-100 (74), published by the Hoist Manufacturer's Institute. These documents contain additional information on safety.

OPERATOR QUALIFICATIONS

AUTHORIZED OPERATING PERSONNEL. Only the following personnel should be permitted to operate a hoist:/.

1. Appointed operators.

2. Maintenance and test personnel, when required to do so in the performance of their duties.

3. Inspectors.

OPERATOR TESTING. Every employer should require that all persons who will be authorized to operate a hoist first pass an examination which accurately measures practical knowledge of electrical wire rope hoists.

PHYSICAL AND MENTAL CONDITION. An operator must meet the following physical and mental qualifica tions:

1. An operator must possess good hearing ability and vision (corrected or uncorrected.) Good depth perception is also required where load spotting must be accomplished at some distance from the operator.

2. An operator must not be afflicted with any known health condition which could cause a sudden inability to react quickly.

3. An operator who is taking medication prescribed by a doctor should be made to present written assurance from his doctor that the medication will not affect the operator's ability to operate the hoist in a safe manner.

4. An operator who is known, or suspected, to be under the influence of alcohol or drugs must not be allowed to operate a hoist under any circumstances.

GENERAL The following are general requirements for safe hoist operation-

1. It is the operator's responsibility to fully acquaint him self with the hoist before attempting to operate it. Know the hoist's rated capacity, its type of control system (single speed or variable-speed) and the function of all operating controls.

4-1

2. Verify that all required periodic lubrication and other periodic maintenance have been accomplished before beginning operation at the start of a shift.

3. If any adjustments or repairs are necessary or if any damage is known, or suspected, the operator must report same to his supervisor or other duly appointed person. The next operator must also be informed upon changing shHts, if the known deficiency has not been corrected.

4. A hoist must not be operated if there is an "out of order" sign, or similar warning sign, hung on the control pendant or main disconnect switch. A sign of this type should be removed only by the person who originally placed the sign, or some other designated person.

5. All operatmg controls shall be tested at the beginning of each shift. If any malfunction appears, it shall be cor rected before actual operations are begun.

6. Before starting up the hoist, make certain that all per sonnel are clear of the area.

7. Keep your hands clear of the hook block and other moving parts when starting up the hoist.

SAFE LOAD HANDLING. Observe the following while actually handling loads:

1. No hoist shall be loaded beyond its rated capacity, except when conducting properly authorized and supervised load tests.

2. The load shall be attached to the hook block by means of a sling or other approved device. Under no circumstances shall the hoist rope be wrapped around the load.

3. The sling, or other approved lifting device, must be fully seated in the saddle of the hook before beginning a lift.

4. Check the hoist rope to make sure that it is not kinked or twisted, or that multiple part ropes are not twisted about each other. Also check to insure that the hoist rope is properly seated on the drum and in the sheaves.

5. With the load lifted only a few inches, check to make sure that the load is properly balanced. If an unbalance exists, lower the load and reconnect the sling to achieve the proper balance.

6. Always inch the hoist into engagement with the load and, after checking for proper load balance, raise the load steadily to the desired height. Avoid unnecessary or sudden stops and starts when raising a load.

7. The hook block must be centered over the load (hoist rope vertical) when the lift begins.

4-2

NOTE•

An exception can be made to rule 7 only with approval from a person appointed to authorize off-center lifts. Assurance must be given by this person that the hoist, its trolley, or its mounting structure will not be overstressed in making the lift. In general, P&H electric wire rope hoists are not designed for off-center lifts.

8. 'At all times, avoid carrying loads over people.

9. Use extreme care to avoid contacting any obstruction with a moving load.

10. Never leave a load suspended in the air unattended. The operator must remain at the controls ready to take action in the event of holding brake failure.

11. The upper limit switch is intended solely as a safety device. It must not be used as a normal operating control. Unnecessary acruation of the upper limit switch shall be avoided.

12. A load or the hook block shall not be lowered below the point where less than two full wraps of wire rope re main on the drum, unless a lower limit device is provided. If a lower limit device is provided, the load or hook block shall not be lowered below the point where less than one full wrap of wire rope remains on the drum.t

MOTOR BRAKE TEST FOR NEAR CAPACITY LOADS. Each time that a capacity or near capacity load is to be lifted, the motor brake shall be tested for its ability to hold the load suspended. Make this test with the load lifted just a few inches off the floor, or other support. If the motor brake fails to hold, do not attempt to handle the load until the brake has been adjusted or repaired, as applicable.

HANDLING PERSONNEL. Personnel shall not be allowed to ride the hook or the load under any circumstances. Nor shall a P&H electric wire rope hoist be applied to manlift cage or passenger elevator service. These hoists are not designed to safely handle personnel, and no attempt should be made to modify them in any way for the purpose of adapting them to a personnel handling application.

INSPECTION

GENERAL. Regular, periodic inspection is essential to con tinued safe performance of a hoist. Careful inspection on a regular basis will reveal potentially dangerous conditions while still in the early stages, allowing corrective action to be taken before the condition becomes dangerous.t

Any deficiency revealed through inspection shall be reported to an appointed person. A determination must be made as to whether a deficiency constitutes a safety hazard before resuming operation of the hoist.

RECORDS AND REPORTS. Some form of inspection record shall be maintained for each hoist, listing all points requiring periodic inspection. A written report should be made monthly on the condition of the critical parts of each hoist. These reports should be dated, signed by the person who performed the inspection, and kept on file where they are readily available to authorized personnel.•

DAILY INSPECTION. Hoists in regular service shall be in· spected daily, or at the start of each shift, for damage, wear, operating malfunctions and other defects. This in· spection shall include, but not be necessary limited to, the following items:

1. All operating controls for proper function.

2. Upper and lower limit switches (as applicable) for proper operation and adjustment.

3. All running wire ropes for twists, kinks, distortion, excessive wear and improper dead-ending.

to safely perform its rated work. Refer to the topic "Main· tenance of Wire Rope" in Section V of this manual for details.

2. Check the hoist drum and all running sheaves for cracks, excessive wear, misalignment and other defects.

3. Check the motor brake for worn discs, rnisadjustment or other defects.

4. Check the entire hoist unit and trolley tor loose bolts or rivets.

5. Check the contactors in the control panel for excessively or worn contacts, loose electrical connections, weak springs and defective wiring. Check the limit switches and controller pushbuttons in the same manner.

6. Check the hook to insure that it is properly secured in its block. Also check the hook latch (it so for damage or restricted movement.

A more thorough inspection procedure for run

7. Check parts such as gears, shafts, pins corrosion, wear, cracks or distortion.

inqs for ning wire ropes is described in Section V of this manual.

• 4. Check the hook for the following:

a. Deformation.

b. Chemical damage (if hook is exposed to corrosive chemicals or atmosphere).

c. Throat opening in excessive of 15 percent of normal. d. A twist of more than 10 degrees from the plane of an unbent hook.

Without exception, an excessively bent or twisted hook must be replaced. An excessive throat opening and/or a severely bent hook indicates that the hoist has been abused or overloaded. In this case, all other load bearing components of the hoist must be carefully examined on a daily basis until there is assurance that no damage has occurred to those components.

PERIODIC INSPECTION. Periodic inspection refers to those inspections which are performed at intervals ranging from one month to one year. Guidelines for establishing intervals under varying operating conditions are contained in Section V (Maintenance). Periodic inspection shall in elude, but not necessarily be limited to, the following:

1. Wire rope used in hoisting loads shall be thoroughly condition•

8. At least annually, inspect the hook for cracks using dye penetrants, magnetic oarticle or other suitable crack detecting method.

HOISTS NOT IN REGULAR USE. A hoist that has been idle for a period of time rnust be checked out as follows, before returned to service:

1. A hoist which has been idle for at least one month but less than six months shall be inspected in the manner de scribed under the topic, "Daily Inspection", above, by or under the direction of a designated person. Also refer to item "3" below.

2. A hoist which has been idle for a period of six months or longer shall be given a complete inspection in the manner described under "Daily Inspection" and "Periodic lnspec tion", above. Also refer to item "3", following.

3. All wire rope that remained on the hoist during an idle period of one month or more shall be given a thorough inspection before placing the rope in service. This inspec tion shall be for all types of deterioration, as described in the "Maintenance of Wire Rope" topic in Section V of this manual, by an appointed person whose approval is for further use of the rope. A written, dated report on the condition of the rope shall be filed.

MAINTENANCE

GENERAL A good preventive maintenance program in· eludes regular lubrication, periodic adjustments the immediate correcting of defects revealed through daily and examined for all s that could impair its ability

4-3

Preventive maintenance combined with camful inspection at regular intervals not only contributes safe hoist operation, but also will extend the of the hoist.

The preventive maintenance pro Jram set up by the hoist user should be based on the! recommendations made in Section V this manual. Detailed records of maintenance should be kept for each hoist.

SAFETY PRECAUTIONS. Observe the following safety when performing maintenance of any type:

1. Open and lock the main disconnect switch in the electrical line feedinq hoist.

nstall orch;r" similar warning signs on both the disconnect switch on the pendant pushbutton st 1tion.

3. The shall be removed only by the person or by some other designated person.

4. Upon completion of the required maintenance, the hoist shall not be operated until all guards have been reinstalled, and until limit switches and load limit devices have been reactivated

LUBRICATION. Lubrication requirements are spelled out in Section of this manual. The recommended intervals specifications must be adhered to.

must nut while lubrir:;mts are

ENTS. Observe the following in making adjust-

1. all critical parts which are cracked, broken, bent or distorted, or which in any way could result in an condition, as rc;vealed through daily and periodic

2. Replacement parts should be obtained from the Corporation.

electrical contacts should be only in sets.

4. Keep pendant control stations clean and the function labels

5. Damaged or missing warning labels shall be immediately replaced.t

TESTING

GENERAL. Prior to returning an altered or repaired hoist, or a hoist that has not been used for preceding 12 months, to service, the following operation and load tests shall be performed.

OPERATIONAL TESTS. Perform the following to verify proper operation of a hoist:

I. After applying electrical power to the hoist, lower and raise the hook block a number of times to insure the accuracy of the control markings and to check the general condition of the hoist.

2. Check the operation of the motor brake. A properly functioning motor brake will stop an empty hook within a distance equal to one inch/1 OFPM of rated hoist speed, following release of the control button.

3. Test the operation and settings of the upper limit switch and lower limit switch (if so equipped). If practical, the initial actuation in the test should be by hand. Following actuation by hand, or if hand actuation is impractical, actuate the limit switches by operating the hoist at the slowest possible speed. Hook block drift at the upper limit shall leave the hook block safely below the rope drum or any other part of the hoist, even at maximum speed. The lower limit switch shall actuate and cause the hook block to stop at a point which allows at least one full wrap of wire rope to remain on the drum. Inoperative limit switches must be readjusted, repaired or replaced, as applicable, before resuming normal hoist operation.e

4. All anchorages and/or suspensions, the trolley, the trolley beam and other supporting components shall be approved by an appointed person.

LOAD TEST. The load test shall be made with a load equal to 125 percent of the hoist's rated capacity, unless a hoist is equipped with an overload device. A hoist equipped with an overload device shall be tested with a 100 percent load. A test of the overload device itself shall follow the load test.

All load tests shall be performed by, or under the direction of, an appointed person.

f tL1

SECTION V•

SECTION V

PERIODIC INSPECTION AND PREVENTIVE MAINTENANCE

Perform periodic inspection and preventive maintenance procedures as outlined in Table 5-1. Instructions for per forming the actual procedures are covered in following topics in this section. These are minimum requirements and both the intervals and operations are based on inter mittent operation of the hoist eight hours each day, five days per week. Depending on the activity, severity of service and environment of the hoist, more frequent inspec tions and maintenance may be required. The operator of the hoist must be responsible for determining the severity of service and operating conditions.

Table 5-1. Periodic Inspection and Preventive Maintenance

E INTERVAL INSPECTION OR MAINTENANCE TO BE PERFORMED

of each shift

Check operation of upper limit switch, motor brakes and controls.

Visually inspect running wire rope for twists, kinks, distortion, excessivr wear and improper dead-ending.

Visually inspect the hook for a throat opening in excessive of 15 dt grees or a twist in excess of 10 degrees from the plane of an unbent hook.

Make a thorough inspection of wire rope as instructed elsewhere in this section.

Remove and inspect magnetic brake disc plate and linings. Clean or replace them as required. Adjust brake operating clearance.

Check oil level in hoist and trolley gear cases. Add oil as required.

1-3 Months

3-6 Months

Inspect contacts of control contactors. All contacts are silver alloy and are not harmed by discoloratron and slight pitting. Do not file these contacts. Replace them only when silver has worn thin or they are severly

Check all wiring for evidence of damage and check security of all electrical connections.

Clean hoist and trolley gear case breathers in solvent. Lubricate exposed teeth on geared trolley wheels. Lubricate trolley wheel bearings and guide rollers. Drain and refi II hoist gear case.

Lubricate sheave in upper and

Apply a small amount of oil to the shaft limit switch.·

6 Months Drain and refill trolley gear case.

of the upper

Annually Inspect hook using a magnetic particle, penetrant or otl1er of detecting cracks. Inspect the safety latch and test its operation applicable)

(if

LUBRICATION

GENERAL. To ensure continuing good operation of the hoist, all points requiring lubrication must be serviced with the correct lubricant at the proper time interval as indicated for each assembly.

The lubrication intervals recommended in this manual are based on intermittent operation of the hoist eight hours each day, five days per week. If the hoist is operated almost continually or on more than one shift, more frequent lubrication will be required. Also, the lubricant types and change intervals are based on operation in an ambient temperature range of 0° to 1 00°F and in an environment relatively free of dust, moisture and corrosive fumes. Con sult the Harnischfeger Corporation for specific lubrication recommendations if environmental conditions are other than those described.

HOIST GEAR CASE. Drain and refill the hoist gear case at least once every six months. Remove the breather and magnetic drain plug (Figure 5-1) to drain the oiL Clean the magnetic drain plug, and then reinstall it in the gear case. Remove the oil level plug and add oil through the breather opening until oil reaches the oil level plug opening.

Figure 5-1. Hoist Gear Case Lubrication

NOTEt

Oil capacities vary from 3 to 16 pints depending on the size of the gear case. The oil capacity of your hoist is cast in raised letters on the gear case just below the breather opening.

Replace the oil level plug. Clean and reinstall the breather.

NOTE

Remove the oil level plug and check the oil level at least once every three months.

Use a high quality gear oil without EP additives for indoor service and outdoor summer service (ambient temperatures above +40°F). Use a high quality automatic transmission fluid, type "A", for outdoor winter service (ambient temperatures below +40°F). The following products meet these requirements:

AGMA No.5 Gear Oil P&H Specification No. 486

Automatic Transmission Fluid, Type "A" P&H Specification

No. 494

AMOCO Industrial Oil 95 Atlantic Richfield- Hytherm S-1000, Duro Oil 900 "Sin- clair", Eagle Oil R&O Heavy Continental Oil Co. - Dectol R&O Lubricating Oil, Grade 92 EXXON Teresstic 85 Mobil Oil Co.- Vactra Oil BB Shell Oil Co. Hydraulic Oil, Grade 71 Sun Oil Co.·OX Ottawa 2085 Texaco- Regal R&O Lubricat- ing Oil, Grade G Union Oil Co. of Calif. - Union 76 Division·Union Turbo R X (Puropale R X Extra Heavy or Red Line Turbine)

Continental Oil Co. - Oexron EXXON- Enco ATF Mobil Oil Co.·Mobil A TF 220 Shell Oil Co. ·Shell Donax T-6 Sun Oil Co.- OX ATF Dexron Texaco- Texamatic Fluid 6673 Sinclair Refining Co.·ATF- Dexron AMOCO American Dexron

ATF

NOTE: This specification covers a petroleum power transmission fluid and lubricating oil properly des-cribed as Dexron fluid.

Use only lubricants listed. Other lubricants may affect the safe performance of the hoist and can result in hoist failure and cause injury or property damage. Approval for the use of other lubricants should be obtained from the Harnischfeger Cor poration to assure safe operation.

MOTOR GEARED TROLLEY GEAR CASES. Remove the oil level plug (Figure 5-2) and check the oil level at one to three month intervals. If necessary, remove the breather and add gear oil until the oil reaches the oil level plug opening. Replace the oil level plug. Clean the breather in a solvent and reinstall it. Drain and refill the gear case every six months. Use the same type gear oil as used in the hoist gear case.•

MOTOR DRIVEN TROLLEY GEAR CASES- VARIABLE SPEED. Drain and refill the gear case at least once every six months. Some gear cast-JS are equipped with a drain plug and others with an oil level pipe (Figure 5-2). The oil level must be turned upside down for draining. When empty, return the oil level to its upright position. Then add oil through the breather opening until the oil level reaches the top of the oil level pipe. Replace the cap or pipe plug. Clean and reinstall the breather. Use the same type gear oil as used in the hoist gear case.

Remove the oil level pipe cap to check the oil level at least every three months. The oil level should be to the top of the pipe. Add oil as

SINGLE SPEED P..ND TWO SPEED

MCJl OR GEARt.D TROLLEY

1\!1

GEARED TROLLEY WHEELS. Apply open gear lubricant at least every six months to the exposed drive and driven gear teeth. More frequent applications will be necessary if the hoist is in constant use or opt3rating under adverse conditions. Apply the gear lubricant sparingly to prevent it from dripping on the beam flanges, which will cause the trolley wheels to slip"

BREATHER

/ I I'

OIL DRAIN

PLUG

--OIL LEVEL

PLUG

Geared trolley wheels arc not lubricated at tho and must be lubricated before the hoist placed into service.

MOTOR DRIVEN TROLLEY MODEL 668

GEARED TROLLEY WHEEL

DO NOT OVER GR

EXCLSS GREASE ON RUNW/\Y WI

CAUSE SLIPPAGE

01 L LEVEL PLUG

OIL ltVEl

PLUG

OIL DRAIN

PLUG

Oil DRAIN

PLUG

., MOTOR DRIVEN TROlLEY MODEL 666••

F 5-2. Trolley Drive Gear Cases

Figure 53. Geared Wheels

5-3

Use a hinh quality open yt::ar lubricant which is adhesive and water resistant (P&H Specification No. 464, or equal).