XE501PA1 Service Manual _111203_Q4.qxd
Contents
1. EEE 2 mxzpinoss 16246 4 for 16676 2 2 eeseheadsoew 18906 2 Pg 29 24906 starting capacitor 110MF 250V 63456 run capacitor 35MF 450V 93131 screws for terminal box cover M6x35 not shown ractel Griphoist Division 68 N 7 16 Direct Control 220V Control Box Parts List XE501PA1 Page 2 of 2 Drawing 22543 w Spare Parts Eatin 1 State 100787 200V 760 Hz Single Phase Date 41805 3 j 20 PES da E mE a 0 B 35 edt PRES 21 51 yi 24 25 1 4 Wo ENDE 30 o 29 ES 100 i CUM vo ___ J y i i tnm uU 5 5 2E 4 16 12 45 13 3 39 26 E E gt P p ss a te 1 D j A iis 45 E s T a 4 f 17 10 37 5 Figure 744 l actel Griphoist Division 69 7 17 Pendant Control 220V Control Box Parts List XE501PA1 Page 1 of 2 Drawing 14835 _ Nw Ew RA CONTROL BOX GC 13 10 4 100757 200V 760 Hz Single Phase for XESO1PAT _ p mer EE EE 4 25 1 588 D A AE EE 8 2225 1 board complete notassembe z E x56 SSS 35 852. _ 2886 1 use block wih piat 2 2 push ton Bock 22 m 2 1 EMERGENCY STOP bloc TENE 2 1 EMERGENCY STOP cover E 596 1 0 250 MES DIN 84 ew 2 Jpedam OO 92 2 1 pendant contrat casingtempiy 4 etofsrewsforteminalbox ns not shown ractel Griphoist Division 70 7 17 Pendant Control 220V Control Box Parts List XE501PA1 Page 2 of 2 Drawing 14835 Spare Parts A Eon 2 State 100797 ____200 760 Hz Single Phase Date 41805 4 53 4 _ _ DUUM e co 20 45 42 52 28 ELA 21 25 24 2 26 27 22 Si 15 Figure 745 ractel Griphoist Division 71 8 WIRING INFORMATION 8 1 Wiring Diagram XE501PA1 Direct Control Plan 14606 Page 1 of 2 ILLES BUFF Oque zczud 21225 7511 LA anl pag udr Auze 9 T i Fa 7 w 4 H leith d k4 3S A lai i LI V ud et m af GO a t EL LE D E HE WO H ith rj on 2 1 99 i td i s VD X La 4 5 edi i 11 ax i HE r T 5 bas 35 dn 4 c d n na
3. sped si Lpiz p Er ELE Eu ED LICE ER gc mom 8 2 Wiring Diagram XE501PA1 Pendant Control Plan 31007 Page 2 of 2 xg lc juepuag udT ADcz eo KERE T TRIN TTE od am 02 1224405 dg CERTES 24 m a ge cx E Sa EEE ACC 2 yei ADs 271 83213 DjXI 1 22 75 PET 1 J 7 uir AIS EL LEE A pzeja ug LE VE 327 coe EM LS Up Uis ioni an oy LATE Ur 3 400 27 4956 1 Hup HIC Baro RH d VIE Ts 9 Lo c a 8 3 Wiring Connection of Stator XE501PA1 1044 3 puluag lo3428uuo2 340 5609 en P _ __ HIF C 2 EYL ITA 96 85048 TA lt JOJ 2VA 72 poe gt i H 7 0 gt X INA ID SUUO g SUUO p Figure 801 Griphoist Division 9 WIRE ROPE SPECIFICATION TIRAK There seems to be some question as to selection of wire rope due to the many people offering wire rope today Before Tractel chooses a supplier of wire rope we run an en
4. RE eme i pom emma Lom C Lem ELLE RE eee RE FDB 13 FDB 13 not shown ractel Griphoist Division of 6 3 Motor Parts List XE501PA1 Page 2 of 2 Drawing 2521 State 020697 LL Y T LLI 2 14 gt Spare Parts for XE501PA1 200V 60 Hz Single Phase 22 bk G EF Le TE A Of LE IS E de 9 Figure 620 Go I EOL amp Araciel Griphoist Division 58 7 CONTROL BOX XE501PA1 2 Check that the emergency stop button 218296 Pos 21 functions normally Figure NOTE 703 Press it to lock in the Off position of the following checks are done without Twist it to check that it springs open into the e a On position Check that it is not loose it is open the cover and tighten the two 7 1 Tools Required Figure 701 screws that hold it in place 5mm allen wrench Volt Ohm meter Digital capacitor meter 150uF readout 2 insulated screwdrivers 8mm socket head nut driver Insulated needle nose pliers Thin straight blade screwdriver 3 Check that the protective cover 35435 Pos 3 around the emergency stop button is in good condition and is not loose Figure 704 Replace it if necessary The 3 screws must be tightened and must have silicone applied to
5. 2 to 18m rated 750 to 1500 15 2 to 15m load 6000 Ibs Work Cages Model PMRO700D PMRO701D VSMV PMRO0710D rated 1000 Ibs Model WCO01 rated 400 Ibs This equipment consists of separate parts inspected at the factory by Underwriters Laboratories Inc and is intended for use in complete complete installations Installations are not inspected by Underwriters Laboratories Inc but should be made in accordance with requirements of authorities having jurisdiction LOOK FOR CLASSIFICATION MARK ON PRODUCT Figure 101 Griphoist Division 4 1 2 Dimensional Information TRACTEL Inc Tirak XE501PA1 with BSO 500 28 23 M cdi zu ie Dae 10603 _ NOTE Dimensions are in inches Figure 102 amp Araciel Griphoist Division 5 1 3 Model Identification Table Type Designation of TIRAK Scaffolding Hoist Tirak type X 7 1 driver disc T 2 driver discs Gripwinch for material handling only US version Execution P Man riding PA 220 V 1 Ph 60 Hz 500 kg for USA CAN only PO with overload No declaration material handling Operation A Air operated D Dual wire rope Tirak E Electric operated Tirak USA Canada Hydraulic operated HB Hydraulic operated with brake N Hand crank on motorshift o Silo hand crank on gear box XSD5 02P Wire Rope in mm Capacity Ibs kg Secondary Brake 1 BSO50
6. TRACTEL INC GRIPHOIST DIV 110 SHAWMUT RD PO BOX 188 CANTON MA 02021 TUFV April 18 2002 Equiptment Scaffolding TRACTEL INC GRIPHOIST DIV 5 4785 110 SHAWMUT RD PO BOX 188 CANTON 02021 Electric scaffold hoists Models ETH 32L XE301P maximum load 700 155 Models ETH35C ETH35C3 ETH35X LE500P LE501P TE401P 401PA XE500P 501P 501PA maximum load 1000185 Models TE1000P 1001P 1001PA XE501PO XE700P 701P XE720P XE721P maximum load 1500lbs Models TE1020P 1021P 1021PA maximum load 2000 Ibs Model XE1020P maximum load 2400 Ibs Model XE2050P maximum load 4400 Ibs Manually operated scaffold hoists Model TMS 600 maximum load 1320 16 Model TU 17 maximum load 1500 Ibs Model TU 28 maximum load 3000 Ibs Model TU 32 maximum load 6000 Ibs Model 408 maxi mum load 880 Ibs Pneumatic scaffold hoists Models ATH32L 32LB 300PB maximum load 700 Ibs Models ATH35C ATH35X 35XB LA500P XA500P 500PB maximum load 1000 155 Models XA700P 700PB XA720PB maximum load 1500 Ibs Model XA1030PO maximum load 1850 Ibs Model TA1020P maximum load 2000 155 Model XA1020P maximum load 2400 155 Model XA2050P maximum load 4400 155 Model XA2650P maximum load 5300 Ibs Independent secondary brakes Model BS15 301 maximum load 1500 16 Model BS20 301 maximum load 3000 Ibs Model BS35 30 maximum load 6000 Ibs Modular work platform Modular Staging 2 to 12 m rated 750 Ibs Models KD01
7. m Figure 503 All Tirak with serial numbers before those listed above were fitted with the non adjustable Lenze type brake Though most of the troubleshooting checks and procedures are the same contact Tractel Inc for exact service details NOTE The Lenze type brake may be exchanged with the Precima brake However you must exchange all of the brake components and file the plastic fan to reduce the thickness and avoid contact with the brake 5 2 Tools Required Figure 504 Allen key Snap ring pliers 10mm wrench 8 amp mmwrench 2 Flat screwdrivers Silicone RTV sealant Tape Calipers or micrometer Feeler gauges Figure 504 Griphoist Division 39 5 3 Brake Inspection 1 Remove the fan cover as shown in Figure 505 If crushed replace and ensure that the fan spins unobstructed Figure 506 it LE hey i LAN LE uM p in JE a 4 E WW ure 508 TERM 2 Inspect the inside of the fan cover for 4 Measurement of the air gap a should be excessive brake dust Figure 507 This 0 012 0 3mm Figure 509 and Figure 510 indicates brake wear caused by an incorrectly adjusted brake or possibly low voltage usage It may also be an indication of excessive EMERGENCY DESCENT usage Figure 509 To T d D O127 0 Summi Figure 510 3 Measure the clearance a between the pressure plate and
8. tirak XE501PA1 Date 10 06 03 Version 2 Draft 5 Service amp Maintenance Manual for Electric Powered Hoists Griphoist Division BASIC TROUBLESHOOTING WARNING This sheet is to be used by certified Tirak technicians only The purpose of this sheet is for quick reference only Most troubleshooting solutions can found on pgs 17 amp 18 of the Tirak Instruction Manual included with each hoist PROBLEM POSSIBLE CAUSE Low power Repair and maintenance of the Tirak hoist should always be accomplished in a safe environment Centrifugal switch stuck closed Start capacitor defective High amps and or heat Stator burned Brake dragging Water damage Hoist overloaded Brake rectifier defective Run capacitor defective Hoist frozen electrically ie Won t run in either direction Brake coil defective Fuse defective Hoist goes up but not down Blocstop has been activated E stop button has been activated Up and or Down button does nothing Fuse defective Centrifugal switch stuck open defective Hoist goes down when up button is pressed Capacitor start and or run Start capacitor defective Hoist will not lift a suspended load Low power Run capacitor defective Main relay coil short circuit Fuse in control circuit blows immediately Fuse defective Thermal protector is shorted Table 001 Griphoist Division TABLE
9. 305 2 Remove the other three 3 cap screw assemblies in the cover Figure 306 consisting of the following a M6x30 socket head cap screws Code 5336 Pos 70 b Lock washers Code 16616 Pos 73 c Flat washers Code 36306 5 Inspect inside of cover Code 43775 Pos 2 for damage or evidence of wire rope jams and cracking near the stirrup bar pocket Inspect pin hole for damage Figure 309 E B rd o gt 7 gt 3 Insert a screwdriver in casing above the stirrup adapter as shown in Figure 307 Carefully pry the casing open Figure 309 Griphoist Division 10 5b Pay special attention to the areas indicated in Figure 310 and Figure 311 surfaces should be smooth to prevent cutting or snagging of the wire rope Replace or repair as needed 2 3 6 Internal Inspection 1 Remove and inspect the stirrup adapter Code 47867 Pos 84 in Figure 312 Ensure it is straight and the anchor pin is Secure Remove and inspect the exit tube Code 43825 Pos 11 shown in Figure 313 Ensure it s free of debris inside Inspect the snap ring Code 6846 Pos 57 and exit tube for damage Clean or replace as needed 7 PANE Figure 313 Remove the two M6x50 socket head cap screws Code 12016 Pos 69 and spring washers Code 16616 Pos 73 in Figure 314 Figure 314 Griphoist Division 11 4
10. J ent he Figure 320 8 Inspect the lower wire rope guiding plate 43845 Pos 15 Figure 321 for wear damage Repair or replace as necessary 9 Inspect the wire rope guiding band 227217 Pos 30 Figure 322 for wear or damage Repair or replace as necessary Griphoist Division 13 NOTE The regular service inspection is now com plete Clean all components with mineral spir its and dry thoroughly 3 7 Reassembly Re grease the pressure system 242227 Pos 31B with wheel bearing or white lithium grease WARNING Never use grease containing molybdenum disulphide moly b or graphite in the Tirak 1 2 Reinstall the lower guide plate 2243845 Pos 15 wire rope guiding device 243865 Pos 13 and upper guide plate 243855 Pos 14 Figure 23 Reinstall the wire rope entrance tube 443835 Pos 12 and snap ring 6846 Pos 57 Place the snap ring onto the entrance tube and rotate it so the tabs are up This extra bit of clearance eases installation of the casing cover Reinstall the exit tube 4243825 Pos 11 with snap ring 26846 Pos 57 tabs up See Figure 18 Reinstall the stirrup anchor bar 2247867 Pos 94 See Figure 17 3 8 Casing Cover Installation m Figure 323 Using a hammer and dowel punch gently tap the alignment dowels flush in the casing cover Figure 323 Carefully place the casing cover over the pressure system dowe
11. OF CONTENTS TIRAK XE501PA1 1 GENERAL INFORMATION UL Listing Card Dimensional Information Model Identification Table Test Certificate 2 SECONDARY BRAKE ATTACHMENT 2 1 BSO500 Secondary Brake Mounting Parts List 3 WIRE ROPE DRIVING SYSTEM 3 1 Introduction 3 2 Tools Required 3 3 Blocstop Removal 3 4 External Inspection 3 5 Casing Cover Removal 3 6 Internal Inspection 3 7 Resassembly 3 8 Casing Cover Installation 3 9 Pressure System Replacement 3 10 Wire Rope Guide Band Replacement 3 11 Radial Packing Ring Replacement 3 12 Sheave Bearing Replacement 3 13 Casing Base Repair Guideband Area 3 14 Stirrup Bar Modification 3 15 Wire Rope Guide Bolt Retrofit 3 16 Wire Rope Drive System Parts List 4 GEARBOX 4 1 Tools Required 4 2 Gearbox Disassembly 4 3 Gearbox Reassembly 4 4 Hoist Position for Oil Level Inspection 4 5 Gearbox Parts List 5 PRIMARY BRAKE FOR MOTOR 5 1 Brake Types 5 2 Tools Required 5 3 Brake Inspection 5 4 Brake Removal 5 5 Disc Inspection 5 6 Brake Air Gap Adjustment 5 Release Stirrup Replacement 5 8 Operational Check 5 9 Brake Coil Resistance Inspection 5 10 Primary Brake Parts List 5 11 Assembly and Adjusting Page NO of 26 26 30 36 37 39 39 40 41 42 43 44 44 45 45 45 Page 6 MOTOR 6 1 Replacement of Motor Winding Stator 46 6 2 Centrifugal Switch Replacement 50 6 3 Motor Parts List 57 7 CONTROL BOX 1 Tools Required 59 7 2 Control Box Cover Inspecti
12. X E of Section 4 3 Figure 410 6 Check for free rotation of both the worm gear 9 Install the internal snap ring removed in step and bull gear Figure 431 They should both 10 of Section 4 3 Figure 434 Ensure the move freely with a slight amount of backlash internal snap ring is completely seated into slight play or space between the gears the base Tap it gently with a brass punch 1 FL br zn Figure 434 AIractel Griphoist Division 31 Figure 431 10 Turn the gearbox over The lower worm gear 13 Install the lower internal snap ring and all should be in the center of the gearbox base spacers below it removed in Step 13 of as shown in Figure 435 oection 4 3 Figure 412 14 Repeat Step 6 of the gearbox reassembly Check for free rotation of both the worm gear and bull gear 15 Inspect both the brass gear and worm gear for alignment and damage Figure 438 m 11 Carefully install the lower worm gear bearing into the base Figure 436 vtr P NM 3 4 1 1 EI Figure 438 16 Turn the gearbox over Slightly grease the cup seal and prepare to install it Figure 439 CAUTION The orientation must be the same as in step 19 of Section 4 3 12 Using a suitable punch or press tap the lower bearing onto the worm gear Figure 437 Ensure that the bearing seats onto t
13. damage does occur gently remove any burrs with emery cloth Figure 329 2 Remove the two 10mm lock nuts and h th f th box Fi ies washers on the rear of the gearbox Figure Remove both screws evenly at the same time 328 This spreads the tension properly amp Araciel Griphoist Division 15 4 Lift the pressure system from the gearbox 6 Begin by placing the new pressure system in Replace the unit Figure 330 the drive assembly 7 Install the pressure system dowel pin into the base first Figure 332 Figure 330 WARNING It is prohibited to attempt repair of the pressure system at the shop level NOTE The earlier hoist had a THREE roller system NOTE They are completely interchangeable with a Use a set of channel lock pliers as shown to two roller system as long as a they are of the align the LEFT bolthole correct capacity 5 After removal of the old system replace it with a new unit of the same capacity 742227 Pos 31B CAUTION The earlier pressure svstems had the roller assemblv rivet off center If your system has this rivet off center it MUST BE INSTALLED with the rivet to the low side next to the sheave See Figure 331 Roller pivoting pin 8 Start installing the LEFT M6x25 allen head screw first 9 Once LEFT screw is started begin installing Positioned towards the RIGHT screw Keep tension on the the traction sheave pressure system with th
14. poor between the wire rope and the sheave There should not be a change in the diameter of the wire rope when worn Summary There is much more to wire rope selection than number of strands and number of wires Tractel supplies only high quality and rigorously tested wire rope from a very few carefully selected and monitored manufacturers 9 1 Wire Rope Specifications XE501PA1 Page 1 of 2 BEEN 1st Choice 2nd Choice 3rd Choice Hoist Hoist Types Tirak Contructi 5 x 19 eque ons Diameter 8 4 mm 0 0 3mm 8 1 8 4 mm 5 16 approx am 0 319 0 326 Minimum Breaking Load 10 000 Ibs 4590 kg Material of Construction Galvanized Steel wire rope XIPS 200 220 n sq mm 6X 17 is classified as a 6 X19 which may have 15 26 wires per strand ractel m Griphoist Division 77 9 1 Wire Rope Specifications XE501PA1 Page 2 of 2 NOTE As of 2 15 2002 5 16 diameter should be used unless otherwise noted as taken from product literature Skyclimber Tirak Saturn Skyclimber CX1250 CS1250 IWRC FC all models Compact Alpha1500 3 8 1st choice Alpha1000 Tirak 3rd choice opider T series Z Mac1000 IWRC X series SC40 IWRC Power Climber PC400 IWRC FC Power Climber Astro IWRC FC PC400 IWRC FC 5 16 or 3 8 Saturn 3rd choice 35X series 32L series Lisbon Hoist 180 050 180 030 Skyman 6 x17 IWRC Saturn 4th choice 35X series 32L series Ti
15. screws A See Section 5 0 When assembling a new brake check adjustment of brake release lever B See Section 5 7 With the brake closed the distance b between anchor disk C and washers D must be 0 028 0 7mm If necessary adjust symmetrically on both sides by means of screws E A A The adjustment of the brake release lever must not be changed afterwards even in case of an air gap a readjustment as security is adversely affected amp Araciel Griphoist Division 45 6 MOTOR 3 Remove the fan 216186 with two screwdrivers placed under the fan and 6 1 Replacement of Motor Winding Stator against the motor shaft and pry upward Figure 603 NOTE ALL The motor and control box must be removed before attempting to replace the motor winding stator 1 Remove the fan cover 4x8 mm hex screws as shown in Figure 601 4 Remove the whole brake assembly by removing the three socket head fixing screws w locking washers Figure 604 Figure 601 2 Remove the fan snap ring 723866 shown in Figure 602 5 Remove the brake disc 47446 and the brake hub 47456 Remove the snap ring 536 and carefully pry the hub from the motor shaft as shown in Figure 605 Figure 605 Figure 602 amp Araciel Griphoist Division 46 6 Figure 606 7 a rover Remove the friction plate 3581
16. seal against water entry 7 2 Control Box Cover Inspection 1 Check that all labels are legible and in the right place Figure 702 If not replace those labels See page 64 for correct location and code Figure 704 amp Araciel Griphoist Division 59 7 3 Ground Cord Plug Check 1 With an ohm meter check each prong to the case of the tirak The long ground prong should show continuity Figure 705 2 Atag tied to the control box indicates the control box type GC13 10 3 and wiring dia gram 14606 Figure 708 The two shorter prongs should not show conti nuity Figure 706 Figure 708 3 Afull size diagram should be folded and tucked in place next to the relays Check that the full size diagram matches the tag Figure 709 If either of the shorter prongs show continuity to ground a short circuit has occurred and must be fixed It is possible that the plug is wired incor rectly or the insulation is cut Open the plug and investigate Also check the cord grip 7 4 Wiring Diagram and General Condition of the Control Box 1 Using a screwdriver open the control box Figure 707 Check for corrosion evidence of water entry Check that the capacitors have not leaked fluid WY ure 700 AMET 709 amp Araciel Griphoist Division 60 7 5 Stator Winding Check NOTE When using an ohm meter deduct the test pr
17. the switch and The following checks are performed with power to creates continuity the hoist motor Whenever power is applied to the hoist use extreme caution especially with the control box open as part are energized Only trained and qualified personnel should service the hoist to avoid injury or death amp Araciel Griphoist Division 66 2 Measure the AC input voltage with a voltmeter at terminal 1 and 3 of the K3 relay Figure 739 If no voltage occurs check the fuse Section 7 6 and bimetal protector Figure 741 4 Measure the DC voltage from the rectifier Change the voltmeter to DC Measure the voltage output from the rectifier at the positive and negative screw terminals 2 7 15 Brake Rectifier Check 1810917 Pos 11 center screws while pressing the UP or DOWN button on the control box cover 1 Push either the up or down button on the Figure 742 and 743 which shows 91 DC volts from the rectifier OK It should read approximately 96 volts If not approximately 2 While the motor is running measure the AC 96 volts replace the rectifier voltage to the brake rectifier by placing the voltmeter probes on relay K3 Pos 14 and 4 refer to the wiring diagram in Chapter 8 or measure on the AC terminals of the rectifier U1 See Figure 740 and 741 on the next page which shows 105 volts AC to rectifier OK control box cover The motor should run Figure 740 3 The vo
18. 0 2 BS BSO500 0 5 16 8 3 700 300 5 1000 500 7 1500 700 8 1600 800 10 2200 1000 16 3500 1600 20 4400 2000 30 6600 3000 1 1 4 6 2 3 8 9 3 10 4 11 5 9 16 14 6 5 8 16 Working Speed f m m min for X2000 3000 or Air motor or Hydraulic motor rs m 9 va 8 ve A S O1 N 3 3Ph 30 60 9 18 35 70 11 22 20 40 6 12 23 45 7 14 ipsempepespmpes w 64 6 15 60 4 5 18 17 70 10 40 12 45 3 5 14 1 1Ph 115 35 rM 9 39 tz 9 NO E Kind of motor 3 Ph 3 phase motor 1 Ph single phase motor DC motor Griphoist Division 6 1 4 Test Certificate XE501PA1 TRAME ii bren FA Poco Fue Priif Zertifikat Test Certificate Certificat d essai Hermit bescheimigen wr Wie confirm thal the delivered Nous confirmons que da das gelieferte machine corresponds to tha livr correspond aux conven den Vereinbarungen bel der oder agreements and that bons de Commande et quill Bestellung en ispricht urd in It has boon delivered im good ete en bon stat gin wancdtireieum Zustand Condition ausgeliefert wurde Crate rie GRE de RSE para G
19. 6 shown in Figure 606 apt Remove the 4x10 mm hex head screws holding onto brake flange shown in Figure 607 shown in Figure 611 Prior to removal pay attention to brake orientation and mark it for realignment Figure Griphoist Division 4f as AN 8 Using a rubber mallet drive out the motor shaft as shown in Figures 609 and 610 Figure 610 9 Remove the four socket head fixing screws holding the lower motor flange to the stator Figure 611 10 Use a rubber mallet to remove the flange 13 Remove the small thermal protector wires from grey X1 and X2 Figure 615 T 1 Figure 615 11 Remove the yellow and black winding wires from Pos 13 Figure 613 14 Remove the four socket head cap screws and lock washers that are holding the control box to the motor Remove the control box Figure 616 Figure 613 12 Remove the ring terminal winding wires black w red z red u and black v as shown in Figure 614 Figure 616 F amp Aractel Griphoist Division 48 15 Replace the old wire winding with a new wire winding as shown in Figure 617 NOTE Reassembly procedure is the reverse of the disassembly procedure Figure 617 16 Ensure that the blue and yellow winding wires remain under the control box crimped or soldered together and insulated as shown in Figures 618 and 619 Figure 619 _ Gripho
20. Inspect the upper wire rope guiding plate Code 43855 Pos 14 and compare it to Figures 315 and 316 6 Remove the entrance tube Code 43835 Pos 12 and snap ring Code 6846 Pos 57 as shown in Figure 318 Inspect the 4b Figure 315 shows how the guiding plate entrance tube and clip for damage Ensure should look like Figure 316 shows a bent or the entrance tube is free of debris Clean damaged wire rope guiding plate repair or replace as necessary gt a 22h 3 DON gt gt lt J Li y gt D J IE Figure 318 gt 7 Inspect the wire guiding device Code 43865 Pos 13 in Figure 319 NOTE Repair or replace as necessary e IF the plate shows damage this indicates a FE wire rope jam has occurred and the pressure MC system must be carefully inspected 5 Inspect the pressure system Code 42227 Pos 31B shown in Figure 317 This inspection must be carried out every time the casing cover is removed Place a straight edge across the top of the pressure system Ensure the system is perfectly straight If any damage has occurred to the system the entire assembly must be replaced see Sec 1 1 9 Griphoist Division 12 NOTE Earlier hoists had brass guiding devices The inspection is the same for either type Figure 320 PL Ini Ag 47 Y AY
21. Motor Specifications KW 14 1 Wire Rope Diameter oe Misc Info Hoist shall self reeve the wire rope Continuous duty motor TEFC Controlled descent brake shall be externally attached to the hoist mechanism Emergency lowering without power shall be by means of a mechanical centrifugal brake Table 903 ractel Griphoist Division 81 TRACTEL Inc GRIPHOIST Division Main Office 110 Shawmut Road Canton MA 02021 Tel 800 421 0246 Fax 781 828 3642 griphoist usa tractel com TRACTEL LTD GRIPHOIST Division 11020 Mirabeau St Anjou QUEBEC H1J 253 Tel 1 514 493 3332 Fax 1 514 493 3342 griphoist canada tractel com TRACTEL Inc GRIPHOIST Division Branch Office 315 Cloverleaf Dr Building E Baldwin Park CA 91706 Tel 1 626 937 6727 Fax 1 626 937 6730 griphoist usa tractel com ractel Griphoist Division
22. TE Sometimes contact cleaner and emery cloth can repair a malfunctioning switch See Figure 645 Figure 645 19 Before installation of a new switch check that it functions properly with a meter Open and close the switch The meter should indicate open Figure 646 and closed Figure 647 when manipulated on the bench Figure 64 Griphoist Division o4 Figure 647 L LR If it stays open clean the contacts with contact cleaner and emery cloth See Figure 648 and 649 i Figure 64 If the switch remains open after cleaning it is recommended that the old switch be replaced with a new switch 20 Reassemble the new mechanical and electrical switch on the motor shaft See Figure 650 21 Replace the bearing cover Code 50345 Pos 7 Figure 640 and reaffix the snap ring Code 536 Pos 20 Figure 639 Repack the ball bearing with grease Note that the seal is on the bottom and the bearing is open to the top See Figure 651 22 With a metal tube Figure 652 tap the bearing onto the shaft until it contacts the snap ring below it See Figure 653 1 Figure 652 595 23 Replace the snap ring Code 536 Pos 20 on the shaft See Figure 635 24 Squeeze the mechanical portion of the centrifugal switch while sliding it up the shaft See Figure 654 With the set screw lock it into position on the shaft See Figure 633 25 Manipulate th
23. _ wie rope guiding XE501PA1 gt N 20106 ractel Griphoist Division 24 3 16 Wire Rope Drive System Parts List XE501PA1 Page 2 of 2 LLL TER WIRE ROPE DRIVE Spare Parts Lit _ State 18 01 00 200V 60 Hz Single Phase for XE501PA1 39 169 73 14 15 83 4 700 50 J1H 5 30 n amp Aractel Griphoist Division 25 TOU 1 Figure 358 4 GEARBOX 4 Remove the 4 socket head screws M6X20 1 4176 Pos 67 in the 4 corners of the cover and carefully pry the cover off with 2 screwdrivers See Figure 403 43785 Pos 3 Allen keys 8 mm 5 mm internal and external snap ring pliers 2 pry bars 2 screwdrivers 1 gear puller 1 rubber mallet 1 adjustable wrench 1 brass punch 1 ballpin hammer Silicone sealant 4 2 Gearbox Disassembly e The following procedure is for complete disassembly of the gearbox We recommend that the procedure be carried out by a Tirak repair facility If repair is essential at the site Figure 404 proceed as follows dus 9 Gently pry the gearbox cover from the base as shown in Figure 404 1 Remove motor See Section 6 1 and disassemble the wire rope drive gearbox see Chapter 3 2 Remove the controlled descent brake and its key 3 Remove the oil plug and copper gasket Drain the oil completely into a clean bucket Inspect the oil for brass flakes or metal shavi
24. ap a to 0 012 0 3mm Unbalanced adjustments will lead to improper brake wear Figure 524 NOTE The adjustment of the gap on the brake release stirrup has NOTHING TO DO with the adjustment of the air gap of the brake Griphoist Division 43 5 Release Strirrup Replacement 1 2 Carefully remove all sealant Figure 525 if the brake release stirrup is to be replaced Use a C clamp to hold the brake assembly together as shown in Figure 526 E 1 A wr v i D s Li Unscrew the two fixing screws E Figure 527 Install the new brake release stirrup B 61726 Install the new fixing screws Figure 528 Install the brake onto the motor Apply silicone to the brake end shield holes prior to installation to prevent water from entering the motor Replace all three screws 7 Measure distance b between the brake retraction plate C and washer D in Figure 529 This distance must be 0 040 1mm If necessary adjust symmetrically on both sides by means of the two screws E 0 040 1 0mm D E Figure 529 5 8 Operational Check Testing must be carried out once the brake has been completely reassembled With the fan cover removed proceed with the operational check 1 With the correct power supplied to the hoist push the up or down button 2 Visually inspect that the anchor d
25. apacitor CB 35uF is located in the control box and is larger in physical size than the start capacitor Figure 732 Detach the two insulated space connectors from the capacitor and attach the digital capacitor meter clips to the capacitor Measure the capacitance It should read 35uF 10 32 to 38uF If the reading is outside this range replace the run capacitor 263456 Pos 45 amp Araciel Griphoist Division 65 7 11 Centrifugal Switch Check With ohmmeter place the the probes on position 5 and 6 of the terminal board M1 Figure 735 The switch should be closed when the motor is not running If it is open Figure 736 it must be replaced See Section 6 2 Centrifugal owitch Replacement Figure 737 1 Tighten 4 socket head screws 42233156 Pos 34 that hold the control box to the motor Figure 738 lt Figure 735 2 Check that the control box base is not distorted or cracked especially at the junction of the box to the motor If damaged it must be replaced 7 12 Pushbutton Checks 1 Open the emergency stop by twisting the red knob It should spring open This should cause the main relay K3 to energize 1 Contacts are marked NO Normally Open or NC Normally Closed Figure 737 shows continuity for a NC contact If the button is pressed it should open A NO switch operates in an opposite manner WARNING 1 Pressing the button closes
26. ay to engage Check the interlock by pressing K1 down Figure 720 Now try pressing K2 down The interlock 3 The DOWN relay K2 coil resistance should N should prevent K2 from downward movement If it does not the mechanical interlock must be replaced rh Jii a b lt rd Pu eff a Figure 720 4 also be approximately 520 ohms Place the ohmeter test probes on the A1 and A2 screws of the K2 relay Check the resistance 500 550 ohms is OK If the connection is open or shorted replace the DOWN relay 2262206 Pos 5 The UP relay K1 coil resistance should be approximately 520 ohms Place the ohmmeter test probes on the A1 and A2 screws of the K1 relay Check the resistance 500 550 ohms is OK If the connection is open or shorted replace the UP relay 4262206 Pos 5 If the relay contacts are OK replace only the coil amp Aractel Griphoist Division 63 7 9 Brake Coil Resistance Check As an additional measure you can short out capacitors and discharge the them by With the ohmmeter test probes placed on the touching terminals 3 or 6 to 4 with insulated center two positive and negative terminals pliers Figure 728 charge is stored it of the brake rectifier U1 measure the resistance Figures 724 an 725 shows 272 ohms OK It should be approximately 270 ohms the connection is open or shorted replace the brake
27. brake coil If excessive brake wear is apparent or the air gap is significantly greater than 0 012 0 3mm measure the brake disc with a caliper See Figure 520 New Disc ECC XE 501PA1 13 47446 2 4 Care must be taken when replacing the hub to damage it This will damage the motor 8 Inspect the friction plate 35816 for wear Figure 518 Replace all worn or damaged components amp Araciel Griphoist Division 42 Maximum brake wear is 0 040 1mm If disc 3 Tighten down the three socket head fixing thickness is less than mm the brake disc must screws w locking washers be replaced 4 Measure the air gap as shown in Figure 523 5 6 Brake Air Gap Adjustment If necessary repeat steps 1 3 until an air gap of 0 012 0 3mm is achieved If adjustment is required proceed as follows The air gap a should be 0 012 0 3mm If necessary adjust by means of the three set screws A and counter nuts as follows 1 Loosen the three socket head fixing screws a few turns as shown in Figure 521 5 Remove each of the three socket head fixing screws separately and apply a bead of silicone Figure 524 to the tip to prevent water entry into the motor Replace all three screws Figure 521 2i m 2 Adjust each of the three 10mm adjustment screws Figure 522 AN EQUAL OF DEGREES to either increase or decrease the air g
28. ce the fuse with the spare by lifting the grey fuse holder Figure 716 Figure 716 7 7 Thermal Protector Check NOTE The thermal protector opens when the motor is hot in order to prevent damage It is normally closed and automatically resets when the motor cools it activates the cause must be found and fixed It could be low voltage a brake problem overload a winding problem or a gearbox problem 1 With the ohmmeter place the test probes on X1 and X2 of the grey terminal board where the two small wires are fixed Figure 717 If the connection is open the stator must be replaced lt Figure 717 2 Check if the thermal protector is shorted to ground Put the meter from X1 or X2 and the case It should be open Figure 718 If continuity exists the stator must be replaced Figure 718 Griphoist Division 62 7 8 Relays 2 The main relay K3 coil resistance should be NOTE approximately 520 ohms Place the The 3 relays are marked K1 K2 and K3 See ohmmeter test probes on the AT and Az Figure 719 screws of the K3 relay Check the resistance Figure 721 shows 528 ohms OK If the connnection is open or shorted replace the relay 26226 5 NOTE K1 K2 and are all inspected in a similiar fashion iL 1 All 3 relays are the same except for the fact that K1 and K2 UP and DOWN have a mechanical interlock 36766 Pos 7 that allows only one rel
29. ch damagex missmg L __ Caumusun BRAKES damage Motos Wen DE net aperalim OPERATING CONTROLS Aether LI RUPEE RH Wau WA 7 Damaged Ganire Box LIMIT SWITCHES LUBRECATION Qperabry uraperly CIE LABELS Li torted E Missing Pw s x wow T eye Luras DRLIM E 5SHEA VES anna SE Beech _ SUPPORTING STRUCTURE Laca Connections LI Contriued ho imposed 1 Wam or deser Dame he EE LJ parle Brower grounder IF ANY 1 I amp DO NOT HOIST JAMIL HEPAESS HAVE HEEN MADE Teens nnd repair made Lick Humber mu Figure 902 amp Araciel Griphoist Division 80 9 5 Hoist Specification XE501PA1 Screen fiber core lubricated preformed IPS or XIPS 5 16 in nominal diameter in 0 319 to 0 331 maximum allowed diameter tolerances for wire rope 811084 minumum actual breaking uid Table 904 Wire rope classification contruction Figure 903 Hoist Model XE501PA1 with BLOCSTOP model BSO 500 lbs 1000 0 Rated Load kg 4500 fmin Lifting Speed py lbs 121 0 in 743 0 in Dimensions over all in 318 0 357 0
30. coil will flash snap and discharge This can also be done by disconnecting the spade connections on the capacitor and shorting them with pliers Figure 729 7 10 Capacitor Checks 1 Check the physical appearance of the 2 capacitors Leakage of fluid or an expanded cap Figure 726 indicates probably damage or malfunction 2 Discharge the capacitors by pushing down on the K2 and K3 relays for several seconds Figure 727 This discharges the capacitors into the winding Griphoist Division 64 3 With a digital capacitor tester measure the start and run capacitance by placing the test clips on position 4 and position 6 of the terminal board M1 Figure 730 shows 156uf OK This should measure 145uF 1096 the sum of the start capacitor CA 110uF and run capacitor CB 35uF If the total is outside this range check each capacitor as follows Figure 732 NOTE The capacitors are marked with their capacitance Make sure the replacements are 35 or 110 uF only Figures 733 and 734 4 start capacitor CA 110uF is located on the cover of the control box Detach the two insulated spade connectors With the digital capacitor meter measure the capacitance It should be 110uF 10 100 to 121 uF Figure 731 shows 114 uF Ok If the reading is outside this range replace the start capacitor 2224906 Pos 44 4 pU 5 The run c
31. conjunction with the BLOCSTOP OVER SPEED dev which s an integral part of the equipment Use of this Jpn vent is unsafe and unlawful without proper fall protection equ pmentused in ac cordance with OSHA require ments 2 Emergency Traval 32264 frin See rRe Descent Labe Notablafi Emergency Descent nameplate SET UP INSTRUCTIONS chor the hoist and connect to y Red button must to start Me motor rt motor and introduce untl it tself auto Ensure free exit Use only wire n good condition with ta er ed end Daily check for bro en wires and kinks enc au cr m er r ui m Machine Type ord Serial No a Figure 901 ractel Griphoist Division 79 9 4 Checklist NOTE Completion of the checklist MUST always be done before operating the hoist TIRAK Hoist Inspection Check List Preventive af metruction Check only components applicable for specific manual for dabis pui pment and Inspection TIRAK hiis meric WIRE ROPE Choke veran at TS WIRE ROPE HOOKS Cracks aa LJ Brakenr wres Wer Eon Excuse weg neg X inkeri nr LJ a
32. durance test or cycle test to make certain that the rope func tions well in the hoist and has good life The European norms require 1000 cycles minimum UL testing requires 500 cycles We require 2000 cycles and test with a high speed hoist 60 ft min to give a more severe dynamic load to the wire rope during starts and stops After 2000 cycles we allow a certain number of broken wires not strands in a given length of rope Too many breaks are a test failure We have no idea how or if other rope suppliers test a rope with our hoist We generally do not test other peoples ropes because it is time consuming and expensive to conduct We would be inundated with samples 5 X 19 vs 5 X 26 Construction 5 strands of 26 wires have smaller wires making up the strands This provides greater flexibility but smaller outside wires wear out faster during normal use Smaller wires are less resistant to abrasion Therefore we primarily recommend 5 X 19 Pl equipment often uses 5 X 26 because winders are part of the system and it coils better Quality of Manufacture If a good control is not made on the tension during manufacture then a loose strand can occur This shows when lowering a load It can cause a jam Preforming requires that tension be monitored To get a high quality rope requires that high quality wires be used creating very tight tolerances A poor zinc plating process can cause slippage Ropes must be lubricated properly or the friction coefficient is
33. e channel locks as Figure 331 shown Figure 333 amp Araciel Griphoist Division 16 10 Once the screw threads protrude out of the base install the lock washers and 10mm nyloc nuts 11 Grease the pressure system as shown in Figure 334 with wheel bearing grease or white lithium grease WARNING DO NOT use molybdenum disulphide moly b grease or graphite type grease NOTE Code 27187 Old style 3 roller pressure system for XE501PA1 Code 42227 New style 2 roller pressure system for XE501PA1 Pressure systems are interchangeable 3 10 Wire Rope Guide Band Replacement 527217 Pos 30 Though replacement is rare it may be necessary if damaged beyond repair This procedure requires that the drive sheave 15 removed 1 Remove the oil drain plug as shown in Figure 335 Ensure that gearbox is lying with the oil plug to the high side to prevent excessive oil loss This will allow air pressure to neutralize in the gearbox 2 Reinstall the oil plug Do not apply too much torque NOTE You will be removing the oil plug again Turn the gearbox over so the sheave is face up Use a block of wood to level the gearbox Remove the wire rope guiding device see oection 3 6 step 6 Figure 336 _ Carefully with two bars remove the sheave as shown in Figure 336 Remove the two M6x16 allen head screws and the damaged wear band Inspect and repair the casing base retai
34. e new switch to see if it opens and closes properly See Figure 654 Figure 654 amp Aractel Griphoist Division 26 Reattach the wires to the switch Figure 655 F a Ya Le 1 E D L E gt i 1 E Figure 655 27 Check the winding for burns or damage See Figure 656 28 Put the cast aluminum brake end shield on the motor shaft See Figure 657 Figure 657 29 Realign the switch and retighten the 3 M4x8 screws Code 16 Pos 28 Figure 629 Place silicone around the bottom of the cast aluminum end shield to seal the joint between the winding and shield 30 Place the motor shaft assembly into the winding align the marks and tighten the 4 M5x25 Code 5886 Pos 26 screws 31 Reassemble the brake per Section 5 12 32 Replace the fan cover 33 Refit the motor See Chapter 6 NOTE Centrifugal switch replacement is now com plete Load test the hoist prior to returning it into service amp Araciel Griphoist Division 56 6 3 Motor Parts List XE501PA1 Page 1 of 2 E HE MOTOR 90L 10 4F Spare Parts Eaton 2 020697 200 760 Singe Phase forXESWMPAT Date 40805 _ e e LS pom Ls eme EE
35. ear as shown in Figure 413 After several 416 careful hits the bull gear assembly should come out through the front of the gearbox 416 T ET 5 T e 4 m m f T E 7 amp 7Iractel 7 Griphoist Division 28 18a Ifa press is available if not refer to step 20 Remove the lower bearing as shown 17b carefully press the complete worm gear Figure 420 assembly from the top of the gearbox out the bottom of the gearbox as shown in Figure 417 NOTE Before removing the bearing from the worm gear notice it s orientation It must be reinstalled in the same orientation 18b Carefully tap the worm gear assembly with a rubber mallet from the top of the base out the bottom of the base as shown in Figure 21 Remove the worm gear and upper bearing 418 through the front of the casing base Figure i 421 19 Once the wear gear assembly exits the bottom of the gearbox install a suitable gear puller Figure 419 22 Inspect the worm gear for wear damage or discoloration ie blueing as in Figure 422 Figure 419 y Figure 422 amp 7Iractel Griphoist Division 29 23 Lay all the internal gear components on a 2 Carefully install the upper bearing and worm clean area in the order of removal Figure gear into the top of the gearbox base Figure 423 Inspect the
36. g into its position Tap before alternately at the 12 6 9 3 o clock positions as shown in Figure 340 on the next page amp Araciel Griphoist Division 18 4 is necessary using the correct gear puller remove the bad bearing as shown in Figure 342 Figure 340 6 Reinstall the sheave and remove excess air as in Section 3 10 5 Reinstall the new bearing and gently seat 3 12 Sheave Bearing Replacement using a press 3243906 Pos 53 6 Reinstall the sheave Follow the procedure Though this is rarely required proceed as follows as outlined in Section 3 10 1 Follow the procedure as above Do not 7 Reinstall all drive components as in an remove the radial packing ring outlined in Section 3 7 2 Carefully remove the sheave with two pry 8 Reinstall the casing cover per Section 3 8 bars 3 13 Casing Base Repair Guideband Area 3 Inspect both top and bottom bearing for wear XE501PA1 or damage Figure 341 NOTE Call TRACTEL for repair kit availability Figure 343 Griphoist Division 19 Casing and guideband repair is necessary where the aluminum edge above guideband 15 damaged or worn Figure 343 on previous page CAUTION DO NOT dril holes within the marked areas shown in Figure 344 Figure 346 2 Remove the wire rope guiding band using a hex driver as shown in Figure 347 1 Grind off casing as shown in Figure 345
37. he lower worm gear as shown in step 10 17 Using a suitable punch either press or tap the cup seal into the base Figure 440 on the next page Continue tapping carefully until the seal meets the internal snap ring installed in Step 9 Figure 437 amp Aractel Griphoist Division 32 4 Figure 443 NOTE The seal should be recessed into the base as shown in Figure 441 20 Install the worm gear external snap ring as shown in Figure 444 A 18 Install the radial packing ring The ring should mount into the base to the shoulder lati Fi 445 indicated in Figure 3 11 installation Figure There are no timing marks on X Series sheaves 21 Inspect the sheave and bearings prior to Figure 442 19 Using the hollow tube tap or press the upper shaft seal into place shown in Figure 443 Aracilek Griphoist Division 33 22 Prior to installation lightly grease the 25 Using needle nose pliers hold the wearband backside of the wearband to prevent onto the recess Using channel locks press corrosion Figure 446 the wearband into the recess as shown in Figure 449 Install the second socket head Screw a Figure 446 LS 23 Install the wearband into the recess of the gearbox case Figure 447 lt a 3 26 Grease radial packing ring prior to installing the sheave Gently press the sheave in
38. isc C lifts evenly upward away from the brake disc A pronounced click or snap should be heard when it retracts magnetically 3 CAREFULLY feel for heat Figure 530 on the next page around the entire electromagnetic brake being cautious around the rotating fan amp Aractel Griphoist Division 44 Figure 531 4 there is any heat being generated re inspect the brake air gap because the disc is most likely dragging 5 If no heat is generated reinstall the fan cover When installing the fan cover pull back as shown in Figure 531 to gain more clearance for the emergency descent lever 5 9 Brake Coil Resistance Inspection Measure the resistance of the brake coil as shown in chapter 7 Control The XE501PA1 should have a brake resistance of approximately 270 ohms Brake coil resistance is also found on the wiring diagram WARNING Upon completion of any brake maintenance it is MANDATORY that a load test of the hoist be completed 5 10 Primary Brake Parts List Brake Code Disc Release Hub Complete Code Code Code Precima Model FDB1S 49756 47446 61726 47456 Resistance 270 ohms Lenze Model Gr 10 96V 18066 17466 17476 17496 Table 501 5 11 Assembly and Adjusting Fix the new brake to the motor and connect it into the control box Check the air gap a 0 012 0 3mm around the brake with a feeler gauge if necessary adjust by means of set
39. ist Division 49 6 2 Centrifugal Switch 3 Take off the primary brake Code 47406 Replacement XE501PA1 Pos 33 by removing the 3 socket head cap screws See Figure 623 1 Remove the motor and control box from the hoist See Figure 620 Remove the fan cover 4x8mm hex head screws Code 16086 Pos 27 Figure 623 4 Remove the brake disc friction disc snap ring hub and key See Figure 624 Figure 620 2 Remove the fan snap ring Code 3866 Pos 21 Figure 621 and pry off the fan Code 16186 Pos 5 using 2 screwdrivers See Figure 622 Make sure the screwdrivers are against the motor shaft when prying Figure 624 5 Remove the 4 M5X25 hex screws Code 5886 Pos 26 that hold the cast aluminum brake end bell housing to the motor See Figure 625 Figure 621 18 d et i E Led rte E o CS e NEN l x gt gt Figure 625 CE i Figure 622 Griphoist Division 50 6 Mark the position of the white centrifugal 8 Unscrew the 3 M4x16 screws Code 16 switch for easy alignment during reassembly Pos 28 holding thecentrifugal switch See Figure 626 See Figure 629 a Lan b Di Figure 626 EN 7 Loosen 2 screws holding the centrifugal 9 Mark the flange for reassembly See Figure switch wires and remove the 2 spade 630 connectors fro
40. l STA ph rs UE x Lm LI TR E 5 4 l I Ex Mar o NT 4 rw aA v x gt ET pul i Lux M _ qh TE U s m E ee nl NEC UT T nr P 5 1 1 cem ees 3 34 2 Figure 454 3 E 3 l actel Griphoist Division 38 5 PRIMARY BRAKE FOR MOTOR WARNING Upon completion of any brake maintenance it is mandatory that a load test of the hoist be completed 5 1 Brake Types All Tirak hoists since 1997 are fitted with the adjustable Precima type brake This section covers the service and repair of this brake only The XE501PA1 has a 96 VDC brake Prior to maintenance verify the brake voltage This voltage is stamped on the brake nameplate printed on the wiring diagram Figure 501 located on the fan cover Figure 502 and is stamped on the top of Precima brakes Figure 503 Model 501PA1 series hoists starting with serial number 5412 are fitted with the Precima type brake E 1 3 s E M g T ae 2 zu O i Eme name shown 1041808 has stamped letters
41. l pin Ensure it sits directly over the pin Figure 324 Th 4 7 1 3 Place one hand on the casing cover as shown in Figure 325 Using a dead blow RUBBER mallet tap the cover onto the base NOTE Keep pressure on the cover to prevent damage to the cover Using a hammer and dowel pin realign the dowels flush with the base Reinstall the four sets of M6 casing cover screws washers and square nuts See Figure 10 Griphoist Division 14 6 Reinstall the three sets of M6 casing cover screws and washers See Figure 11 CAUTION Ensure that the cotter pins are bent completely over to prevent any sharp edges 7 Reinstall the Blocstop straps and Blocstop 8 Load test the hoist NOTE General service is now complete If during the general service damage was discovered proceed as follows Figure 327 ES 3 9 Pressure System Replacement 342227 Pos 318 If damage such as bent side plates when checked with a straight edge in Figure 326 has occurred to the pressure system by a rope jam the pressure system must be replaced 328 3 Remove the two M6x25 allen screws shown in Figure 329 NOTE These screws will still have some tension caused by the pressure system Be careful NOT to strip them upon removal 1 Carefully remove the pressure system dowel pin by lifting it straight out its position Figure 327 Be sure not to damage the pin If
42. ltage to the rectifier should be approximately 110 volts Figure 740 Griphoist Division 67 7 16 Direct Control 220V Control Box Parts List XE501PA1 Page 1 of 2 Drawing 22543 E3063 CONTROL BOX GC 13 10 3 Edition 1 Spare Parts 22544 State 10 07 97 200V 60 Hz Single Phase for XE501PA1 Date 4 18 03 xm 1 emiaiboxcomplete NENNEN 3 1 terminal box with cover empty SS 17846 terminal box gasket DK80 112R 02 3 3935 1 EMERGENCYSTOP protection E 22925 1 poma 60956 replacement coil only 220V 26 3 eoo 575 1 mechanicalinterlockin NENNEN e 2 1 __terminal board complete not assembled SS 10917 bridge rectifier B500 440 2SiG S 25 5 erminaiblock 285 E 18566 2 Gentfication label 1 10 NNNM 22366 1 use block with plate NENNEN 21076 2 276 2 push button block NNNM 2 push buton cover E arae 1 EMERGENCYSTOP block 18296 1 EMERGENCY STOP cover E 1 MERGENCYSTOP abel NENNEN 1 faveur abe DOWN 23696 plug with cover 3P 20A 250V ex 15026 cable bushing with strain relief Pg 21 25056 2 ceble bushing 18276 16 18256 1 insolating tube 2 0 33 11021 3 insolating tub 4 2x0 6 33156 4 socket head cap screw M5x15 DIN 912 DIN 84 326 5 heeseheadssew 2
43. m beneath the screws See Figures 627 and 628 10 With a rubber mallet tap the cast aluminum brake end bell Code 63257 Pos 4 Figure 631 Figure 628 4 Figure 631 Griphoist Division 91 11 Remove the shaft assembly Figure 632 13 Remove the ball bearing 6004 RS1 Code 16536 Pos 18 by removing the snap ring Code Pos Figure 635 and pulling with a bearing puller See Figures 636 and 637 Figure 632 12 Loosen the set of screws holding the mechanical part of the centrifugal switch See Figure 633 and push the assembly away from the ball bearing to allow room for a puller See Figure Figure 634 Figure 635 Figure 636 Figure 637 Griphoist Division 52 14 Remove the bearing Note that one side is 17 Remove the white centrifugal switch and sealed and the other side is not See Figure mechanical actuating mechanism See 638 Figure 641 and 642 15 Remove the snap ring Code 536 Pos 20 in Figure 639 NOTE We suggest you layout the parts on the workbench for ease of reassembly See Figure 16 Remove the bearing cover Code 50348 643 Pos in Figure 640 Figure 643 Figure 640 amp Araciel Griphoist Division 53 18 Check the centrifugal switch contacts for burn malfunction etc Manipulate the switch to see if the contacts open and close See Figure 644 Figure 644 NO
44. mbH Figure 103 amp Araciel Griphoist Division 2 SECONDARY BRAKE ATTACHMENT XE501PA1 2 1 BSO500 Secondary Brake Mounting Parts List Drawing 13479 BLOCSTOP BSO 500 Date State 05 04 95 200V 60 Hz Single Phase for XE501PA1 4 1803 A bs 9 BLOCSTOP secondary brake E NG DS SA AL vae Upwards BC I should 2052 als Em nr adis se and pushi EMERGENCT STOP Lower ihe platiorm check that he USO braki the load centrifugal weights must regularty tnr ta BLOCSTOP me fu valens n I Figure 202 Mi ire bo puli sec wore rape LAS mast aa e Figure 203 45735 Blocstop Pin 0 472 x 2 677 in 12 x 68 mm 9816 Blocstop Washer 0 472 1 0 748 x 0 039 in 12 2 19 x 1 mm 46637 Mounting Strap A 6 71 in 170 5 mm w lug slight bend 66785 Mounting Strap B 6 71 in 170 5 mm 6 46496 Cotter Pin 0 157 x 0 984 4 x 25 mm l actel Griphoist Division 8 3 WIRE ROPE DRIVING SYSTEM 3 1 Introduction Although the drive system of the Tirak hoist is one of the most simplest and reliable system in the market it still requires service from an authorized repair station for safe and efficient operation It is recommended the following service proced
45. mples SAE 85W 140 GLS BP Hydrogen EP90 SHELL Spirax HD90 TEXACO Multigear EPG S80 W90 amp Araciel Griphoist Division 36 4 5 Gearbox Parts List XE501PA1 Page 1 of 2 Drawing 196007 Spare Parts Ust _ E 3207 06 09 01 200V 60 Hz Single Phase for XE501PA1 4 18 03 Code 29377 29367 43785 27167 43795 27177 43805 27217 33A 21940 25906 41936 41946 41956 41966 41976 3 686 41986 39976 36026 536 8976 7256 42006 37426 64186 42026 42036 25936 43036 43046 62 37646 37656 4186 4176 16616 casing base without gears XE501PA1 34 1 34 2 34 3 34 4 adjusting washer 35x45x0 3 DIN 988 adjusting washer 35x45x0 5 DIN 988 radial packing ring 00 230 15 DIN 3760 1 To compensate for eventual clearance between distance tube 8 and or whornwheel 6 and ball bearing 52 XE501PA1 ractel Griphoist Division Ry 5 gt CO NI I 9 O1 O1 o O 37 4 5 Gearbox Parts List XE501PA1 Page 2 of 2 Drawing 196007 Spare Parts Ust State 06 09 01 200V 60 Hz Single Phase for XE501PA1 Lm n JU Es i 4 L ag ES E JU _ na i Am lu _ rrr u
46. ngle Phase for XE501PA1 Date 4 18 03 Specification Wire Rope Drive Gearbox XE501PA1 5 16 inch 8mm 8 43775 36307 43825 43835 43865 43855 43845 40335 21246 43026 27217 31B 42227 33A 21940 Casing Cover iN gt Driver disk 0 5 16 inch 8mm wire rope entry tube ower wire rope guiding plate 500 U min N N OI BR MT gt N o ring C2 E501PA1 gt N 837 PO 85 W 140GL5 ololzic 918 SIZ m 5 lt ele O ale D l gt 9 lo 515 als 2 X O ol ale g 2 2 lt 2lo o amp o D ressure system complete I earbox oil Q 41576 EE 37686 41986 536 204202 2RS DIN 625 ria gt EE EE CE Gm see 1 CE 46 6 E TE 73 E pene paie 8 e 3 je _ TT pmeesdaperwihancogpin ESE 8 9me C86 4595 _ 3 esa 4227 700 20887 tsar 1 emergency descent handle LLL 8647 ete straps for BEOCSTOP BSO 500 E 457 1 sre 1705 with suppor CE pin on BLOCSTOP 2277 48 55 421 4 56 6 x20 DIN 94 184 5 4646 cotter pin 184 6 66785 strap 170 5 74975 __ __
47. ngs which indicates wear 4337646 Pos 62A Figure 402 amp Aractel Griphoist Division 26 6 Gently pry the sheave from the base Figure 9 Remove the seal 37686 Pos 40 The seal 405 Be careful not damage the wire rope Is destroyed during removal and must be guide band replaced after reassembly of the gearbox 10 Remove the large internal snap ring 1 8976 7 Remove the carrying handle from hoist Pos 46 below the shaft seal Figure 409 Figure 406 11 Remove any and all spacers 425936 Pos Figure 406 55 below the internal snap ring Figure 410 26 8 Remove the snap ring which sits above the seal on the input shaft See Figure 407 536 Pos 45 1 Figure 4 3 There may be more than one spacer below the Figure 407 3 internal snap ring A amp Iraetel Griphoist Division Zt 12 Carefully turn the gearbox over and remove 15 Remove the bull gear as shown in Figure 414 the cup seal 2241986 Pos 41 at the bottom after completing step 12 of the Tirak See Figure 411 Dispose of the old seal 2 16 Inspect the brass gear for any wear or damage Figure 415 Replace if necessary 13 Remove the internal snap ring 43036 Pos 56 under the cap seal in Figure 412 17 Inspect the steel bull gear and bearing for 14 Using a rubber dead blow mallet hit the bull any wear damage or discoloration Figure g
48. ning lip as needed see Section 3 13 Place a light coat of grease on the back of the new wear band Install the new wear band Make sure the band sits firmly into the casing base recess as shown in Figure 337 on the next page amp Araciel Griphoist Division 17 10 Press or use a rubber mallet to push the sheave into place The air will expel from the oil plug The sheave should move into position as air escapes Figure 339 NOTE DO NOT stand in front of the oil plug hole as oil may spray 11 Reinstall the oil plug and tighten 7 Using vise grips twist the band into the recess Figure 338 Tighten the two M6x16 allen head screws 3 11 Radial Packing Ring Replacement 442016 Pos 50 Replacement is only necessary if oil is leaking and the original packing ring is damaged cut or bent 1 Remove the oil plug pressure system wire rope guiding device and sheave as above NOTE There are no timing marks on the sheave 2 Clean the area carefully 3 With two pry bars gently remove the old 8 Reinstall the sheave into the gearbox There packing ring Do not damage the base Will be resistance due to the air trapped below the sheave 4 Lightly grease the new packing ring and place it in its position 9 While holding the sheave in place turn the hoist over so that the oil plug is to the high 5 Using a brass punch or wooden dowel tap side again Remove the oil plug same as the packing rin
49. obe resistance from any reading for accuracy Figure 710 Shown as 0 2 ohms i Figure 710 1 With an ohm meter measure the resistance of the starting winding W Z by placing test probes on Position 1 W and Position 2 Z of terminal board M1 4 0 ohms is normal Figure 711 shows 3 8 ohms OK This is found on the wiring diagram 14606 the connection is open the stator must be replaced 3 With an ohm meter measure resistance of the run winding U V by placing the test probes on position 4 U and position 5 V of terminal board M1 2 0 ohms is normal Figure 713 on next page shows 1 9 ohms This is found on the wiring diagram 14606 If the connection is open the stator must be replaced Figure 713 4 Check that the run winding is not shorted to ground Figure 714 on next page There should be no continuity between U or V and the control box casing ground If the connection is shorted the stator must be replaced 2 Check that the starting winding is not shorted to ground Figure 712 There should be no continuity between W or Z and the control box casing ground If the connection is shorted the stator must be replaced amp Aractel Griphoist Division 61 Figure 714 7 6 Fuse Check F1 421076 Pos 17 1 With an ohmmeter check continuity by placing the test probes on X1 and the opposite terminal of the fuse Figure 715 If no continuity is found repla
50. on 59 7 3 Ground Cord Plug Check 60 7 4 Wiring Diagram and General Condition 60 of the Control Box 7 5 Stator Winding Check 61 7 6 Fuse Check F1 62 7 7 Thermal Protector Check 62 7 8 Relays 62 7 9 Brake Coil Resistance Check 63 7 10 Capacitor Checks 64 7 11 Centrifugal Switch Checks 64 7 12 Pushbutton Checks 66 7 13 Control Box Base 67 7 14 Power Check 67 7 15 Brake Rectifier Check 67 7 16 Direct Control 220V Control Box Parts List XE501PA1 68 7 17 Pendant Control 220V Control Box Parts List XE501PA1 70 8 WIRING INFORMATION 8 1 Wiring Diagram XE501PA1 72 Direct Control Plan 14606 8 2 Wiring Diagram XE501PA1 74 Pendant Control Plan 31007 8 3 Wiring Connection of Stator XE501PA1 76 9 WIRE ROPE ADDITIONAL INFORMATION 10 1 Wire Rope Specification Tirak 77 10 2 Tirak Instruction Manual 10 3 Labels and Nameplates 79 10 4 Checklist 80 10 5 Hoist Specification XE501PA1 81 NOTE Griphoist Division 3 Throughout the text parts will be referred to as codes and positions e g stirrup bar Code 47867 Pos 84 These codes and positions can be found at the end of each chapter in the Parts Lists and Exploded Views 1 GENERAL INFORMATION 1 1 UL Listing Card Northbrook llinois 847 272 8800 Melville New York 631 271 6200 Santa Clara California 408 985 2400 Research Triangle Park North Carolina 919 549 1400 Underwriters Laboratories Inc Camas Washington 360 817 5500
51. rak 4th choice T series X series Griphoist Division 78 okyclimber CX1250 Compact Alpha1000 Power Climber 400 Astro Compacted Tirak Saturn all models 2nd choice 1st for reelers L series Table 902 9 3 Labels and Nameplates 1 Advice Label controll NOTICE 3 Motor nameplate GREIFZUG GmbH 6 Warning label 1 wire If the motor docs not move th h the STOP THE HOIST d descent br his hori rs equipped with a controlled device that w engage in case of pr Descent can be stopped with mara operation of the secondary brake ake operation zucomatically mary failure 51 Le A hui d wire rope IMMI EDIATE zd 7 Wire rope diameter labe VA pe cox WITS 5 16 General Warning amp Advice label WARNING Only author properly framed and physically fit personnel operate this sbict scoor dence with the instrucbons on the hoist and applica codes Copy ofinstuciens mustbe kept with the hoist Operating WARNING Immediately STOP RUNNING THE HOIST if wire rope does het move through EMERGENCY DESCENT Take brake release lever out of handle and insert in motor cover hole Push lever upwards STOP release laver CAUTION The TIRAK only be used in
52. t mc rare AT mem 4 Perm M zou ai ad 4 72 8 1 Wiring Diagram XE501PA Direct Control Plan 14606 Page 2 of 2 Ting seg ti 3371 54 A 133419 udT AQ zrz 59 5 OG Lidl ki de BERE d cz LE x am pipe Sys 34 5 422 91 pci DOR Ld Lj ui n aec Da 95 2 7 Leu Lid 12071 1 J PE 5 ipi 327 n op iere Seni un puros 31 27 4 5 40077 ce Si wep EL 09 ET p agen nus 8 2 Wiring Diagram XE501PA1 Pendant Control Plan 31007 Page 1 of 2 zs Okie oe juepuag udT ADcz pau um KERE x JOEL 1224405 d n edt oe ee n 5 M Y JE Z 0223271 acc asp 2 AI 2718321 Li 0122 12171 7 J uia c TT 5 BS CETHANE LORT Up Un ania un HER LE
53. the black brake body with a feeler gauge This should be done in all three places between the 3 fixing screws every 120 degrees Figure 508 amp Araciel Griphoist Division 40 5 4 Brake Removal 2 Remove the fan 16186 with two screwdrivers placed under the fan and Tn ids rione against the motor shaft and pry upward to removal attenuon to the Drake orien Figure 513 tation and mark it for realignment Figure 511 We 3 Ifthe fan key 16256 is removable do so If not just wrap some tape around the keyway for safety Figure 514 515 1 Remove the fan snap ring 3866 shown in Figure 512 4 Remove the three socket head fixing screws w locking washers 5 Remove the whole brake assembly Figure 516 Griphoist Division 41 NOTE It is not necessary to unwire the brake re brake end shield holes have silicone applied to th Thi t t 6 Remove the brake disc 47446 and inspect water entry into the motor Figure 519 it Section 5 5 Replace if worn or damaged 7 Ifthe brake hub 47456 needs replacement remove the snap ring 536 and carefully pry the hub from the motor shaft as shown in Figure 517 a Figure 519 5 5 Disc Inspection The thickness of a new brake disc depends on the size of the brake The brake size is marked on the top of the
54. to place Continue pressing the sheave into the base until the V groove of the sheave is opposite the wearband as shown in Figure 450 27 Replace the O ring in the gearbox casing b cover Lightly grease the O ring prior to EEUU installation Figure 450 24 Using channel locks press the wearband into the recess as shown Install the soc heap screw as shown in Figure 448 Figure 448 4 Griphoist Division 34 28 Lightly coat the 4 socket head screws with silicon prior to installation Figure 451 Tap the cover onto the base and tighten the screws down Figure 453 Overhaul of the hoist gearbox is now complete 29 Fill the gearbox with 2 0 liters of SAE N WARNING N 85W 140 GLS gear oil Do not overfill the gearbox Refer to Section 4 5 The hoist must be load tested prior to returning to service Check the hoist for abnormal noise vibra tion or heat 30 Install the oil plug and gasket Figure 452 Figure 452 31 Restamp or mark the gearbox with the serial number of the hoist in the location shown in Figure 453 amp Aractel Griphoist Division 35 4 4 Hoist Position for Oil Level Inspection level Drain Fill Plug Location P Ts ies 7 L i o lt a 4 Pus E oy gy 2 1 Quarts P 2 0 Liters Exa
55. ton 1 _ 200V 60 Hz Single Phase for XE501PA1 Date 4 18 03 Instructions a Open the Tirak remove pressure system driver disk d and name plate if fixed to the the casing cover A e b Machining of the casing cover A f Put on device C so that all three straight pins D fit into the holes E of the casing 9 Using an 8mm three lipped core drill supplied and through the drill bushing F drill a hole into the casing cover c Machining of the casing base B Put on device C so that all three straight pins D fit into the holes E of the casing Using an 8mm three lipped core drill supplied and through the drill bushing F drill a hole of minimum 34mm depth into the casing base Install the driver disk and pressure system Fit wire rope guiding bolt G Check the distance X and fit correct number of adjusting washers H Close the casing and put on the name plate if removed under a Wire rope guide bolt for retrofit version ONLY 78755 Washer 8x14x1 DIN 988 67206 Hoist Serial Numbers Guide bolt 74875 is factory installed on all XE501PA hoists beginning with S N 20106 The following hoist can be retrofitted XE501PA S N 8377 amp up Figure 357 Griphoist Division 23 3 16 Wire Rope Drive System Parts List XE501PA1 Page 1 of 2 Drawing 19600 spare Parts Ust WIRE ROPE DRIVE 8 _ 18 01 00 200 60 Hz Si
56. until upper edge of wire rope guiding band looks like Figure 346 Ty mh pe Figure 347 3 Fasten drill guide to casing as shown Figure 348 Figure 345 Figure 348 Griphoist Division 20 4 Drill a 3 2 mm diameter hole 15 mm deep as shown in Figure 349 A G myi Figure 349 al 5 Tap a M4 hole 12 mm deep as shown in Figure 350 into the hole that was just drilled Ere ML T D i d iu T Figure 351 7 Install a 4 10 DIN 933 hex head screw into the casing Figure 352 mme Nih ko T Figure 350 E IST E hi 6 Replace the wire rope guiding band shown in Figure 351 I Figure 352 amp Araciel Griphoist Division 21 Figure 353 Fix screw with Loctite 222 Figures 353 amp 354 8 e LS 4 C gt St Figure 354 798 RN i Position of screw head is arbitrary as shown in Figure 355 9 Position of screw head is arbitrary as shown in Figure 356 Figure 356 3 14 Stirrup Bar Modification XE501PA1 A one piece stirrup bar adapter code 47867 has replaced the two piece adapter that consisted of a pin code 64575 and stirrup bar code 14347 Griphoist Division 22 3 15 Wire Rope Guide Bolt Retrofit XE501PA1 INSTALLING THE WIRE ROPE GUIDING BOLT TECHNICAL INFO re Ea
57. upper and lower bearings 426 for wear or damage Replace if necessary n NOTE If a machine press is available it will ease the installation of the worm gear NOTE 3 press is not available a hollow tube and Prior to reassembly carefully clean the new casing a rubber mallet may be used carefully to tap base to ensure no filling dirt or debris are present the bearing and worm gear in the base as Figure 424 shown in Figure 427 Figure 424 1 Install the upper worm gear bearing about 3 Install the bull gear assembly as shown in halfway on the worm gear towards the upper Figure 428 end of the shaft Figure 425 Figure 425 me 1 Figure 428 amp Aractel Griphoist Division 30 4 press is not available carefully tap the 7 Using a hollow tube or press install the bull gear into position as shown in Figure upper worm gear bearing below the slot in 429 the base for the internal snap ring removed in step 7 of Section 4 3 shown in Figure 432 Figure 429 SG 5 9 Alternate tapping bull gear and the worm gear After several careful taps they should Push the bearing down until it is below the slot NOTE shown in Figure 433 The bull gear is fully installed when the bearing meets the casing base as shown in Figure 430 27 weg 8 Install any and all spacers removed in step 11 Figure 430 7
58. ures are performed every six 6 months but they may need to be repeated more often depending on the work environment the hoist is subjected to 3 4 External Inspection NOTE 1 Inspect outer casing for damage Pay extra attention to the area indicated shown downtime 3 2 Tools Required Figure 301 Rubber mallet Pry bars 2 Straight edge ruler 12 min 10mm Box wrench Screwdriver flat Allen key mm Allen key Diagonal cutting pliers 2 Figure 301 3 3 Blocstop Removal Using diagonal cutting pliers detach the Blocstop BSO500 strap from the hoist by removing the top cotter pin shown in Figure 302 Figure 303 Look for imprints that may indicate further damage inside Figure 303 Inspect the stirrup adapter shown in Figure 304 TIRAK ONLY for wear or damage If the Stirrup bar 47867 Pos 84 is bent it indicates improper rigging Replace if necessary Figure 304 Griphoist Division 9 3 5 Casing Cover Removal 1 Remove the four 4 cap screw assemblies in the corners Figure 305 consisting of the following a M6x50 socket head cap screws Code 12016 Pos 69 b Lock washers Code 16616 Pos 73 c Flat washers Code 36306 d Square nuts Code 39356 Pos 74 4 When the cover opens enough insert a second screwdriver Begin to lift evenly at the corners of the cover as shown in Figure 308 Figure
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