Home

Yale LodeKing Wire Rope Hoist

Contents

1. 22 23 TROLLEY OPERATION amp MAINTENANCE 24 40 General POW OV e 24 NSTAWAUION e 24 Start up and Pre Operational Inspection 25 CPC 25 29 NS CCUM aa eaa aa a 29 30 5 eee ans 30 33 Replacement Parts 34 40 RECOMMENDED SPARE PARTS 41 WARRANTY de nnn 41 ES LODEKING 2 115633 12 Nov 2012 LODEKING MODEL NUMBER SYSTEM Example Model 1060703312102 60 ton LodeKing Top running suspension 33 ft of lift 12 ft min Double reeved Gage is 102 in 1 3 1 3 2 3 L 060 T 033 12 102 Model Capacity Tons Suspension Or Mounting for Top Runner for Deck Mount Lift Feet Lifting Speed FPM Gage In LODEKING 3 115633 12 Nov 2012 HOISTS HOIST OPERATION amp MAINTENANCE SAFE HOISTING PRACTICES For your own safety and that of your fellow workers Material Han dling Equipment must be used as recommended by the Manufac turer Failure to heed the following recommendations could endanger your life Use good common sense and judgement at all times Safety is the responsibility of the operator of the equipment You must be competent and attempt to foresee and avoid all hazardous conditions To be s
2. Re reeve 115633 12 Nov 2012 HOIST OPERATION amp MAINTENANCE TROUBLESHOOTING Load Drifts or Drops Motor Noisy Possible Cause Possible Cause Remedy Remedy Motor brake slipping Adjust brake Check for oil on brake discs Motor bolts loose Tighten Adjust for proper clearance See brake instructions Check for bent rotor shaft or worn bearings Motor brake not closing Replace worn or damaged parts Rotor dragging in stator With vector control the inverter will fault and warning horn will sound in the event of any brake related issues If these conditions are observed Brake slip or failure to set see the hoist inverter manual to troubleshoot inverter related brake faults and the brake manual for proper adjustment of brake Motor bearings loose Replace bearings Transformer Overheats or Burns Out Possible Cause Remedy Brake Coil Burned Out _ Wrong tap used Replace transformer if necessary Possible Cause on primary side Primary tap must match line voltage Wrong coil Replace with proper voltage coil Shorted transformer Replace Motor brake too tight Adjust brake See brake instructions Shorted control circuit Correct short Hoist Does Not Operate Possible Cause Remedy Blown or loose fuse Tripped breaker Lose terminal screws Low voltage Low voltage or no voltage to push button circuit Defective push button Wire may be pinched broken or bare Motor
3. CONNECT A SUITABLE GROUND WIRE IN THE SUPPLY WIRING TO A SOLID GROUND AND TO THE SUPPLY GROUNDING LUG SUPPLIED IN THE HOIST CONTROL PANEL LODEKING HOISTS 5 PUSH BUTTON CONTROL A WARNING TO INSURE CORRECT OPERATION OF THE SAFETY LIMIT STOPS IT IS VERY IMPORTANT THAT THE HOOK TRAVEL IS IN THE HOISTING DIRECTION WHEN THE UP BUTTON IS PRESSED IF IT IS NOT INTERCHANGE ANY TWO OF THE MOTOR LEADS IN THE MOTOR CONDUIT BOX DO NOT CHANGE PUSHBUTTON WIRING INTERCHANGING WIRES ON THE LINE SIDE OF THE INVERTER WILL NOT AF FECT SHAFT ROTATION DIRECTION IF THE HOIST IS OPERATED WITH INCORRECT POWER CONNEC TIONS THE SAFETY LIMIT STOPS WILL BE INEF FECTIVE AND SERIOUS DAMAGE AND DANGEROUS ACCIDENTS MAY RESULT 5 115633 12 Nov 2012 HOIST OPERATION amp MAINTENANCE Adjustments of Limit Switches 1 HOISTS UPPER LIMIT SWITCH After the hoist is determined to be running in the proper direction lower the hook to approximately eight feet 8 below the hoist Check the limit switch by running the hook upward and lifting the rod or weight by hand When the rod or weight is lifted from one half inch 1 2 to two inches 2 the hoist should cutoff Any further lifting of the rod or weight should close the lowering circuit and cause the hook to lower UPPER AND LOWER LIMIT SWITCH Note warnings and cau tions below ROTARY CAM LIMIT SWITCH SEE NEXT PAGE FOR DIAGRAMS OPERATION Rotation of drive s
4. Remedy Ground hoist Repair or replace Replace Make sure hoist is properly grounded 115633 12 Nov 2012 HOISTS HOIST OPERATION amp MAINTENANCE HOIST GEAR DRIVE General Instructions One can receive the detailed installation and maintenance instruc tions by entering a serial number or NORD order number at the appropriate location on the NORD web site 1 Record the serial number from your gearmotor gear reducer or motor nameplate or record the serial number found on your order confirmation Go to www nord com docs to download the appropriate operating instructions EXAMPLE www nord com docs Unit Documentation You can recieve your unit s installation and maintenance instructions by entering a serial number or order number The order number serial number can be found on your order confirmation or on the unit s nameplate 820932346200 Search Information Serial number 8209323462 00 Model type 9032 1AX 132 M 4 CUS BRE100 1622 VZ Mounting position M4 Documents BIM1040 90 1 amp 92 Helical Bevel US English 1350 KB BIM1002 Hollow Keyed Shaft amp Fixing Element Kit US English 157 KB BIM1090 Motor Brakes US English 960 KB Kubler Encoder Wiring US English 200 KB Documents for 820932346200 US English 2667 KB D Documents for 820932346200 US English 2454 KB Safety Notes All work including transportation storage installation electrica
5. Lubrication frequency will need to be increased dependant on the severity of service Oil re quired is Aral Degol BG 220 gear oil Suitable substitutes are Texaco Pinnacle 220 amp Shell Omala 220 Do not mix lubricant types this applies in particular to mineral and synthetic lubricants Too much lubricant can lead to overheating Gearcase is not provided with nor requires a vent plug Motor Gearcase Oil Horsepower Capacity liters 0 75 55 18 1 0 75 18 1 5 1 2 40 2 0 1 5 55 3 0 2 2 55 TO CHANGE GEARCASE OIL 1 Disconnect and lock out power supply 2 Unplug motor connection 3 Unbolt complete gearmotor from endtruck Gearmotors weigh up to approximately 75 Ibs I Remove drain filler plug on top of gearcase as shown in figure 5 Tip motor to drain oil in to proper container Properly dispose of used oil Fill gearcase with correct amount of oil per chart above and replace drain filler plug O Mount complete gearmotor back on endtruck and bolt back into place Using a torque wrench tighten all bolts to 7 5 ft Ibs torque for 115 mm 4 5 and 160 mm 6 3 end trucks and 18 ft Ibs torque for 200 mm 7 9 and 260 mm 10 2 end trucks Re install motor plug N 8 Turn power back on to crane and test run checking for any signs of leaks DRAIN FILLER PLUG Figure 5 Gearcase Drain Filler Plug HOIST amp TROLLEY For hoist and trolley lubrication instruction
6. apparently wrong Any discrepancies or suspected discrepancies shall be immediately reported to crane operator s supervisor Below is a check list which can be used for this inspection Pre Operation Inspection Checklist Item Inspection Instruction Check that crane or hoist is not tagged with Tagged Crane or Hoist an out of order sign Test run that all motions agree with control device _ Control Devices markings Check that all motions do not excessive drift and LI Brakes that stopping distance is normal Check for damage cracks nicks gouges deforma Hook tions of the throat opening wear on saddle or load bearing point and twist Refer to the manual furnished by the original crane manufacturer If a hook latch is required check for LI Hook Latch proper operation Check for broken wires broken strands kinks and _ Wire Rope any deformation or damage to the rope structure Check for cracks nicks gouges wear and Hoist Chain stretch check that the chain is in the upper and lower sprockets and in the chain guide Reeving Check that the wire rope is properly reeved and that rope parts are not twisted about each other Check that the upper limit device stops the lifting motion of the hoist load block before striking any _ Limit Switches part of the hoist or crane Check for any sign of oil leakage on the crane _ Oil Leakage and on the floor beneath the crane Check for an
7. 1164 TRT 1173 Order by reducer LT6282 TRT 1174 LT7282 Center Drive TRT 1165 TRT 1175 LT2282 TRT 1211 LT3282 TRT 1212 TRT 1221 Axle Retaining 174282 1213 1222 4 LT5282 TRT 1214 TRT 1223 Order by reducer 16282 7 TRT 1224 LT7282 Center Drive 5 Driver Wheel Key TRT 1242 TRT 1243 6 Trailer Axle TRT 1252 TRT 1253 Quantities listed are for one 1 complete end truck LODEKING 38 115633 12 Nov 2012 TROLLEY OPERATION amp MAINTENANCE HOISTS PARTS LIST CONTINUED Reference No Description Component Quantity Required Truck Wheel Size 40 through 50 Ton Capacity 60 Ton Capacity 20 30 ST 20 30 TT Driver Wheel 40 60 ST m 404 604 TT d Wes amp 208 508 ST TRT 1311 TRT 1321 30 50 1312 1322 55 105 1313 1323 55 105 1314 1324 20 30 204 304 Trailer Wheel idi 8 40 60 Order by rail size amp 30 50 ST TRT 1411 TRT 1421 tread type 304 508 TT TRT 1412 TRT 1422 55 105 ST TRT 1413 TRT 1423 554 1054 TT TRT 1414 TRT 1424 9 Bearing Cage with hole TRT 1502 TRT 1503 10 Bearing Cage w o hole 3 TRT 1512 TRT 1513 11 Wheel Bearing 4 TRT 1522 TRT 1523 12 Bearing Cage Bolt 12 TRT 1532 TRT 1533 13 Bearing Cage Lockwasher 12 TRT 1542 TRT 1543 14 Lubrication Fitting 4 TRT 1552 TRT 1
8. 5 400 0 787 20 0 650 16 5 800 0 787 20 0 650 16 5 BRE 1200 0 866 22 0 689 17 5 As new condition Worn condition brake rotor replacement is required Brake Pad Replacement reference Spare Parts list on next page When the brake pad is worn the pad should be replaced to maintain proper brake operation and ensure safety Required Tools 1 Phillips head screw drivers fan shroud removal 2 External snap ring pliers fan and brake hub removal 3 Large flat head screw driver or small pry bar fan removal 4 Metric T handle wrenches and open end wrenches Procedure 1 Remove the fixing screws 946 securing the fan cover 940 to the motor end shield 932 If the brake has a hand release 937 the lever arm should be removed by unscrew ing it 2 Remove the fan cover 940 and note the position of the hand release slot if applicable 3 Remove the snap ring holding the cooling fan 939 and carefully remove the cooling fan 939 key and second snap ring 997 4 If the brake is equipped with a dust boot 992 remove it 5 Remove the socket head cap screws holding the brake coil 936 to the motor end shield 932 6 Remove the brake coil 936 noting the hand release 937 and power cable locations 7 Slide the brake rotor 993 off the brake hub 938 which is secured to the motor shaft 8 Clean the brake install the new brake rotor pad and reas semble the brake in reverse order of th
9. INSPECTION CHECKLIST Fill out inspection checklist at the back of this manual sign date and file for future reference Quarterly Inspection ALL ITEMS UNDER DAILY AND MONTHLY INSPECTION Check for excessive magnet gap Lubricate linkage as required 115633 12 Nov 2012 HOIST OPERATION amp MAINTENANCE Annual Inspection 1 ALLITEMS UNDER DAILY MONTHLY AND QUARTERLY INSPECTION 2 EQUALIZE SHEAVE IDLER SHEAVE AND PINS Check for cracked or worn sheaves pins and bearings 3 HOOKS Magnetic particle or other suitable crack detecting inspection should be performed if need is indicated by external appearance Check for loose retaining nuts and collars 4 LOAD BEARING PARTS Check for worn cracked or distorted parts such as suspension housings outriggers clevises yokes hook blocks suspension bolts shafts locking devices and bearings on hoist also on trolley if so equipped 5 MOTOR BRAKE Check for excessive or uneven disc wear On direct acting check for excessive magnet gap Lubricate linkage as required A CAUTION PRIOR TO TESTING ALL SUPPORTING STRUCTURES ANCHORAGES AND OR SUSPENSIONS MUST BE APPROVED BY THE APPOINTED PERSON FOR THE TEST LOADS USED 6 WIRING AND TERMINALS See that all connections are tight Terminals are to be securely crimped to wires and the insulation sound Bent terminals can usually be straightened to provide a tight fit Replace terminals or wire if necessary 7
10. ON THIS EQUIPMENT EACH STEP OUTLINED BELOW MUST BE FOLLOWED FOR PROTECTION AGAINST ELECTRICAL SHOCK AND INJURY FROM MOVING COMPONENTS CAUTION WHEN MOUNTING ROTARY LIMIT SWITCH ALIGN DRIVE SHAFT D WITH COUPLING TO MINIMIZE STRESS ON SHAFT AND BUSHINGS DO NOT USE HAMMER OR SIMILAR TOOL TO FORCE COUPLING OR SPROCKET ONTO DRIVE SHAFT EXCESSIVE STRESS ON SHAFT MAY RESULT IN DAMAGE TO ROTARY LIMIT SWITCH AND COULD INVALIDATE WARRANTY A WARNING AT LEAST THREE WRAPS OF ROPE MUST REMAIN ON THE DRUM IN THE LOWEST POSITION A WARNING WHEN UPPER PLUGGING LIMIT SWITCH IS USED MAKE SURE TRAVELING NUT OR GEARED LIMIT SWITCH TRIPS FIRST ALLOWING THE ROD OR WEIGHT TYPE SWITCH TO ACT AS THE BACKUP LIMIT 115633 12 Nov 2012 HOIST OPERATION amp MAINTENANCE Rotary Cam Limit Switch Adjustment Diagrams Adjusting Tool C Cam Screw D Drive Shaft Assembly E Black Timing Line Black on white cam for Standard Dwell White on black cam for Long Dwell Cam Adjustment LODEKING Guide Hole Cam Gear Assembly White for Standard Dwell Black for Long Dwell J Notch K Contact Block and 2 6 32 x 1 screws L Contact Block Screws N Helical Cam Drive Gear Assembly P Ground Screw Q Top Plate Screws Switch Mounting Plate S Cam Mounting Plate T Cover U Threaded Outlet 115633 12 Nov 2012 HOIST OPERATION amp MAIN
11. SHEAVES AND DRUMS Inspect rope sheaves and drums for excessive wear When the groove of a sheave or rope drum becomes worn excessively it should be replaced Worn grooves on the drum or sheave can greatly reduce the useful life of the hoisting rope 9 BEARING LUBRICATION The motor sheave and outer drum bearings are a pre lubricated sealed design and normally will not need to be lubricated 10 INSPECTION CHECKLIST Fill out inspection checklist at the back of this manual sign date and file for future reference Function Testing After Repair A CAUTION PRIOR TO TESTING ALL SUPPORTING STRUCTURES ANCHORAGES AND OR SUSPENSIONS MUST BE APPROVED BY THE APPOINTED PERSON FOR THE TEST LOADS USED After repair or replacement of parts function test hoist by operating unloaded hoist into both upper and lower limits first with slowest speed possible then with increasing speeds up to maximum Limit switch mechanisms must be adjusted so they will trip in sufficient time to prevent damage to any part of the hoisting arrangement See instructions for adjustment of limit switches Then test operation of hoist and brake by lifting 10096 of rated load A normal load lifted may be substituted if no load bearing parts were altered If hoist is equipped with a load limiting device and load bearing parts have been altered the first test load should be only 10096 of rated load The test should be prepared by the person responsible and kept
12. air gap is checked by placing a feeler gage between metal anchor plate and the brake coil housing as shown in the diagram below This procedure is identical even for the larger BRE800 and BRE1200 twin rotor brakes 1 Loosen the fixing screws that attach the brake to the motor s end shield by approximately half a turn If required the brake assembly may be loosened slightly from the motor s end shield by turning the threaded setting bolts hollow screws that surround the fixing screws coun ter clockwise into the brake coil housing 3 Depending upon whether or not the air gap needs to be de creased or increased turn the fixing screws accordingly until the desired nominal air gap Table 6 is reached as measured using the appropriate feeler gauge a Turning the fixing screws clockwise allows the brake coil housing to be moved towards the anchor plate and reduces the air gap b Turning the fixing screws counter clockwise allows the brake coil housing to be moved away from the anchor plate and increases the air gap If the setting bolts hollow screws were adjusted as sug gested in Step 2 re secure the brake coil housing firmly against the motor s end shield by turning the setting bolts hollow screws clockwise out of the brake coil housing Tighten the fixing screws to the appropriate torque 6 Re check and measure the air gap in multiple locations to check for appropriate spacing Repeat the steps as needed
13. brake and the hand lever air gap must be adjusted before the brake is assembled to the motor Once adjusted properly the hand lever air gap setting should not be altered even when readjusting the air gap setting 115633 12 Nov 2012 HOIST OPERATION amp MAINTENANCE MOTOR BRAKE INSTALLATION amp MAINTENANCE CONTINUED Setting the Brake Air Gap NORD spring loaded brakes are virtually maintenance free However the air gap of the brake rotor or brake disc must be periodically checked and adjusted If necessary the worn brake rotor must be replaced The Brake Air Gap Settings table serves as guide to check and set the brake air gap as needed When a complete brake motor is supplied by NORD the air gap is already set at the factory If the brake is ordered as a part the air gap must be set in the field All brake air gap adjustments must be made with the brake assembled to the motor and the power off brake engaged The brake air gap is checked by placing a feeler gage between metal anchor plate and the brake coil housing as shown in the diagram below This procedure is identical even for the larger BRE800 and BRE1200 twin rotor brakes ARMATURE PLATE MOTOR END SHIELD SETTING BOLT HOLLOW SCREW MOTOR END SHIELD COIL HOUSING METAL ANCHOR PLATE DC BRAKE STATOR FIXING SCREW FEELER GAUGE BACK OF MOTOR FAN SHROUD REMOVED LODEKING HOISTS Procedure The brake
14. brake casing which releases the brake rotor and allows the motor shaft to rotate NORD brakes are DC voltage brakes and in most instances are supplied with a motor mounted brake rectifier for easy connections to AC power AC power is taken directly from the power line or from the terminal block of the motor and converted to DC by the supplied rectifier Basic Brake Operation Brake Engaged Brake Released Brake endshield Armature plate Coil E A Hub Body Springs Brake disc Brake Air Gap In order to obtain optimal brake performance and maximum brake life it is necessary to periodically check and reset the brake air gap As the brake rotor wears and decreases in thickness the air gap will increase If the air gap is too large the brake coil may not have enough magnetic force to pull the metal armature disc across the gap and the brake will drag When a complete brake motor is supplied by NORD the air gap is already set at the factory If the brake is ordered as a part the air gap must be set in the field All brake air gap adjustments must be made with the brake assembled onto the motor and power off brake engaged Hand Release Lever HL It is common to supply the NORD brake with a hand release lever assembly The hand release lever allows the brake to be manually released without requiring that the brake be energized with volt age The lever has a spring return that allows the brake to be hand released and re
15. brake coil burned Defective stator Rotor loose on shaft Defective push button cord Replace or tighten fuse Reset breaker Check and tighten all loose screws Check voltage at line side of mainline contactor when provided or line side of hoist fuse base Check voltage at output side of transformer Wrong voltage tap may have been selected For example 460 volt tap used when line voltage is 230 volt Check control circuit fuse Check contact points at push button to see if points touch If not replace Check for lack of continuity or short to ground Replace Check to make sure coil is proper coil for voltage applied Rewind stator Replace Motor Overheats Excessive Amperage Draw Possible Cause Remedy Defective stator Worn motor bearings Bent rotor shaft Rotor dragging in stator Stator loose in frame Low voltage Replace or rewind stator Replace Replace Tighten motor bolts Check for foreign matter between rotor and stator Check for worn motor bearings Rewind stator if necessary Reposition and anchor in accordance with motor manufacturers instructions Check with local utility company and or increase wire size LODEKING HOISTS 13 Possible Cause Hoist not grounded Power leads or control wires shorted to hoist frame Grounded motor Slight electrical leakage from any of the electrical components on hoist Hoist Shocks Operator
16. completely disassemble the hoist follow the disassembly proce dures in the order listed To disassembly any one specific part of the hoist follow the instruc tions for that specific section 1 REMOVE HOIST ROPE BOTTOM BLOCK OR BOTTOM HOOK 1 Remove or readjust geared limit to negate lower limit see instructions a through f 2 Operate hoist in down direction until no cable remains on the drum Remove rope clamps and pull rope from the drum 3 Remove power from the hoist 4 Remove rope clamps 5 Remove limit switch weight from the hoist cable 6 Remove pin holding equalizer sheave yoke in hoist frame 4 part rope only 7 Remove shafts holding the sheaves in the yoke or frame and remove cable 2 REMOVE MOTOR BRAKE DIRECT ACTING A CAUTION DISCONNECT ALL POWER TO THE HOIST BY DISCONNECTING THE POWER FEED LINE BEFORE ATTEMPTING SERVICE OR REPAIR a Disconnect encoder cable from encoder b Remove fan shroud screws and remove shroud c Loosen set screws holding encoder to shaft and remove encoder d Remove screws holding fan to shaft and remove fan e Disconnect brake cable within motor terminal box and remove cable from terminal box f Remove four socket head screws holding brake to motor Remove brake 3 REMOVE GEAR CASE a Run hoist in down direction and clear all rope from the hoist drum b Remove drum supports and drums Caution must be used when removing drums to ensure
17. load movement is required EXTEND BOOM RETRACT BOOM STOP TELESCOPING BOOMS TELESCOPING BOOMS Arm extended and palm down With both fists in front of body with Use one hand to give any motion ONE HAND SIGNAL One fist in front ONE HAND SIGNAL One fist in front move arm horizontally back and thumbs pointing toward each other signal and place the other hand of the chest with the thumb tapping of the chest with the thumb point forth motionless in front of the hand the chest ing outward and heel of fist tapping A 6 giving the motion signal the chest EMERGENCY STOP With both arms extended and palms down move arms horizontally back and forth DOG EVERYTHING Clasp hands in front of the body LODEKING TRAVEL ONE TRACK LAND CRANES ONLY Indicate track to be locked by raising fist on that size Rotate other fist in front of body in direction that opposite track is to travel from the crane operator s perspective MULTIPLE TROLLEYS Hold up one finger for block marked 1 and two fingers for block marked 2 Regular hand signals to follow 28 TRAVEL BOTH TRACKS LAND CRANES ONLY Use both fists in front of body making a circular motion about each other indicating direction of travel forward or backward puff T 4j gt MAGNET IS DISCONNECTED Crane operator spreads both hands apart with palms up TRAVEL BRIDGE TRAVEL With arm extended forward am
18. often small compared to the costs associated with this type of oil analysis program A WARNING NORD suggests replacing the gear oil if oil analysis indicates any of the following e Viscosity has changed by approximately 10 or more e Debris particles silicon dust dirt or sand exceed 25 ppm e content exceeds 150 200 ppm e Water content is greater than 0 05 500 ppm e The total acid number TAN tests indicate a signifi cant level of oxidative break down of the oil and a critical reduction in performance If the TAN number measured changes by more than 5 over the new oil then an oil change would be recommended 115633 12 Nov 2012 HOIST OPERATION amp MAINTENANCE HELICAL amp BEVEL REDUCER LUBRICATION CONTINUED Mounting Position and Oil Fill Quantity Vent Plug Locations All NORD Gear reducers are shipped from the factory with Reducer venting allows for air pressure differences that occur a pre determined oil fill level in accordance to the specified during operation between the inner space of the reducer reducer size and mounting position For additional information and the atmosphere while ensuring leak free operation The please see the separate mounting position diagrams and the AUTOVENT is standard for all vented gear units unless corresponding oil fill quantity tables for the specified gear unit otherwise noted The gearbox name tag will indicate the mounting position that AUTOVENT
19. supplied by NORD All reducer drain plugs are metric socket head cap screws For The open vent comes closed upon delivery with a transportation easier identification it is NORD s standard practice to provide sealing plug see Warning a hex head screw for the fill level plug For ease of draining the used oil from the gear reducer use the socket head screw located at the lowest part of the gearbox WARNING To prevent build up of excessive pressure sealed vents must be activated as shown prior to gear unit start up Drain Plug Fill Level Plug Activated Vent Filtered Vent NORD may offer an optional filtered vent which allows gases to permeate but does not allow dust and debris to pass through the vent ES LODEKING 23 115633 12 Nov 2012 HOISTS TROLLEY OPERATION amp MAINTENANCE This manual contains important information to help you install operate maintain and service your new top running trolley We recommend that you study its contents thoroughly before putting the trolley into use With proper installation application of correct op erating procedures and practicing the recommended maintenance suggestions you will be assured of the maximum service from your trolley The trolley described in this manual are intended for indoor service Trolleys to be used for outdoor service require special consider ations IMPORTANT When ordering replacement parts be sure to include Catalog Part and Serial Nu
20. 13 13282 30 50 TT 2064 TRT 2114 5511 1054 ST TRT 2065 TRT 2115 5511 1053 TT TRT 2066 TRT 2116 304 504 ST TRT 2067 TRT 2117 DRIVER WHEEL 303 5053 TT TRT 2068 TRT 2118 55 105 ST TRT 2069 TRT 2119 5511 1054 TT TRT 2070 TRT 2120 30 50 ST TRT 2071 TRT 2121 DRIVER WHEEL 30 50 TT TRT 2072 TRT 2122 Wheel rod 55 105 ST TRT 2073 TRT 2123 Assemblies 55 105 TT TRT 2074 TRT 2124 DRIVER WHEEL 3043 504 ST TRT 2125 Order by drive type ASSEMBLY 30 50 TT TRT 2126 rail size amp tread LT6282 55 105 ST 2127 type 55 105 TT TRT 2128 30 50 ST DRIVER WHEEL 30 50 TT _ _ ASSEMBLY 55 105 ST 55 105 TT Approximate Weight of Assembly Ibs 235 415 203 304 ST 20 30 TT 40 60 ST 403 602 TT Center Drive 30 50 ST TRT 2089 TRT 2139 Assembly 304 508 TRT 2090 TRT 2140 55 105 ST TRT 2091 TRT 2141 5511 1053 TT TRT 2092 TRT 2142 Approximate Weight of Assembly Ibs 235 415 204 304 ST E 20 30 40 60 ST Trailer Wheel 40 60 TT 2 Assembly 30 50 ST TRT 2097 TRT 2147 30 50 TT TRT 2098 TRT 2148 55 105 ST TRT 2099 TRT 2149 55 105 TT TRT 2100 TRT 2150 Approximate Weight of Assembly Ibs 225 400 Quantities listed are for one 1 complete end truck If bronze wheels or rail sweeps are required follow the Key No with a B for bronze ST Straight Tread Wheels TT Tapered
21. 2382 201 Gear 202 Pinion Shaft 203 Gear 204 Pinion Shaft 205 Gear 206 Pinion 207 Output Shaft 208 Key 209 Oil Seal 210 Oil Seal 211 Snap Ring 212 Shim 213 Anti Friction Bearing 214 Gasket 215 Inspection Cover 217 Vent Plug 218 Gasket 219 Bolt 220 Key Conditionally used part LODEKING PINION SHAFT 221 Snap Ring 222 Anti Friction Bearing 223 Bore Plug 224 Retaining Washer 225 Lock Washer 226 Bolt 227 Bolt 228 Gasket 229 Thrust Washer 230 Input Cover 232 Gasket 233 Key 234 Drain Plug 235 Gasket 236 Thrust Washer 237 Anti Friction Bearing 238 Anti Friction Bearing 239 Snap Ring 240 Bore Plug PRESS ON ad 241 Shim 242 Thrust Washer 243 Gearcase 244 Snap Ring 245 Anti Friction Bearing 246 Key 247 Shim 248 Anti Friction Bearing 249 Spacer 250 Bore Plug 254 Thrust Washer 261 Nilos Ring 262 Nilos Ring 263 Nilos Ring 264 Nilos Ring 918 Key 919 Snap Ring 115633 12 Nov 2012 HOIST OPERATION amp MAINTENANCE M 205 T KN ji 55 254 207 208 e Ej PN To EN M ot SK 1382 NB SK 6382 SK12382 203 Gear 204 Pinion Shaft 205 Gear 206 Pinion 207 Output Shaft 208 Key 223 Bore Plug Conditionally used part LODEKING 229 Thrust Washer 244 Snap Ring 245 Anti Friction Bearing 246 Key 2
22. 47 Shim 248 Anti Friction Bearing 249 Spacer 250 Bore Plug 254 Thrust Washer 261 Nilos Ring 262 Nilos Ring 263 Nilos Ring 264 Nilos Ring 115633 12 Nov 2012 HOIST OPERATION amp MAINTENANCE Troubleshooting This section identifies some of the most common issues involved with NORD Gear speed reducers and provides recommendations to assist you in defining and answering your questions as you work with our products You may also contact our Engineering Application departments if your questions are not answered in the table below Problem with the Reducer Possible Causes Suggested Remedy Check rated capacity of reducer replace with Overloading Load exceeds the capacity of the reducer unit of sufficient capacity or reduce the load wee TM Check lubricant level and adjust up to Insufficient lubrication O Check lub level and adjust d Improper eck lubricant level and adjust down to Lubrication Excessive lubrication recommended levels Pe Flush out and refill with correct lubricant Wrong lubrication ac recommended Inspect mounting of reducer Tighten loose bolts Loose foundation Weak mounting structure and or reinforce mounting and structure Bolts Loose hold down bolts Tighten bolts Replace bearing Clean and flush reducer Runs Noisy Failure of bearings May be due to lack of lubricant and fill with recommended lubricant Overload Che
23. 553 Rail Sweep 20 30 Rail 15 Rail Sweep 40 60 Rail Rail Sweep 30 50 Rail TRT 1611 TRT 1621 Rail Sweep 554 1055 Rail TRT 1612 TRT 1622 16 Rail Sweep Bolt 12 TRT 1652 TRT 1653 17 Rail Sweep Locknut 12 TRT 1662 TRT 1663 R3 TRT 1771 TRT 1771 Bumpers R4 TRT 1772 TRT 1772 18 R5 TRT 1773 TRT 1773 Includes nuts amp R6 TRT 1774 TRT 1774 lockwashers R7 TRT 1775 TRT 1775 R8 TRT 1776 TRT 1776 R3 TRT 1781 TRT 1781 R4 TRT 1782 TRT 1782 Flat R5 TRT 1783 TRT 1783 19 2 Washers R6 TRT 1784 TRT 1784 R7 TRT 1785 TRT 1785 R8 TRT 1786 TRT 1786 Quantities listed are for one 1 complete end truck ST Straight Tread Wheels TT Tapered Tread Wheels If bronze wheels or rail sweeps are required follow the Key No with a B for bronze For example a 9 bronze driver wheel for 20 30 rail with straight tread must be ordered as TRT 1301B LODEKING 39 115633 12 Nov 2012 TROLLEY OPERATION amp MAINTENANCE PARTS LIST CONTINUED Truck Wheel Size 40 through 50 Ton 60 Ton Capacity Capacity Reference Component TET ay No Description Required 20 30 ST 20 30 40 60 ST DRIVER WHEEL 408 608 _ ASSEMBLY 304 504 ST TRT 2055 12282 30 50 2056 55 105 ST TRT 2057 55 105 TT TRT 2058 20 30 ST 20 30 TT 40 60 ST DRIVER WHEEL 40 60 TT _ _ ASSEMBLY 304 504 ST TRT 2063 TRT 21
24. 8 230volt 3phase 60Hz 45152021 45152031 45152041 7 380volt 3phase 50Hz 460volt 3phase 60Hz 1 45152023 45152033 45152043 5 5volt 3phase 60Hz 45152024 45152034 45152044 ES LODEKING 36 115633 12 Nov 2012 TROLLEY OPERATION amp MAINTENANCE 40 THROUGH 60 TON CAPACITY 16 17 Uf T 11 yl J fy 9 10 12 332370 1 ES LODEKING 37 115633 12 Nov 2012 TROLLEY OPERATION amp MAINTENANCE HOISTS PARTS LIST Truck Wheel Size Reference Component Quantity 40 through 50 Ton 60 Ton No Description Required Capacity Capacity 42 TRT 1021 TRT 1051 48 TRT 1022 TRT 1052 54 TRT 1023 TRT 1053 60 TRT 1024 TRT 1054 66 TRT 1025 TRT 1055 72 TRT 1026 TRT 1056 78 TRT 1027 TRT 1057 84 TRT 1028 TRT 1058 90 TRT 1029 TRT 1059 Truck Tube 96 TRT 1030 TRT 1060 Weldment 102 TRT 1031 TRT 1061 1 108 TRT 1032 TRT 1062 Order by 114 TRT 1033 TRT 1063 wheelbase in 120 TRT 1034 TRT 1064 126 TRT 1035 TRT 1065 132 TRT 1036 TRT 1066 138 TRT 1037 TRT 1067 144 TRT 1038 TRT 1068 150 TRT 1039 TRT 1069 156 TRT 1040 TRT 1070 162 TRT 1041 TRT 1071 168 TRT 1042 TRT 1072 174 TRT 1043 TRT 1073 LT2282 TRT 1121 LT3282 TRT 1122 TRT 1131 Driver Axle LT4282 TRT 1123 TRT 1132 2 LT5282 TRT 1124 TRT 1133 Order by reducer LT6282 TRT 1134 LT7282 Center Drive TRT 1125 TRT 1135 LT2282 TRT 1161 LT3282 TRT 1162 TRT 1171 Reducer Key LT4282 TRT 1163 TRT 1172 3 LT5282 TRT
25. 803203 4 4 11803203 8 8 1 2 11680701 2 13 Bumper R3 11680703 2 2 11680703 2 2 Bumper R4 11680702 2 2 11680702 2 2 Bumper R5 11680705 2 11680705 2 Flat Washer R1 Flat Washer R2 11803101 2 14 Flat Washer R3 11803101 2 2 11803101 2 2 Flat Washer R4 11803103 2 2 11803103 2 2 Flat Washer R5 11803103 2 11803103 2 15 H S Hex Head Bolt Cl 8 8 11802509 12 24 11802509 14 20 16 Hex Nut 10399110 12 24 10399110 14 28 17 Washer 11803502 12 24 11803502 14 20 18 Slotted Roll Pin 11807001 2 11807001 2 19 Hand Hole Cap Plug 10849811 4 8 10849811 4 8 9 LODEKING 35 115633 12 Nov 2012 TROLLEY OPERATION amp MAINTENANCE Figure 8 Gearmotor 15 amp 20 Ton Capacity 25 amp 30 Ton Capacity MT 200 mm Truck 260 mm Truck 260 mm Truck Description Quantity kW 1 hp 1 55 kW 2 hp 2 2 kW 3 hp Part Number Part Number Part Number Gearmotor Repair Parts 1 Mounting Hardware Kit 1 45152052 45152053 Brake Rectifier 380 460V amp 575V 1 45152065 Brake Rectifier 190 200 230V 1 45152066 Complete Brake Kit 180VDC 190 200 230V amp 380 460V 1 45152059 45152061 Complete Brake Kit 250VDC 575V 1 45152060 45152062 4 Fan Kit where applicable 1 45152077 45152078 5 Shroud Kit 1 45152082 45152083 6 Mating Easy Connect Plug where applicable 1 11829301 Complete Gearmotor Assembly 190volt 3phase 50Hz 20
26. D BE INSPECTED ACCORDING TO THE ABOVE PARAGRAPH ON WIRE ROPE INSPECTION IF DAMAGED ROPE IS FOUND CHECK DRUM AND FRAME MEMBERS FOR DAMAGE How to Measure Wire Rope The correct diameter of a wire rope is the diameter of a circum scribed circle which will enclose all the strands It is the largest cross sectional measurement The measurement should be made carefully with calipers The illustrations below show the correct and incorrect method of measuring the diameter of wire rope Wrong Way Right Way 10 LODEKING GENERAL INSTRUCTIONS Procedure for Reeving Wire Rope on Drum DOUBLE REEVED UNITS Note Rotary cam limit switch must be set for 3 safety wrap 1 Anchor the rope in the drum on one side Install rope retainer Stretch out rope to make sure there are no twists or kinks 3 Reeve the free end of the rope through the bottom block and all sheaves 4 Anchor the free end of the rope in the other side of the drum Install rope retainer 5 Push the UP button to reeve both sides of the drum making sure there is enough force on the rope to insure proper reeving in all drum grooves Note When the bottom block is raised to the upper limit the block should be at the midpoint of the ungrooved portion of the drum and even with idler sheave If this is not so the unit is reeved incorrectly A WARNING ALL UNITS WITH A LOWER LIMIT SWITCH MUST HAVE A MINIMUM OF THREE WRAPS OF WIRE ROPE ON THE DRUM WHEN
27. ES THAT HAVE BEEN SITTING IDLE FOR SIX MONTHS OR GREATER SHALL RECEIVE A COMPLETE PERIODIC INSPECTION PRIOR TO ITS USE LODEKING 30 MAINTENANCE General Maintenance services required on top running cranes are for the most part simple periodic inspections and adjustments Procedures for lubrication routine adjustments and replacement of parts if required are described in the following paragraphs Lubrication AXLE BEARINGS Axle bearings on the 4 5 115 mm and 6 3 160 mm diameter wheels are permanently lubricated with no additional lubrication requirements Axle bearings on the 7 9 200 mm and 10 2 260 mm diameter wheels require periodical lubrication To access grease fittings remove the rail sweep Fitting is located on the pilot diameter of each bearing cage four total per endtruck as shown in figures 3 amp 4 Lubricate with NLGI 2 General Purpose Grease every three months Replace rail sweep upon completion Using a torque wrench tighten all bolts to 72 ft lbs torque for all size end trucks Frequency of and type of lubrication used may be adjusted based the severity of the duty cycle and operating environment GREASE FITTING Figure 3 Trailer Wheel GREASE FITTING Figure 4 Drive Wheel 115633 12 Nov 2012 HOISTS TROLLEY OPERATION amp MAINTENANCE GEARMOTOR Endtruck The gearcase lubricant should be changed after 10 000 hours of use based on moderate Class C service
28. EVEL REDUCER LUBRICATION Importance of Proper Lubrication Proper gearbox lubrication is essential in order to reduce friction heat and component wear Lubricants reduce heat and wear by inserting a protective fluid boundary between mating parts and preventing direct metal to metal contact Lubricants also help prevent corrosion and oxidation minimize foam improve heat transfer optimize reducer efficiency absorb shock loads and reduce noise Most NORD reducers are shipped from the factory with a pre determined oil fill level in accordance to the specified reducer size and mounting position Standard Oil Type The following tables indicate the standard oil fill type used Please see user manual U11000 for more specific information and for optional helical and bevel gear lubricants Serviceable Gear Units Helical In line Clincher Parallel Shaft Right Angle Bevel NORDBLOC Series In line NORDBLOC 1 Series In line Standard Series In line Standard Oil Fill ISO VG 220 Mineral Oil For shipping purposes the following large Clincher gear units are supplied without oil Clincher Sizes SK11282 SK11382 and SK12382 Maintenance free Lubricated For Life Gear Units Clincher sizes SKO182NB SK0282NB amp SK1382NB Standard Oil Fill r ISO VG220 SHC PAO NORDBLOC Sizes SK172 Synthetic Oil SK272 SK371F SK372 SK373 SK320 Maintenance free units are supplied as sealed units
29. Hoists on passenger elevators A WARNING DO NOT USE YALE HOISTS OR TROLLEYS FOR PASSENGER ELEVATOR APPLICATIONS Inspection Preventive Maintenance and Testing A preventive maintenance program should be initiated for this hoist immediately after it is entered into service The preventive mainte nance program should comply with recommendations in the ap plicable Yale Parts and Instruction Manual and all pertinent Federal State and Local regulations Regular inspections maintenance and testing required should be followed for the life of the hoist and writ ten inspection records kept as specified Sample inspection check lists are included in back of this manual Extra inspection checklists can be obtained from your nearest authorized Yale Distributor 115633 12 Nov 2012 HOIST OPERATION amp MAINTENANCE YALE HOIST DUTY SERVICE CLASSIFICATIONS Operational Time Ratings Uniformly Distributed Work Periods Infrequent Work Period Typical Areas Hoist Running 50 Time of Application 3 _ 4 5 6 on Time Time From Max No of Min Hr Starts Hr Cold Start Min Starts General Machine Shop fabricating assembly storage and warehousing Where loads and utilization are randomly H3 distributed with total running time of equipment not n 199 a 0 exceeding 15 25 of the work period High volume handling in steel warehousing general machine shops fabricating assembly mills and found
30. ISTS TROLLEY OPERATION amp MAINTENANCE Periodic Inspection Periodic inspections are to be performed by a qualified designated person Inspection intervals vary by class of service For Class C Service crane they are to be performed annually at a minimum Frequency of this inspection may have to be increased based on the severity of the duty cycle and environmental conditions the crane is subjected to A written dated and signed inspection report shall be provided and maintained on file All worn damaged or mal functioning parts are to be repaired or replaced to maintain a SAFE operational crane Refer to the typical Inspection Schedule and Maintenance Report found elsewhere in this manual Items to be inspected include but are not limited to 1 All functional operating mechanisms for misadjustment interfering with crane operation 2 Operating parts for excessive wear 3 All safety devices for malfunction 4 All connections and mountings for loose bolts nuts and other fasteners for tightness All structural members and welds for deformation cracks or corrosion All electrical apparatus including control contactors limit switches push button stations for signs of pitted contact points wear or deterioration All hoists and trolleys installed on the crane in accordance with the manufacturer s recommendation A WARNING ALWAYS LOCK MAIN SWITCH IN THE OPEN POSITION OFF BEFORE INSPECTION NOTICE CRAN
31. NE STARTING CONTROLS IS NOT PERMITTED WILL RESULT IN DAMAGE AND PREMATURE FAILURE OF THESE UNITS AND VOID ANY WARRANTY NOTICE PRIOR TO PLACING THE CRANE INTO SERVICE THE CRANE SHALL RECEIVE AN INITIAL INSPECTION THIS INSPECTION SHOULD BE PERFORMED BY A QUALI FIED PERSON IN ACCORDANCE WITH ANSI ASME B30 2 OR B30 17 LOCAL STATE AND PROVINCIAL STANDARDS AND REGULATIONS 115633 12 Nov 2012 HOISTS TROLLEY OPERATION amp MAINTENANCE START UP AND PRE OPERATIONAL INSPECTION After the crane has been installed on the runway and the crane hoist and trolley has been connected to electrical service but prior to plac ing into service as a minimum the following inspections should be made by a qualified person Check the main collector system for proper adjustment to main tain proper contact with conductors Check along runway for pos sible interference if power is supplied by a cable reel or festooned cable A WARNING LOCK MAIN RUNWAY DISCONNECT SWITCH IN OPEN POSITION BEFORE ATTEMPTING TO ADJUST MAIN COLLECTORS OR CONDUCTORS Check the cross and pushbutton festoon conductors for adjust ment including cable loop depth and tracking Check oil level in both drive gearcases and axle bearing grease fittings if provided for proper lubrication If lubrication is required refer to the LUBRICATION SECTION of this manual Inspect crane to make certain that all bolted connections and attachments are prop
32. NVERTER SHALL BE DONE BY A QUALIFIED CRANE TECHNICIAN PER THE MANUFACTURER S INSTRUCTION MANUAL EACH CRANE HAS A MAXIMUM SPEED SETTING BASED ON ITS CAPACITY SPAN DUTY CLASSIFICATION ETC DO NOT EXCEED MAXIMUM SPEED FOR WHICH THE CRANE WAS SPECIFIED WHEN ORDERED STEP 5 The trolley motion buttons are typically labeled Left and Right The hoist motion buttons are typically labeled Up and Down Practice and become acquainted with these controls STEP 6 Once the operator s are acquainted and comfortable operating the crane and the hoist trolley they shall learn the Pre Shift inspection procedure Refer to the INSPECTION section of this manual A WARNING IF WHEN DEPRESSING THE HOIST UP BUTTON THE HOOK SHOULD LOWER STOP AT ONCE DO NOT ATTEMPT TO OPERATE AGAIN REPORT THIS CONDITION TO THE PROPER SUPERVISOR FOR CORRECTION WITH THE INSTRUCTIONS FUR NISHED WITH YOUR HOIST MANUAL BY A QUALI FIED CRANE TECHNICIAN Set lower limit switches of the hoist and insure proper functioning per the Hoist Manufacturer s Manual When operating the hoist in the up direction CAREFULLY OBSERVE the relationship of the hook block and the bottom of the hoist frame The hoist upper limit switch when working properly should cause the hoist up motion to stop and or reverse direction 115633 12 Nov 2012 TROLLEY OPERATION amp MAINTENANCE A WARNING Once the crane has successfully passed its Start up
33. OPERATING MAINTENANCE amp PARTS MANUAL MANUAL 2 115633 12 Yale HIGH CAPACITY ELECTHIC WIRE ROPE HOISTS HOISTS Capacities from 15 to 60 tons TABLE OF CONTENTS ORDERING MODEL NUMBER SYSTEM 3 HOIST OPERATION amp MAINTENANCE 4 23 Safe Hoisting 8 4 Before Operating Hoist Applying the Load Moving the Load Parking Safety Laws for Passenger Elevators Inspection Preventive Maintenance and Testing Yale Hoist Duty Service Classifications Repair Parts Ordering amp Return Information b Hoist Serial Numbers 5 metalation INSTRUCTIONS mem 5 Adjustment of Limit Switches sss 6 7 BASIC SUSPENSIONS 8 Hoist Maintenance and Inspection 8 10 Daily Inspection Monthly Inspection Quarterly Inspection Annual Inspection Function Testing After Repair Wire Rope Mainenance and Inspection NR ER 10 11 Disassembly amp Reassembly 12 Miisel ipsro uc ptr 13 Hoist Gear Drive Information sess 14 17 Motor Brake Installation amp Maintenance 18 21 Helical amp Bevel Reducer Lubrication
34. OPERATION amp MAINTENANCE Learning the Controls After making certain the crane is completely and properly installed with the crane connected to the electrical service and all the instal lation and start up inspections made the crane operator s should learn and become acquainted with the controls On cranes having any or all motions electrically operated the opera tor should locate the runway disconnect and make sure this switch is locked open POWER OFF The operator should now operate the various push buttons to get the feel and determine that they do not bind or stick in any position The operator should become familiar with push button location for their respective motions as well as start and stop buttons normally the top two green and red buttons which operate the crane main line contactor The mainline contactor will shut off power to all motions A WARNING IF ANY PUSH BUTTON BINDS OR STICKS IN ANY POSITION DO NOT TURN THE POWER ON DETERMINE THE CAUSE OF THE MALFUNCTION AND CORRECT IT BEFORE OPERATING THE CRANE Learning the Controls While Operating Crane with No Load Having inspected and tried the control the crane operator is now ready to try the crane under power A CAUTION ALWAYS ALLOW THE TROLLEY TO COME TOA COMPLETE STOP BEFORE CHANGING DIRECTION ABRUPT CHANGE OF TROLLEY DIRECTION WHILE IN MOTION MAY CAUSE ADVERSE OPERATING CHARACTERISTICS OR DAMAGE TO TROLLEY AND DRIVE COM
35. PONENTS STEP 1 Close the crane runway disconnect switch STEP 2 Close the crane disconnect switch mounted on the crane The crane main disconnect switch is located in the bridge panel and is operable from the front of the panel without opening the panel The switch is operated by rotating the handle The OFF and ON posi tions of the switch are marked on the switch assembly The bridge control panel also contains a 3 pole mainline contactor This contactor is connected in the electrical system on the load side of the crane main disconnect switch so that all the crane power flows through this contactor The mainline contactor is opened and closed turned off and on by means of the stop start buttons on the pendant push button station This stop start circuit as well as other control circuits typically operate at 115 volts This 115 volt control circuit voltage is obtained from a transformer mounted in the bridge control panel STEP 3 Press the start or green push button which will close the mainline contactor applying power to all control devices The crane is now ready for use LODEKING STEP 4 The drive motors on the trolley are controlled by inverters programmable variable frequency control Standard programming on Yale provided controls is two step infinitely variable The motion buttons on the pushbutton for the crane typically labeled FWD and REV are two step buttons for this progra
36. Pushbutton O gt Qo Wiring Motor Brake When so Equip O Couplings Gears Shafts amp Bearings Frame c Wheels E Bumpers Guards Conductors Collectors Monorail Joints N Monorail 2 Main Conductors Main Collectors General Condition O Load Attach Chains Rope Slings amp Connect Change Gearcase Lub Grounding Faults O Seetext for daily amp weekly requirements Signed amp dated report required OSHA Typical Inspection Schedule and Maintenance Report form User must adjust O Inspection interval X Magnetic particle or equivalent examination required inspection interval and components to suit their individual conditions and usage E LODEKING 33 115633 12 Nov 2012 TROLLEY OPERATION amp MAINTENANCE REPLACEMENT PARTS The following parts lists and illustrations cover standard model cranes Typical units are used as the basis for the exploded parts illustrations therefore certain variations may occur from the parts information given For this reason always give the catalog number sales order number model number motor horsepower voltage phase and frequency when ordering replacement parts For motors gear cases and electrical components give complete nameplate data A WARNING NON FACTORY AUTHORIZATIONS OR MODIFICA TION OF EQUIPMENT AND USE OF NON FACTORY REPAIR PARTS CAN LEAD TO DANGEROUS OP ERATION AND INJURY TO AVOID INJURY DO NOT ALTE
37. R OR MODIFY EQUIPMENT WITHOUT FACTORY AUTHORIZATION DO USE ONLY FACTORY PROVIDED REPLACEMENT PARTS The numbers assigned to the parts of the various assemblies in the parts lists may not be the part numbers used in manufacturing the part They are identification numbers that when given with the catalog number permits us to identify select or manufacture and ship the correct part needed ES LODEKING 34 115633 12 Nov 2012 TROLLEY OPERATION amp MAINTENANCE 15 THROUGH 30 TON CAPACITY Figure 7 End Truck Assembly 45150901 exp 15 amp 20 Ton Capacity 200 mm Truck 25 amp 30 Ton Capacity 260 mm Truck Description Driver Wheel 65 mm tread 23487701 1 1 23487801 1 1 Driver Wheel 88 mm tread 23487703 1 1 23487903 1 1 Trailer Wheel 65 mm tread 23487702 1 1 23487902 1 1 Trailer Wheel 88 mm tread 23487704 1 1 23487804 1 1 3 Bearing Cage Open Driver 23488101 1 1 23488201 1 1 4 Bearing Cage Closed Trailer 23488102 3 3 23488202 3 3 5 5 5 11802728 12 12 11802718 12 12 6 Hi Collar Lock Washer 11803202 12 12 11803203 12 12 7 Bearing 10380106 4 4 10380106 4 4 8 Grease Fitting 06099 5 5 06099 5 5 Rail Sweep 65 mm tread 23488901 2 2 23489001 2 2 Rail Sweep 88 mm tread 23488902 2 2 23489002 2 2 10 10 1 50 5 5 11802729 4 4 11802729 8 8 11 M10 Flat Washer 11803101 4 4 11803101 8 8 12 M10 Hi Collar Lock Washer 11
38. T DESIGNED OR SUITABLE AS A POWER SOURCE FOR LIFTING LOWERING STEP 2 OR TRANSPORT OF PERSONS Move the crane to the load making certain the load hook is high enough to clear any obstruction in its path Position the hoist and trolley so that the load hook is centered over the load Lower the load hook for load attachment For larger sized loads the use of a rigging or load director may need to be used to direct the lift and movement of the load This person should use the proper hand signals as shown in this manual The crane operator should respond only the signals of the designated person directing the load except for emergency stop as shown on the next page OPERATOR HAND SIGNALS A WARNING PRIOR TO ATTACHING OR LIFTING A LOAD KNOW THE WEIGHT OF THE LOAD AND THE BELOW THE HOOK LIFTING DEVICES SPREADER OR LIFTING BEAMS MAGNETS GRABS SLINGS ETC THE TO TAL WEIGHT OF THE LOAD AND LIFTING DEVICES SHALL NOT EXCEED THE RATED CAPACITY OF THE HOIST AND OR CRANE STEP 3 Attach load to load hook Slowly raise the hook until the slack has been taken out of the below the hook devices When the floor man signals and the operator is satisfied the load is secure in the sling lift the load slowly until clear Now hoisting speed can be increased and maintained until the load is clear of all obstructions or the floor man gives the signal to stop STEP 4 Starting slowly and increasing speed as distance permits move the tr
39. TENANCE Basic Suspensions The basic hoist suspension type is a top running motorized trolley 1 2 for double rails Before mounting on beam or rail make sure supporting structure has adequate strength to safely support the loading which will be imposed On top running motorized trolleys make sure rail size is correct for wheels and that distance between rails is correct for trolley throughout entire rail lengths Preventative Maintenance Schedule The required periods between inspections will vary due to the wide range of duty cycles and operating conditions encountered with equipment The following recommended inspection periods are based on duty of specified service rating with single shift operation 40 hours per week under normal environmental conditions If the hoist is used under adverse environmental conditions it should be inspected more frequently Daily Inspection Inspect the following items before operating hoist 1 ELECTRICAL CONNECTIONS Check for worn or frayed wires for loose connections and for damage to or improper operation of push button assembly 2 LIMIT SWITCH Check the upper and lower limit switch by run ning the hook without load and at the slowest speed obtainable to the maximum up and maximum down positions Then test with increasing speeds up to maximum The switch should shut the hoist off before the bottom block contacts the rod or weight type limit switch at the upper extreme Three wra
40. THE BOTTOM BLOCK IS IN THE LOWEST POSITION 115633 12 Nov 2012 HOIST OPERATION amp MAINTENANCE Reeving Types Yale powered wire rope hoists and winches are reeved in various ways to gain desired advantages Proper reeving insures maximum life of the hoist drum wire rope and bottom block assembly while obtaining the best characteristics of capacity lift and speed for the basic unit Reeving is double i e two ropes coming from the drum Close headroom hoists are double reeved Part designates the number of times the rope runs between the hoist and bottom block For example With 2 part double reeving the rope runs from the rope drum to the bottom block up to the equalizer sheave back to the bottom block then back to the rope drum indicating 4 parts of rope supporting the load The drawings below show the characteristics of each principal method of reeving Advantages of double reeved units include minimum lateral hook drift Keeping load in the same approximate position in relation to the drum and beam and a lower hoist headroom requirement 10 Part Reeving d E 9 LODEKING HOISTS 11 4 Part Reeving 12 Part Reeving 115633 12 Nov 2012 HOISTS HOIST OPERATION amp MAINTENANCE Disassembly A CAUTION BEFORE DOING MAINTENANCE WORK ON THIS HOIST READ THE FOLLOWING INSTRUCTIONS THOROUGHLY REFER TO THE REPLACEMENT PARTS SECTION FOR PARTS IDENTIFICATION To
41. The AUTOVENT helps prevent bearing and was provided For mounting orientations other than shown in gear damage by behaving like a check valve to block the entry the mounting position charts please consult NORD Gear of foreign material water dust corrosives etc The breather opens at approximately 2 3 psi during operation and closes tightly as the gearbox cools This option is perfect for humid A WARNING conditions and wash down environments helping to maintain proper oil cleanliness and reducing foaming and oxidation Actual oil volume can vary slightly depending upon NORD may choose to offer one of two style options as shown the gear case size mounting and ratio Prior to in Figure 1 The 2 AUTOVENT comes closed upon commissioning the reducer check the oil fill level delivery with a transportation sealing plug see Warning using the reducer s oil level plug and drain or add additional oil as needed The minimum acceptable oil level is 0 15 in 4mm below the oil level hole AUTOVENT Types T j Type 2 with transportation plug Oil Plug Locations All gear units are assembled with the oil fill level oil drain and vent plugs installed in their proper locations according to the specified mounting position All standard plugs are metric and utilize sealing gaskets between the head of the plug and the reducer housing Drain and Fill Level Plugs Open Vent An optional open vent be
42. Tread Wheels For example a 9 bronze driver wheel for 20 30 rail with straight tread must be ordered as TRT 1301B 115633 12 Nov 2012 i LODEKING 40 TROLLEY OPERATION amp MAINTENANCE RECOMMENDED SPARE PARTS FOR YOUR YALE CRANE Certain parts of your crane will in time require replacement under normal wear conditions It is suggested that the following parts be purchased for your crane as spares for future use e 1 Set of Wheel Bearings e 1 Set of Fuses Note When ordering parts always furnish the part number and the manufacturer s serial number WARRANTY WARRANTY AND LIMITATION OF REMEDY AND LIABILITY A Seller warrants that its products and parts when shipped and B Upon Buyer s submission of a claim as provided above and its its work including installation construction and start up when substantiation Seller shall at its option either i repair or replace performed will meet applicable specifications will be of good its product part or work at either the original f o b point of de quality and will be free from defects in material and workmanship livery or at Seller s authorized service station nearest Buyer or ii All claims for defective products or parts under this warranty must refund an equitable portion of the purchase price be made in writing immediately upon discovery and in any event within one 1 year from shipment of the applicable item unless C This warranty is contingent upon Buyer s proper ma
43. actices to avoid and precautions to take for his own safety and the safety of others Observance of these rules in addi tion to frequent examinations and periodic inspection of the equip ment may save injury to personnel and damage to the equipment DO Always center trolley over load when hoisting DO NOT stand and DO NOT cause or allow others to stand or get under any load the trolley is supporting DO keep clear and make sure others keep clear of any load the trolley is supporting DO NOT attempt to operate trolley before completing tests and adjustments Improper and careless operation can result in a hazardous condition for operator and load ALWAYS be sure load is clear of obstruction before traversing load CAUTION IF TROLLEY IS MOUNTED ON A RAIL THEN END STOPS MUST BE INSTALLED TO PREVENT TROLLEY FROM RUNNING OFF THE END OF THE RAIL RESULTING IN INJURY TO THE OPERATOR AND OTHERS AND DAMAGES TO THE LOAD AND OTHER PROPERTY END STOPS FOR THE TROLLEY MUST ALSO BE INSTALLED Refer to hoist and trolley instruction manuals for safety warnings on hoists and trolleys Read and comply with ANSI B30 2 or B30 17 latest edition Read and comply with all local state and national safety codes A CAUTION MAKE SURE ALL INSTALLATION AND START UP INSPECTION HAVE BEEN MADE IN ACCORDANCE WITH INSTRUCTIONS FURNISHED WITH THE HOIST AND TROLLEY BEFORE TURNING ON THE POWER 115633 12 Nov 2012 HOISTS TROLLEY
44. afe as possible the hoist must be given proper preventive maintenance and testing as described in the ANSI B30 16 Safety Code For Overhead Hoists and this manual Before Operating Hoist 1 Do not operate hoist unless you are properly trained physically fit and authorized to do so You must be familiar with all operat ing controls of the hoist warnings and instructions on the hoist the safe hoisting practices listed in this manual ANSI B30 16 Safety Code For Overhead Hoists and all pertinent Federal State and local regulations before beginning operation 2 Donot allow unqualified personnel to operate the hoist Test all controls and limit switches and make sure hoist is well lubricated at beginning of each shift Make sure needed lubrica tion adjustments or repairs are made by appointed personnel before operations are begun 4 Be familiar with the equipment and its proper care Do not operate hoist if adjustments or repairs are necessary if any damage or undue wear is known or suspected or if any warning operating or capacity instructions normally attached to hoist are damaged obscured or missing Report these items promptly to the proper person and also notify next operator when changing shifts Do not operate hoist if it is functioning improperly Do not operate hoist with an out of order sign attached until sign has been removed by a properly authorized person 7 Donot adjust or repair hoist unless qualified for
45. als if necessary An excessively black color lubricant indicates a chemical change in the lubricant caused by excessive heat which in turn is caused by heavy duty cycles Lubricant that is very black in color must be replaced to prevent shortened life of drive components Lubricate wire rope and other points as required Refer to lubrication chart CAUTION FOR OPTIMUM LUBRICATION AND COOLING OIL LEVEL MUST BE MAINTAINED AT THE SIGHT GAUGE LEVEL HOOK Check hook retaining nuts and collars and means used to secure them Replace hook if throat opening allows safety latch to disengage from throat opening or if there is 10 degrees or more twist from normal plane of hook PUSH BUTTON Check the ground connections to be sure that the wire cores from the push button cable and the power cord are secured Tighten the grounding screw and replace the lock washer if it is missing BEARINGS Check all bearings for noisy operation which is an indication of wear HARDWARE Check for loose bolts nuts and rivets WIRE ROPE Check conditions of wire rope using inspection checklist Refer to wire rope inspection WARNING LABELS Check for absence or illegibility of warning decals and tags and replace if necessary A WARNING NEVER ALLOW WIRE ROPE TO OPERATE DRY SUPPORTING STRUCTURE OR TROLLEY Should be checked for continued ability to support the imposed loads Check for loose suspension or support bolts axle nuts etc 10
46. and Pre Op DO NOT CONTACT OR STRIKE THE HOIST FRAME erational Initial inspection and all the crane operators have been WITH THE HOOK BLOCK IF THE HOIST MOTION IS successfully trained and or licensed it is now ready to be placed NOT INTERRUPTED BY THE LIMIT SWITCH STOP THE HOIST BY REMOVING YOUR FINGER FROM THE BUTTON AND OR DEPRESSING THE STOP BUTTON DO NOT ATTEMPT FURTHER OPERATION UNTIL THE LIMIT SWITCH IS OPERABLE CONSULT THE HOIST MANUFACTURER S INSTRUCTIONS Operating the Crane A WARNING DO NOT OPERATE A CRANE HOIST OR TROLLEY HAVING UNUSUAL VIBRATIONS SOUNDS WARN INGS OR WITH ANYTHING WRONG OR APPARENTLY WRONG DANGER MAY BE PRESENT THAT THE CRANE OPERATOR CANNOT SEE DETERMINE AND CORRECT THE CAUSE OF THE UNUSUAL CONDI TIONS AND MAKE CERTAIN THAT THE CRANE CAN BE OPERATED SAFELY NOTICE JOGGING IS THE RAPID AND REPEATED PRESSING OF A MOTION PUSHBUTTON HOIST TROLLEY TO GET THE EQUIPMENT TO MOVE IN SHORT INCRE MENTS OR INCHING ALTHOUGH JOGGING MAY BE NECESSARY TO POSITION A LOAD EXCESSIVE JOGGING WILL CAUSE PREMATURE WEAR AND FAIL URE OF MOTORS BRAKES AND CONTROLS IT WILL ALSO CAUSE THE MOTORS TO QUICKLY OVERHEAT RESULTING IN THEIR THERMAL PROTECTION TO DIS ABLE TROLLEY MOTION UNTIL COOLED STEP 1 Turn power on to the crane disconnects and mainline If not already done so perform Pre Shift Inspection refer to the Inspection Sec A WARNING tion of this manual THIS EQUIPMENT IS NO
47. brakes are DC rectified solenoid activated spring set disc type brakes Brake is intended to be used strictly as a holding brake and does NOT have any torque adjustment for decel erating and stopping the crane Deceleration and stopping is to be provided by the variable frequency inverter motor control Brake Air Gap Inspection Brake Removal and Replacement To inspect brake air gap refer to figure 6 If brake air gap exceeds the maximum allowed or is not functioning properly the brake may need to be replaced Follow these instruc 1 Disconnect and lock out power supply tions 2 Remove brake cover 1 Turn power off to crane and lock out 3 Carefully roll the o ring back towards the magnet body exposing the air gap between the armature plate and magnet Use feeler gauge and measure the gap between the armature plate and mag 2 Unplug motor leads open motor conduit box and disconnect brake leads from rectifier net If gap exceeds maximum allowed replace the brake 3 Remove brake cover 4 Remove retaining ring and fan if applicable Motor Normal Maximum Brake Mounting Bolt Horsepower Air Air Gap 5 Remove 3 mounting bolts holding brake magnet body in place Pull brake leads from motor remove magnet brake coil and rotor ai 2 0 3mm 6 Re assemble in reverse order and tighten mounting bolts to 1 0 75 pua specified torque 0 2 mm 012 in 3 Nm 1 5 1 2 008 in 2 2 ft Ibs 7 Turn power bac
48. ck rated capacity of reducer Insufficient Level of lubricant in reducer Check lubricant level and adjust lubricant not properly maintained to factory recommended level Overloading of reducer Replace broken parts T can cause damage Check rated capacity of reducer pu Internal parts are broken or missing Key missing or sheared off on input shaft Replace key Properly align reducer and coupling Coupling loose or disconnected Tighten coupling Replace seals Autovent may be clogged Worn seals Caused by dirt or grit entering seal Replace or clean Check lubricant level and adjust Overfilled reducer Oil Unit runs hot to recommended level Leakage or leaks Clean or re place being sure to prevent Vent clogged any dirt from falling into the reducer Incorrect fill level Improper mounting position such as wall Check mounting position on the name tag or ceiling mount of horizontal reducer amp verify with mounting chart in manual LODEKING 17 115633 12 Nov 2012 HOISTS HOIST OPERATION amp MAINTENANCE MOTOR BRAKE INSTALLATION amp MAINTENANCE The standard NORD motor brake is spring set When power is re moved and the brake is de energized power off the brake springs exert a force against the armature plate in turn preventing the brake rotor or brake disc from rotating When the brake coil is energized power on a magnetic field builds and pulls the armature plate across the air gap to the
49. comes necessary to return the complete hoist or certain parts to the factory a letter requesting such a return is necessary This let ter should contain an explanation for requesting the return A return authorization will be issued giving you clearance for returning the hoist or parts to the factory Before the unit is shipped from the factory it is rigidly tested and carefully adjusted for proper operation However the following points must be checked to insure correct installation and avoid damage to the hoist 1 ROPE AND DRUM Check the hoist rope for any signs of damage and make sure it lies properly in the grooves of the drum and sheaves Make sure the rope is well lubricated 2 LUBRICATION Every attempt has been made to ship the hoist with the proper amount of lubricating oil in the gearcase Before placing the unit in operation check the level on the sight gauge The oil should be level with the level hole If more oil is needed consult the Lubrication Chart Also make sure breather plug hole is cleared 3 CURRENT SUPPLY make sure the electric current supply corresponds with the rating listed on the hoist nameplate Make sure duty cycle capabilities of hoist are fully understood by all operators 4 ELECTRICAL CONNECTIONS Open the control box and check all the electrical connections to be sure they are tight and that none of the hardware vibrated loose during shipment CAUTION THE HOIST MUST BE GROUNDED TO DO THIS
50. dical in accordance with the latest editions of ANSI ASME B30 2 B30 17 and CMAA 78 These inspections are necessary to ensure the equipment is safe for use and operating at its required performance level Inspection criteria described herein are general requirements Specific inspection criteria will be based on the options and accessories provided with your crane Refer to the manufacturer s maintenance manual for the hoist trolley and its specific inspection criteria Initial Inspection New re installed altered repaired and modified cranes shall be inspected prior to initial use Inspection of all altered repaired or modified cranes may be limited to the provisions affected by the work as determined by a qualified crane technician Inspections shall include but not limited to clearances operating speeds lu brication control settings safety devices etc Refer to START UP and PRE OPERATIONAL INSPECTION elsewhere in this manual LODEKING 29 Pre Shift Inspection A pre shift inspection shall be performed by the crane operator or designated person at the beginning of each shift or the first time the crane is used during each shift This is a visual and operational inspection to ensure the equipment is in good working order Items to be checked include limit switches brakes electrical equipment and all safety devices Crane is to be operated without a load to check for any unusual sounds vibrations or anything that may be
51. e steps outlined ES LODEKING 20 115633 12 Nov 2012 HOIST OPERATION amp MAINTENANCE MOTOR BRAKE INSTALLATION amp MAINTENANCE CONTINUED Parts List Precima Brakes 995 996 939 ok ing sin 7 4 4 aN ME M EON 1 lt L 2 7727777 77 7777 rA 2 NE Hu ris Normal Design Enclosure IP55 Optional Brake with optional IP66 enclosure with following options RG Stainless Steel Disc Item 990 SR Dust Boot includes Option RG Item 992 HL Hand Release Item 937 932 Non drive end shield 936 Brake coil 937 Manual brake lever optional 938 Brake hub 939 Fan 940 Fan cover 946 Fixing screw 994 Armature plate 995 Spring 996 Pressure plate adjustment 997 Adjustable ring 998 Bushing seal optional 971 O ring optional 990 Friction plate optional 991 Setting bolt 992 Dust protection ring 993 Brake rotor 999 V ring optional Only for brakes that are 5 Nm to 40 Nm Spare Parts NORD Motor Brake Rotor Brake Hub Brake Hub Hand Release Stainless Disc Dust Boot Frame Item 993 Item 938 Bore Style HL Item 937 RG Item 990 SR Item 992 BRE5 63 71 80 19120042 19100112 15 mm h
52. erly tightened and that all electrical connec tions are secure Inspect and adjust the motor brake air gap Refer to the MAINTE NANCE SECTION of this manual The hoist trolley should be inspected as instructed in the hoist trolley manufacturers instruction manual For a double girder crane inspect the clearance between wheel flanges and the girder rail per manufacturers requirements If hoist is equipped with adjustable limit switches confirm settings meet the applications requirements Inspect the alignment of the trolley end stops to the trolley Turn power on at both disconnects and mainline Inspect hoist for reverse phase condition by ensuring push button operation cor responds to intended direction of travel and correct if necessary per manufacturer s instructions Operate the trolley to verify both motors operate in the same direction 10 With no load operate hoist trolley back and forth the full length of girder During the operation ensure and verify proper clear ances from obstructions per CMAA ASME B30 2 ASME B30 17 and OSHA requirements 11 Load testing the crane should be performed in accordance with ANSI ASME B30 2 or B30 17 local state and or provincial codes and regulations A written report should be prepared dur ing the performance of this test and placed on file OPERATION Operator Qualifications Safe and efficient crane operation requires skill extreme care good judgment alertne
53. ex 19150042 19130042 19110042 BRE 10 63 71 19120082 19100212 15 mm hex 19150082 19130082 19110082 BRE 10 80 90 19120082 19100222 20 mm hex 19150082 19130082 19110082 BRE 20 80 90 112 19120162 19100322 20 mm hex 19150162 19130162 19110162 BRE 20 100 19120162 19100332 25 mm hex 19150162 19130162 19110162 BRE 40 90 100 19120322 19100452 25 mm spline 19150322 19130322 19110402 BRE 40 112 19120402 19100442 30 mm hex 19150322 19130322 19110402 BRE 60 100 19120602 19100532 25 mm spline 19150602 19130602 19110602 BRE 60 112 19120602 19100542 30 mm spline 19150602 19130602 19110602 BRE 60 132 19120602 19100552 35 mm spline 19150602 19130602 19110602 BRE 100 132 160 19120802 19100652 35 mm spline 19150802 19130802 19110802 BRE 150 132 19121502 19100752 35 mm spline 19151502 19131502 19111502 BRE 150 160 180 19121502 19100772 45 mm spline 19151502 19131502 19111502 BRE 250 160 180 19122402 19100872 45 mm spline 19152402 19132500 19112502 BRE 250 200 19122402 19100882 50 mm spline 19152402 19132500 19112502 BRE 400 200 225 19124002 19100912 60 mm spline 19154003 10114020 19114002 For brake coil part numbers contact manufacturer The large BRE 800 and BRE 1200 twin rotor brakes are supplied to NORD pre assembled and complete For parts list details and spare parts information please contact NORD 115633 12 Nov 2012 LODEKING 21 HOISTS HOIST OPERATION amp MAINTENANCE HELICAL amp B
54. haft D in either direction causes all cam gear assemblies 1 to turn actuating the contact blocks K A timing line appears in the notch J when the corre sponding contact block is actuated Cam for each contact block is independently adjustable Each contact block contains one normally open and one normally closed contact set ADJUSTMENT 1 Operate the equipment until the desired travel limit is reached taking into account coasting or braking dis tance 2 Loosen the screw C for the cam wheel which actuates the contact block you wish to adjust 3 Insert the adjustment tool G into the guide hole H closest to the cam wheel being adjusted Engage teeth on adjustment tool with teeth on cam wheel 4 Rotate adjusting tool either direction until the black line E appears in the notch J This will be the approximate position at which the contact block will be actuated 5 Tighten the cam screw C Avoid over tightening which could damage screw and screw threads CAUTION TERMINAL OF INDIVIDUAL SNAP SWITCH MUST BE WIRED SAME POLARITY CONTACT BLOCK TERMINALS VIEWED FROM TOP A Terminals N C B Terminals N O SPDT Switch DPDT Switch Timing line is black on white standard dwell cam Line is white on black long dwell cam LODEKING When Adjusting Limit Switches A WARNING HAZARDOUS VOLTAGE CAN CAUSE DEATH SERIOUS PERSONAL INJURY OR PROPERTY DAMAGE DISCONNECT POWER BEFORE WORKING
55. he hoist until you and all other personnel are clear of load 24 Make sure load has proper clearance before moving 25 Inch the hoist slowly into engagement with a load but avoid excessive plugging inching and quick reversals of load 26 Do not lift load more than a few inches until it is well balanced in the sling or lifting device 27 Each time a load approaching rated capacity is handled check load brake action by raising load just clear of supports and continuing only after you are sure brake is operating properly 28 Do not transport load over personnel 29 Never carry personnel on the hook or the load 30 Avoid swinging of load or load hook when traveling the hoist 31 On trolley mounted hoists avoid sharp contact between trolleys or between trolleys and rail stops 32 Do not use limit devices as a normal means of stopping the hoist These are emergency devices only 33 Do not exceed the maximum duty cycle specified by the manufacturer Parking 34 Do not leave load suspended in the air for extended or unat tended periods 35 Keep load block above head level when not in use Safety Laws for Passenger Elevators The safety laws for passenger elevators specify construction details that are not incorporated In Yale Hoists We recommend that pas senger elevator operation equipment be used that meets all state and national safety codes Yale Hoists will not accept responsibility for applications of Yale
56. he unit in this case the tension force of the slings must not exceed a 45 angle In some instances it may be appropriate to use additional lifting straps or slings in order to assure safe transportation of the assembly Always use sufficiently rated handling equipment and ensure that adequate safety measures are taken to protect personnel from injury during transportation Once the NORD assembly is properly installed remove the transportation fixtures Material Disposal Properly dispose of all used gear units and internal parts in accordance with all local regulations In particular all lubricants must be properly collected and disposed For confirmation of specific materials used in a specific reducer or gearmotor assembly please consult NORD with the appropriate unit identi fication cation or serial number Components Material Gear wheels shafts rolling bearings parallel keys snap rings spacers shims etc Steel Gear housing and housing components Cast iron or Aluminum depending on type and size Worm gears Bronze alloy Radial seals sealing caps and rubber components Coupling components Elastomers with some steel Plastic or Elastomer with Steel Asbestos free sealing or gasket Housing gaskets and flat oil seals material various types used Gear Oil Mineral SHC Synthetic or PG Synthetic can vary 115633 12 Nov 2012 HOIST OPERATION amp MAINTENANCE SK 1382 NB SK 6382 SK1
57. intenance Seller specifically assumes installation construction or start up and care of Seller s products and does not extend to normal responsibility All claims for defective products or parts when wear and tear Seller reserves the right to void warranty in event Seller specifically assumes installation construction or start up of Buyer s use of inappropriate materials in the course of repair or responsibility and all claims for defective work must be made in maintenance or if Sellers products have been dismantled prior to writing immediately upon discovery and in any event within one submission to Seller for warranty inspection 1 year from completion of the applicable work by Seller provid ed however all claims for defective products and parts must be made in writing no later than eighteen 18 months after shipment Defective items must be held for Seller s inspection and returned to the original f o b point upon request THE FOREGOING IS EX PRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER EXPRESS IMPLIED AND STATUTORY INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABIL ITY AND FITNESS D The foregoing is Seller s only obligation and Buyer s exclusive remedy for breach of warranty and is Buyer s exclusive remedy hereunder by way of breach of contract tort strict liability or otherwise In no event shall Buyer be entitled to or Seller liable for incidental or consequential damages Any action for breach of
58. k on to crane and test brakes for proper operation 3 0 2 2 016 in Motor End Bell Brake Mounting Bolts 4 Roll o ring back into place and re install brake cover 5 Turn power back on to crane and test brakes for proper operation Brake Rectifier Removal and Replacement Rectifier is located inside the motor conduit box cover To replace follow these steps 1 Disconnect and lock out power supply quU i Retaining Rings 2 Unplug motor leads and open conduit box 3 applicate 3 Remove rectifier unplug wires 4 Plug wires into replacement rectifier l l Shroud Bolt a Connect brake leads to DC side of rectifier terminals marked Plastic Fan guo Brake Disc where applicable O Rin Magnet Bod b Connect leads from the plug to the AC side two terminals j marked 5 Re assemble in reverse order disassembly Figure 6 Motor Brake 6 Turn power onto crane and test for proper operation Electrical 1 Gearmotors a The gearmotors are inverter duty If gearmotor requires any service or repairs other than what is described in this manual the complete gearmotor must be replaced b For hoist and trolley motors consult the hoist and trolley literature 2 Control Panel a All connections should be checked frequently for tightness 3 Hoist and Trolley Panel brakes limit switches etc Consult hoist and trolley litera ture for maintenance and spare
59. l connection commissioning servicing maintenance and repair must be performed only by qualified specialists or personnel It is recom mended that repairs to NORD Products are carried out by the NORD Service Department Instructions related to operational safety will be emphasized as shown A WARNING All work involved in the transport connection commissioning and maintenance of any NORD prod uct must be carried out by qualified and responsible technicians All applicable national regional and local work regulations and safety requirements must also be complied with NORD assumes no liability for personal injury accidental death or equipment damage and malfunctions resulting from failure to comply with installation or operating instructions safety notes or any work regulations and laws Gear unit installation and maintenance work may only be performed when no power is available to the prime mover or motor Electric motors electrical brakes and variable frequency drives contain potentially dangerous high voltage Prior to installation or maintenance shut down the power at the circuit breaker or power switch While working on the drive make sure the power from the prime mover is isolated or secured on lock out to prevent accidental start up and to safeguard against injury Surfaces of motors and gear units may become hot during operation or shortly after start up In some instances additional protection against acciden
60. ler For information regarding attaching lifting and moving the loads during installation refer to ANSI B30 2 latest edition Chapter 2 3 Overhead and Gantry Cranes Single or Multiple Girder Top Running Trolley Hoist ANSI B30 17 latest edition Chapter 17 3 Overhead and Gantry Cranes Trolley Single Girder Underhung Hoist and other applicable codes A WARNING BEFORE INSTALLING THE CRANE ON THE RUNWAY LOCK THE RUNWAY CONDUCTOR DISCONNECT SWITCH IN THE OPEN OFF POSITION Prior to the start of any crane erection the building should be measured to confirm span and clearances These measurements should be checked against the corresponding crane measurements to insure correctness of fit After assuring that the crane fits the building determine orientation of crane position with respect to the runway In addition verify building and runway power supply to ensure it matches the power requirements of the crane These types of cranes are usually lifted into position on the runway in one piece Total weight of this crane should be checked against lifting equipment selected for erection of this crane Immediately after the crane is placed on the runway rails check the wheel flange clearances to the rail Clearance between the side of rail head and inside flange of wheel should be between a total of 3 4 and 1 1 8 depending on the wheel and rail combination and whether or not the truck is centered on the rail Total wheel f
61. loat should not be less than the 3 4 as recommended by CMAA Specifications 70 and 74 LODEKING 24 A WARNING Before attempting any electrical connections the main power switch feeding the runway conductors must be LOCKED IN THE OPEN OFF POSITION NOTICE A FUSED DISCONNECT SWITCH OR CIRCUIT BREAKER MUST BE INSTALLED AND ELECTRICALLY POSITIONED BETWEEN BUILDING POWER SUPPLY AND CRANE RUNWAY CONDUCTOR SYSTEM THIS DISCONNECT MUST BE LOCKABLE IN THE OPEN POSITION IN SIGHT AND IN REACH FOR THE CRANE OPERATOR AND CLEARLY LABELED A SECOND LOCKABLE DISCONNECT IS REQUIRED ON THE BRIDGE CRANE ELECTRICALLY POSITIONED BETWEEN THE RUNWAY CONDUCTOR SYSTEM AND BRIDGE CONTROLS REFER TO ARTICLE 610 OF NFPA NO 70 NATIONAL ELECTRIC CODE OSHA REGULATION 1910 179 ANSI ASME B30 2 AND B30 17 LOCAL STATE AND PROVIN CIAL STANDARDS AND REGULATIONS FOR SPECIFIC REQUIREMENTS A CAUTION IN ACCORDANCE WITH ARTICLE 610 OF NFPA NO 70 NATIONAL ELECTRIC CODE A SEPARATE BONDING CONDUCTOR MUST BE RUN FOR GROUND GROUNDING THROUGH THE WHEELS TO GIRDERS AND RUNWAY STEEL IS NOT PERMITTED A CAUTION GEARMOTORS PROVIDED WITH THIS TROLLEY ARE INTENDED FOR VARIABLE FREQUENCY CONTROL ONLY THE BRAKE USED ON THE GEARMOTOR IS A HOLDING BRAKE WITH NO PROVISION FOR TORQUE ADJUSTMENT SEVERE LOAD SWING WILL RESULT WITHOUT THE CONTROLLED DECELERATION WHEN STOPPING PROVIDED BY THE VARIABLE FREQUENCY CONTROL THE USE OF CONTACTOR ACROSS THE LI
62. maintenance of hoist 8 sure the power supply is disconnected before maintenance and repair procedure is performed 9 Do not use the wire rope as a ground for welding 10 Do not touch a welding electrode to the wire rope Applying the Load 11 Never wrap the wire rope around the load or allow it to drag under load 12 Always use slings or other approved devices to attach load 13 Be sure the sling is properly seated in the saddle of the hook Do not allow hook latch to support any part of load 14 Do not apply a load to tip of hook or in such a way as to cause bending or prying forces on the hook or hook support block 15 Be sure wire ropes are not kinked or twisted or that multiple part ropes are not twisted about each other 16 Do not operate hoist if wire rope is not seated properly in the grooves of the drum or sheaves 17 Do not load hoist with less than two wraps of rope on the drum 18 Center hoist unit over the load before lifting Avoid side pull 19 Never pick up a load beyond the rated capacity appearing on the hoist except for properly authorized tests 20 Do not use a load limiting device to measure the maximum load to be lifted It is a safety device only LODEKING Moving the Load 21 Do not engage in any activity which will divert your attention while operating hoist 22 Respond to signals from designated personnel only except for stop signals 23 Never lift a load with t
63. may be more susceptible to sliding or scuffing wear In these operating conditions it may also be beneficial to consider an increased lubrication viscosity and or a lubrication with improved anti wear additive packages The user should consult with their primary lubrication supplier before considering changes in oil type or viscosity Maximum Oil Sump Temperature Limit To prevent reducer overheating the reducer s maximum oil sump temperature limit must not be exceeded for prolonged periods of operation up to 3 hours continuous operation depending upon reducer size Maximum Oil Temperature Limit Oil Type AGMA 9005 D94 Mineral 80 85 C 176 185 F 95 C 203 F Synthetic 105 C 220 F 107 C 225 F Use caution when specifying gear reducers for high temperature service If there is concern about exceeding the allowable safe operating temperatures please consult NORD to discuss alternatives The Importance of Routine Oil Analysis Routine oil analysis sound lubrication practices and good tracking of oil performance trends will help establish proper lubrication maintenance and change out intervals To maxi mize equipment reliability NORD Gear generally recommends a condition based lubrication maintenance program One may take exceptions to this general recommendation on sealed for life or maintenance free gear units or smaller and less costly gear units In these instances the replacement cost of the gear unit is
64. mbers of the endtrucks and or drive gearmotor along with individual part numbers of components needed as identified elsewhere in this manual Information given in this manual is subject to change without notice GENERAL DESCRIPTION General These top running trolleys are designed to operate on parallel crane runway beams with ASCE Rail from 25 to 105 rail or square bar Specific rail range is wheel diameter dependant Motors are de signed for operation on three phase power supplies from 190 to 415 V 50 Hz and 200 to 575 V 60 Hz Trolley motors and brakes are de signed and intended strictly for variable frequency control operated by pushbutton pendant or radio control Pendant may be located and suspended from an independent festoon or attached directly to the hoist and trolley Top running double girder cranes described herein are built to 1 through 20 tonne with spans to 50 feet 15 2 meter Cranes are designed per CMAA Specifications 70 and 74 to meet Class C Moderate Duty Service classification Basic Construction Each endtruck has a drive and trailer wheel which run on the runway rails The wheels are double flanged flat tread with an integral rotat ing axle supported by anti friction bearings Each endtruck is driven by a helical gearmotor and brake This drive engages the drive wheel by a splined connection INSTALLING TROLLEY The installation of the crane on the runway shall be performed only by a qualified crane instal
65. mming The first step is the initial starting speed of the crane and it also performs a speed hold function The second step of the button performs an acceleration function To operate the crane press the button for desired direction FWD or REV to the first step The crane will start moving and accelerate to its programmed starting speed Press the same button further to the second step and the crane will accelerate up to full speed If the crane reaches a desired speed during this acceleration back the button off to the first step to hold that speed If the crane is traveling too fast and you wish to slow it down release the motion button completely and the crane will start to decelerate Once the desired slower speed is obtained press button to the first step to hold that speed To bring the crane to a stop release the motion button com pletely the crane will decelerate to a stop and the holding brakes will set Practice operating the crane in both directions accelerating to intermediate and full speeds decelerating to a slower speed and bringing it to a stop Get acquainted with the operating characteris tics of this crane acceleration deceleration and stopping distances to ensure smooth load movement accurate load positioning and to minimize load swing NOTICE IF DEFAULT SETTINGS FOR THE TROLLEYS VARIABLE FREQUENCY CONTROL INVERTER DOES NOT MEET YOUR SPECIFIC REQUIREMENTS IT CAN BE RE PROGRAMMED PROGRAMMING OF THE I
66. n the condition of the bearings and axles a bearing puller may be required Be careful not to damage bearing fits on axle 9 Inspect axle bearing diameter and wheel tread diameter and flange for excessive wear spalling and work hardening on the tread and flange nicks and gouges on bearing diameters etc Replace wheel if necessary 10 Prior to re assembling bearings to axle pack the roller bearings with grease Use NLGI 2 general purpose grease unless the severity of the duty cycle and or operating environment warrants otherwise Press bearings onto wheel axle ensure they are fully seated 11 Assemble both bearing caps onto bearings 12 Place wheel assembly onto runway rail and roll it into place in the endtruck Orient the grease fitting if provided on bearing cap pointing towards the rail sweep 13 Carefully lower endtruck ensuring bearing caps and the endtruck pilot diameters align properly Install and tighten bear ing cap bolts Using a torque wrench tighten all bolts to 36 ft lbs torque for 115 mm 4 5 160 mm 6 3 and 200 mm 7 9 end trucks and 72 ft lbs torque for 260 mm 10 2 end trucks 14 Lower endtruck onto runway rail 15 Re install rail sweep and gearmotor Connect motor power plug Hefer to page 30 for torque specifications 16 Turn power back on to crane and inspect crane for proper opera tion 115633 12 Nov 2012 TROLLEY OPERATION amp MAINTENANCE MOTOR BRAKES Standard motor
67. olley toward the point where the load is to be lowered Decelerate and stop by releasing the push button Final spotting is accom plished by pressing the button to the first step to creep into position STEP 5 Learn to judge the stopping distance of the trolley both with light and full loads This will enable you to spot loads with the minimum amount of jogging and excessive load swing ES LODEKING 27 115633 12 Nov 2012 OPERATOR HAND SIGNALS LOWER RAISE BOOM With arm extended downward and Arm extended and fingers closed up forefinger pointing down move with thumb pointing upward hand in small horizontal circle USE MAIN USE WHIPLINE HOIST HOIST AUXILIARY HOIST With forearm vertical and Tap fist on head then use Tap elbow with one hand forefinger pointing up move regular signals then use regular signals hand in small horizontal circle i E y y y 1 LOWER BOOM LOWER BOOM amp SWING EXTEND BOOM Arm extended and fingers closed RAISE LOAD Arm extended with fingers in TELESCOPING BOOMS with thumb pointing downward Arm extended and thumb pointing direction of swing of boom With both fists in front of body down flex fingers in and out as long with thumbs pointing outward Lom v as load movement is required RETRACT BOOM MOVE SLOWLY TELESCOPING BOOMS EXAMPLE HOIST SLOWLY RAISE BOOM amp LOWER LOAD Arm extended and thumb pointing up flex fingers in and out as long as
68. om the limit switch 5 REMOVE CONTROLS OR CONTROL BOX a Remove all power from the hoist b Disconnect and tag all wires coming into the control box c Remove nuts bolts and lockwashers holding control panel in the box d Remove control panel e Disconnect all flex conduit limit switch cord push button cord and power leads from control box f Remove nuts and lockwashers holding control box and remove Control box may be heavy and should be supported before removing Reassembly The assembly sequence is basically the reverse of the disassembly sequence previously described The following special instructions should be observed during reassembly 1 Before the gear case is assembled all internal parts should be inspected for damage or excessive wear Replace parts as required Be sure the drum shaft is free of paint or other material which would interfere with installation Lubricate the shaft with Never Seez to prevent galling Be sure the motor brake is properly adjusted before it is installed on the motor Bolt gear case to the frame using 4 M30 bolts x 2 25 mm dowel pins Slide drums into gear case The drum spacer goes on the drum opposite the motor Install outer bearing support It may be required to move the bearing support fore aft to align the bearing Check alignment with a dial indicator to measure runout at the outboard shaft Contact factory if runout exceeds 0 0003
69. on file for future reference ES LODEKING 9 115633 12 Nov 2012 HOISTS HOIST OPERATION amp MAINTENANCE Wire Rope Inspection All wire rope should be inspected once a month and a signed and dated inspection report maintained The inspection checklists at the back of this manual can be used to record these inspections Wire rope should be replaced if any of the following conditions are noted 1 Twelve randomly distributed broken wires in one rope lay or four broken wires in one strand in one rope lay 2 Wear of one third 1 3 of the original diameter of outside individual wires Kinking crushing birdcaging or any distortion of the wire rope structure 4 Evidence of heat damage Broken Wires Kinked Bird Cage 5 Reductions from nominal diameter of more than the following values New Rope Diameter Maximum Reduction 5 16 inch and under 1 64 inch 3 8 inch through 1 2 inch 1 32 inch 9 16 inch through 3 4 inch 3 64 inch 7 8 inch through 1 1 8 inch 1 16 inch 6 Rope clamps should be checked to ensure bolts are properly torqued CAUTION REPLACEMENT WIRE ROPE SHOULD BE THE SAME SIZE GRADE AND CONSTRUCTION AS THE ORIGINAL WIRE ROPE BEFORE REPLACING WIRE ROPE READ REEVING PROCEDURE AFTER WIRE ROPE REPLACEMENT CHECK FOR PROPER LIMIT SWITCH OPERATION A WARNING ROPE PILE ON HOISTING DRUM WILL SEVERELY DAMAGE THE HOISTING ROPE IF THIS CONDITION IS NOTED THE HOISTING ROPE SHOUL
70. p hand open amp slightly raised making a pushing motion in the direction of travel TROLLEY TRAVEL With palm up fingers closed and thumb pointing in the direction of motion jerk hand horizontally 115633 12 Nov 2012 HOISTS TROLLEY OPERATION amp MAINTENANCE A WARNING NEVER LEAVE AN UNATTENDED LOAD HANGING FROM THE CRANE LOAD MUST BE SAFELY PLACED ON FLOOR PRIOR TO THE CRANE OPERATOR LEAVING THE CONTROLS When crane is not in use during the work period it should be parked in a safe location such as the end of the bay or a location that will not interfere with the movement of people materials and equipment Turn power off to the mainline contactor of the crane Store the pendant against a wall or column to prevent damage from traffic At the end of the work period or day park crane as described herein and turn power off at both disconnects Responsibility for Safe Operation Each crane operator should be held directly responsible for the safe operation of his crane The crane operator should STOP the crane and refuse to handle loads when 1 there is any doubt as to SAFETY 2 any unusual vibrations or sounds are noticed before or when starting the lift or traverse motions 3 there are arguments or disagreements with the floor man or hitchers 4 the operator feels ill or is not alert INSPECTION Overhead cranes are subject to four levels of inspection Initial Pre Shift Frequent and Perio
71. parts information ES LODEKING 32 115633 12 Nov 2012 INSPECTION SCHEDULE AND MAINTENANCE REPORT CRANE SERIAL NO MFGRS _ CUSTOMER CRANE IDENTITY NO ___ CAPACITY ___ LOCATION IN PLANT ___ I TYPE THIS INSPECTION IS MONTHLY SEMI ANNUAL ANNUAL VOLTAGE INSPECTED BY DATE COMPONENT UNIT OR PART RECOMMENDED CONDITION Check column best indicating condition when part or AND LOCATION INSPECTION INTERVAL unit is inspected Use note column to the right if condi CORRECTIVE ACTION NOTES tion is not listed below a Indicate corrective action taken during inspection and 5 m Go note date For corrective action to be done after inspec gt 2 0 tion a designated person must determine that the c 5 oo a Ane 5 oe o S L5 og existing deficiency does not constitute a safety hazard 5 Eg g S 5 SO ma before allowing unit to operate When corrective action 29 HE S5 2505 is completed describe and note date in this column S S 8852 PES Ea 35 D ae E35 TEE TD EET e Motor Motor Brake Mechanical Load Brake Overload Clutch Couplings _ Gears Shafts amp Bearings O Upper Block Lower Block Hook amp Throat Opening e Record Hook Throat Opening Hoist Rope e X Rope Drum Guards O Limit Switch O ds Trolley Panel O amp E Hoist Panel e2 5
72. ps of rope 8 should remain on the drum at the shut off point at the lowest extreme If adjustment is necessary refer to geared limit switch section 3 HOOK Check for cracks or deformation Check for damaged or missing latch A bent or twisted hook indicates overloading or abuse of unit Other load bearing components of the hoist or trolley should be inspected if overloading is apparent or sus pected The bottom hook must swivel freely 9 4 WIRE Check for proper seating in drum grooves Check for wear unstranding fraying kinks or broken wires in the wire rope and condition of end connections If damage is noted see wire rope instructions under monthly inspection 5 HOOK DRIFT With a load the hook should stop promptly when the push button is released Hook drift of more than 2 inches indicates the motor brake is malfunctioning See quarterly and annual inspection instructions for more details 6 UNUSUAL CONDITIONS Excessive noise oil leaks etc should be investigated CAUTION DO NOT OPERATE THE HOIST IF ABOVE INSPECTION INDICATES THAT MAINTENANCE IS NEEDED LODEKING 8 HOISTS jn 2 MOTOR BRAKE Check for excessive or uneven disc wear Monthly Inspection ALL ITEMS UNDER DAILY INSPECTION LUBRICATION Check the level and condition of the gearcase lubricant The level must be maintained at the gearcase sight gauge If the level is low check for leaks Replace gaskets and shaft se
73. ries H4 Total running time does not exceed 35 of work period Sun Loads at or near rated capacity frequently handled Material bulk handling in combination with buckets magnets or heavy attachments Often cab operated H5 Duty cycle exceeds 3596 and approaches continuous Up to continuous 600 Not Applicable Not Applicable operation User must specify exact details of operation including attachment weights Repair Parts Ordering Information This parts and instruction manual contains information required to install and maintain your Yale LodeKing Series Electric Hoist To insure prompt service each repair parts order should be placed with your local distributor and must contain the following information Please give all information listed below in items 1 through 4 This will enable your distributor to fill your order promptly 1 Give complete data from hoist nameplate including hoist serial number model number voltage frequency and hertz 2 Give part numbers description and quantity of parts required 3 Give correct shipping destination 4 For ordering motor repair parts give all data on the hoist gearcase and motor nameplates INSTALLATION INSTRUCTIONS Hoist Serial Numbers The hoist serial number is stamped on the nameplate The nameplates also designate the model number capacity speed current characteristics and service rating of the hoist or trolley Return of Parts If it be
74. s refer to the manu facturer s manuals LODEKING Wheel and Bearing Removal amp Replacement Refer to parts illustration Figure 7 To remove the wheels follow the steps below 1 Remove load and below the hook devices from hook Move hoist and trolley to opposite end of crane from end work is being done A WARNING MAKE SURE THAT TRUCK IS ADEQUATELY SUPPORTED SO THAT IT CANNOT DROP WHEN WHEEL IS REMOVED DUE TO THE WEIGHT OF THE WHEELS AND BEARING CAGES MAKE SURE THAT THE PROPER EQUIPMENT IS IN PLACE TO SAFELY REMOVE THE WHEELS AND BEARING CAGES FROM THE END TRUCK ALSO LOCK MAIN RUNWAY DISCONNECT SWITCH IN THE OPEN POSITION OFF WHEN WORKING ON WHEELS ADJACENT TO RUNWAY CONDUCTORS 2 Disconnect power and lock out 3 Remove load from wheel axle This can be accomplished by jack ing or lifting at the girder s Jacking or lifting only one end of the truck may permanently damage the crane 4 If working on driver wheel unplug motor leads from gearmotor and remove gearmotor from bearing cage Remove rail sweep from endtruck and bolts from bearing cages 5 Jack endtruck to height that will allow bearing cage to roll out from end of endtruck 6 Roll wheel bearings and bearing caps assembly from under endtruck and remove from runway Be careful not to drop bearing caps bearings and wheel from runway height 7 Remove bearing caps bearings should stay on wheel axle 8 Remove bearings from axle Depending o
75. ss concentration and knowledge of and rigid ad herence to proven safety rules and practices No person should be permitted to operate a crane or hoist 1 who does not possess the above characteristics 2 who is not qualified or has handicaps that could adversely affect such operation 3 who has not been properly instructed 4 who has not been informed and does not have a thorough knowl edge of all applicable safe operating practices including those in this book as well as of rigging equipment and practices LODEKING 25 NOTICE SEE APPLICABLE NATIONAL STATE AND LOCAL SAFETY CODES AND REGULATIONS FOR ADDITIONAL REQUIREMENTS RELATING TO SAFE OPERATING PRACTICES INCLUDING ANSI B30 2 OR ANSI B30 17 LATEST EDITION Operating Rules Operating rules listed below are an earnest effort to encourage SAFETY and are not intended to take precedence over individual plant safety rules and regulations or rules set forth by various ap plicable codes A good operator operates his crane as smoothly as possible and knows and follows the suggested rules below for safe efficient crane handling Operating Precautions A WARNING THESE TROLLEYS HOISTS ARE NOT DESIGNED NOR INTENDED TO BE USED FOR SUPPORT OR TRANSPORT OF PEOPLE OR FOR TRANSPORTING LOADS OVER PEOPLE Safe operation of an overhead hoist is the operator s responsibility Listed below are some basic rules that can make an operator aware of dangerous pr
76. tal contact may be necessary Use caution to avoid burns or serious injury LODEKING 14 Observe Published Performance Range amp Nameplate Data A WARNING Observe the data on all reducer nameplates and verify published ratings for the NORD item s in question Do not operate any NORD equipment outside the published per formance range Failure to comply may result in damage to the drive unit driven machine or the environment U S Nameplate NORD GEAR CORPORATION USA WWW NORD COM serial Number Gear Ratio TORQUE SPEED FOR GEAR LUBRICATION Da ES STEMS SEE MANUAL service Factor Torque Rating Q Output Speed RPM Mounting Position European Nameplate Getriebebau MORD GrbH amp Co KG D 22914 Bargteheide O Model Type serial Number Siehe Wartungsanleitung See maintenance instructions Gear Ratio Voir instructions d entretien speed Transportation and Handling A WARNING Do not attach other machinery Make sure that all eyebolts and lifting lugs are tight and lift only at designed points Protect the mounting surface from possible damage during transportation or loads to the NORD assembly since the supplied lifting bolts are not designed for this purpose If the gearmotor or assembly is equipped with two suspension eye bolts then both locations should be used for transportation and placement of t
77. that the hollow bore does not become nicked or damaged c Remove bolts 4 from under the gearbox mounting plate d Lift gear case from trolley frame A CAUTION THE GEAR CASE ASSEMBLIES CAN BE VERY HEAVY IF POSSIBLE IT IS BEST TO SUPPORT THEIR WEIGHT PRIOR TO REMOVAL LODEKING 12 4 REMOVE LIMIT SWITCH TRAVELING NUT OR GEARED a Geared Upper and Lower Limit Switch 1 Disconnect all power from hoist 2 Remove the cover from the limit switch and disconnect the wiring Note the color coding or tag the wires so they can be reconnected correctly Loosen the cord fitting and remove the cord 3 Remove the bolts and lockwashers that hold the limit switch assembly to the bracket Remove the limit switch assembly from the bracket b Weight Operated Upper Limit Switch 1 Disconnect all power from the hoist 2 Remove the clamping screws holding operating weight around the wire rope and remove the weight 3 Remove bolts holding the limit switch bracket to the hoist and remove the limit switch assembly Loosen the clamping screw holding the hub on the limit switch shaft and remove the hub and lever assembly Note its position carefully so it can be reinstalled correctly Remove the screws holding the limit switch to the bracket Remove the limit cover and disconnect the wiring Note the color coding or tag the wires so they can be reconnected correctly Loosen the cord fitting and remove the cord fr
78. this warranty must be commenced within one 1 year after the cause of action has accrued ES LODEKING 41 115633 12 Nov 2012 COLUMBUS McKINNON CORPORATION FAMILY OF BRANDS CM BUDGIT ES COFFING sHAW BOX Hoists HOISTS HOISTS Phone 800 888 0985 716 689 5400 Fax 716 689 5644 www cmworks com 2012 Columbus McKinnon Corporation All Rights Reserved MANUAL 115633 12 1112 BB
79. turned automatically to its set position The handle of the hand release lever can be unscrewed for easy removal When a brake motor with hand lever is supplied by NORD both the hand lever air gap and brake air gap are set at the factory When ordered as parts proper hand lever and air gap adjust ments must be made in the field Hand lever adjustments must al ways be made prior to assembling the brake to the motor All brake air gap adjustments must be made with the brake assembled to the motor and the power off brake engaged Hand release lever LODEKING 18 Brake Hand Lever Installation amp Adjustment Direction of hand release Hand lever y Hand Lever Air Gap 1 Place the hand lever over the brake housing as shown and align the pins 2 Screw the bolts with washer and spring into the pins 3 Using a feeler gage adjust the hand lever air gap per the table below Hand Lever Air Gap Setting Dimension Brake Size BRE5 1 BRE 10 1 0 040 BRE 20 1 0 040 BRE 40 1 0 040 BRE 60 1 0 040 BRE 100 1 2 0 047 BRE 150 1 2 0 047 BRE 250 1 2 0 047 BRE 400 1 5 0 059 BRE 800 1 5 0 059 BRE 1200 When setting the hand lever gap or dimension y the magnetic brake coil housing and the anchor plate must be kept uniform all around A WARNING To assure proper assembly and proper functioning of the brake the hand lever must be assembled to the
80. until the desired air gap spacing is uniform and consistent all the way around the brake Brake Air Gap Settings Fixing Screw Nominal Maximum Brake Tightening Torque Air Gap Setting Air Gap BRE5 2 2 3 0 008 0 2 0 024 0 6 BRE 10 4 4 0 008 0 2 0 028 0 7 BRE 20 7 4 10 0 012 0 3 0 031 0 8 BRE 40 7 4 10 0 012 0 3 0 035 0 9 BRE 60 18 25 0 012 0 3 0 039 1 0 BRE 100 18 25 0 016 0 4 0 043 1 1 BRE 150 18 25 0 016 0 4 0 043 1 1 BRE 250 37 50 0 020 0 5 0 047 1 2 BRE 400 37 50 0 020 0 5 0 047 1 2 BRE 800 37 50 0 024 0 6 0 047 1 2 BRE 1200 37 50 0 024 0 6 0 047 1 2 Tolerance 0 004 in 0 1 mm Brake air gap must be re adjusted before the stated value 19 115633 12 Nov 2012 HOIST OPERATION amp MAINTENANCE MOTOR BRAKE INSTALLATION amp MAINTENANCE CONTINUED Brake Rotor Brake Disc Wear Assessment Periodically the brake rotor or brake disc must also be checked for wear If the brake rotors wear approaches the minimum allowed thickness then the part should be replaced Use the table below to determine whether or not the brake rotor requires replacement Brake Rotor Thickness Nominal Brake Minimum Brake Rotor Thickness Rotor Thickness BRE5 0 295 7 5 0 177 4 5 BRE 10 0 335 8 5 0 217 5 5 BRE 20 0 406 10 3 0 295 7 5 BRE 40 0 492 12 5 0 374 9 5 60 0 571 14 5 0 453 11 5 100 0 630 16 0 492 12 5 150 0 709 18 0 571 14 5 250 0 787 20 0 650 16
81. with no vent plug Consult NORD prior to ordering if interested in ordering any of the above sizes as serviceable gear units Consult the sticker adjacent to the fill plug to determine the type of lubricant installed at the factory Some units have special lubricants designed to operate in certain environments or intended to extend the service life or service temperature range of the lubricant If in doubt about which lubricant is needed for a certain application please contact NORD Gear Lubrication Replacement If the gear unit is filled with mineral oil the lubricant should be replaced at least after every 10 000 operating hours or after every two years If the gear unit is filled with synthetic oil the lubricant should be replaced at least after every 20 000 operating hours or after every four years Often gear reducers are exposed to ex treme ambient conditions hostile environments wet conditions or dirty and dusty operating areas Especially in these situations it is important to establish a condition based oil service interval LODEKING 22 Oil Viscosity Viscosity or the oil s resistance to shear under load is often con sidered the single most important property of any gear oil Often one will consider making a viscosity correction to the oil to improve the performance when operating the gear unit at low temperature or high temperature In cases of extreme load conditions gear pairs and anti friction bearings
82. y unusual sounds from the crane or Unusual Sounds hoist mechanism while operating the crane or hoist Warning and Safety Labels Check that warning and other safety labels are not missing and are legible Housekeeping and Lighting Check area for accumulation of material to prevent tripping or slipping Also check area for poor lighting Frequent Inspection Frequent inspections are to be performed by a qualified designated person Inspection intervals vary by class of service for Class C Service cranes they are to be performed monthly at a minimum Hooks and wire rope or load chain are to be inspected in monthly intervals as a minimum and recorded including date serial trace numbers and a signature Frequent inspections also include a thorough operational inspection Items to be inspected include limit switches lubrication levels in all gearcases wheels bearings etc brakes electrical equipment and all safety devices Crane is to be operated without a load to check for any unusual sounds vibrations or anything that may be apparently wrong The designated person shall determine if conditions found are a hazard and a more detailed inspection is necessary Refer to the typical Inspection Schedule and Maintenance Report in this manual NOTICE CRANES THAT HAVE BEEN SITTING IDLE FOR A PERIOD BETWEEN ONE TO SIX MONTHS SHALL RECEIVE THE FREQUENT INSPECTION PRIOR TO ITS USE 115633 12 Nov 2012 HO

Download Pdf Manuals

Related Search

Related Contents

telecharger le manuel d`utilisation  MANUAL DEL OPERADOR  ST7110-30A Series User Manual  Pinza Extech  機械器具 0 6 呼吸補助器 管理医療機器 酸素濃縮装置 ー 287 3002  新取扱説明書(日本語/英語版)はこちら  Betriebsanleitung - Software Updates  Philips PPF632 fax machine  User Guide: School Data Submission – Elementary  CL-7 Voltage Regulator Control Installation  

Copyright © All rights reserved. Failed to retrieve file