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INSTRUCTION MANUAL

AIR HOIST

EHW-60
EHW-60R
EHW-120
EHW-120R

02-04-04-0001-0516-00-BA-ENG-PLA

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Summary of Contents for EHW-120

Page 1: ...INSTRUCTION MANUAL AIR HOIST EHW 60 EHW 60R EHW 120 EHW 120R 02 04 04 0001 0516 00 BA ENG PLA ...

Page 2: ...ring Limit Switch 7 5 3 Check of the Lifting Height 8 5 4 Load Test 8 6 Checks before Operation At the beginning of each shift 9 6 1 Check before Start up 9 6 2 Check by ldling Operation 9 6 3 Check by Load Operation 9 7 Periodic lnspections 10 8 Maintenance and lnspection 11 8 1 Lubrication 11 8 2 lnspection 12 8 3 Storing the Hoist 16 8 4 Troubleshooting 17 9 Brake Adjustment 18 10 Disassembly a...

Page 3: ...nough to support the weight of the hoist plus the weight of the rated Ioad etc The customer has the responsibility for this 1 2 lnstructions for Safe Operation lf there is any conflict between the instructions in this manual and safety rules of your company give priority to ones which are more strict than others 1 2 1 General Handling WARNING Never operate the hoist unless the contents of this man...

Page 4: ...ring Iimit switch will not work 1 2 4 Operation and Handling WARNING Never Iift a Ioad greater than the rated capacity of the hoist The rated Ioad is marked on the hoist body Never stand on a suspended Ioad Never use the hoist for Iifting lowering or transporting people Always stand clear of the Ioad Never walk under a suspended Ioad and keep out of its area of projection Never place hands feet et...

Page 5: ... work on a Ioad suspended by the hoist Never perform electrowelding work on a Ioad suspended by the hoist Never use the wire rope of the hoist as a ground for welding Never attach a welding electrode to the wire rope of the hoist Never Iift any single Ioad with 2 or more hoists Never lock the push button switches The hoist must be operated by the operator hirnself I herself at all times When movin...

Page 6: ...t correct andrepair the problems immediately Periodically inspect the hoist thoroughly and replace any worn or damaged parts Stretched worn or damaged hooks should be discarded Never attempt to repair it just replace it with a new hook e Always put up an instruction sign EQUIPMENT BEING INSPECTED DO NOT OPEN THE VALVE etc before carrying out maintenance inspection or repair Never do anything if yo...

Page 7: ...ecks of the Product Check the delivered hoist is what you ordered check the name plate Check there was no damage or deformation on the hoist during transportation Check the pressure of the available air supply corresponds to the working air pressure of the hoist 3 2 lnstructions on Werking Conditions WARNING Never use the hoist at a temperature below 100C or above 50 C CAUTION Do not install and l...

Page 8: ... is correctly rigged onto the supporting member and the hook latch is correctly closed Never use a supporting memberthat suspends the hoist at an angle 4 2 Before Air Connection WARNING The hoist is designed to operate within a working air pressure range of 0 4 0 6 MPa 4 6kgf cm 60 BSpsi Always keep the working air pressure no greater than 0 6 MPa 6kgf cm lf necessary use an air regulator for redu...

Page 9: ...iping 5 Checks after Installation and Test Run 5 1 Check of Hoisting Operation Always keep the working air pressure no less than 0 4 MPa l4kgflcm 60psil At the initial operation repeat up I down operations several times at low speed then go to the full speed operation Adjust the speed by Controlling the pushing force on the push buttons At this point check the lubricator is feeding lubricant to th...

Page 10: ...spring dose not collide with the hoist body during required work lf do change the mounting height of the hoist 5 4 Load Test Lift the rated Ioad a few inches off the floor and check ability of the brake to stop and hold the Ioad without excessive dritt ln case of using the hoist with the trolley traverse the trolley over the entire length of 1 beam with the rated Ioad suspended a few inches off th...

Page 11: ...ight WARNING lf the buffer spring collides with the hoist body while the stopper is in contact with the locking portion of the wire rope the wire rope will be damaged and the suspended Ioad may drop causing serious danger 5 Check the trolley wheels track the rails properly and the wheels and rails are not worn 6 Check the Iifting sling suspension fastening is not damaged or worn 6 2 Check by ldlin...

Page 12: ... inspection depends on the operating environment operating frequency and loading conditions of the hoist Therefore make the inspection interval shorter according to your operating condition For inspection items and methods see Chapter 8 Section 8 2 lnspection II Annual lnspection Disassembly is required Gompletely disassemble the hoist at least once a year for inspection and maintenance Gorreet an...

Page 13: ... Always excute the Ioad test after disassembling the hoist for maintenance or inspection See Section 8 2 9 General Operation lnspection Always use the hoist correctly for safety and getting the best service 8 1 Lubrication 1 Air motor To prevent the air motor from dry operation continuously lubricate using a lubricator Adjust the lubricator so that lubricant is fed at a rate of s sdrops per 1 m3 o...

Page 14: ...NLGI National Lubrication Grease Institute to the 0 rings for dynamic seal 8 2 lnspection 1 lnspection of Hook and Service Limit WARNING Never repair the hooks Always replace a stretched worn or damaged hook with new one llllnspection on Hook Opening Craks and Wear lf any of the following conditions apply to the inspected hook never reuse always replace with new one The hook opening is visibly str...

Page 15: ... against reverse winding overlowering Iimit switch works Then inspect the wire rope Never use the wire rope having any one of the following defects Kinked deformed or corroded The number of broken wires reaches the service Iimit The reduction of diameterreaches the service Iimit Wear Limit and Limit of Broken Wires The number of broken wires in one lay should be no greater than 10 of all wires And...

Page 16: ...re there flaws deformation or wear on 0 rings 49 53 Brake cylinder 48 Brake wheel 32 Brake cone 51 0 ring 53 S h a ft 3 0 0 ring 49 Spring 50 Lining IIWear Limit of Lining mm Replacement Parts Always replace Springs 50 whenever Brake cone 51 is replaced Replace all Springs 50 at the same time 4 lnspection of Hook Holder ls there any deformation or cracks on the hook holder Are the bolts and set sc...

Page 17: ...Valve body 14 in the disassembly drawing on Page 28 or 30 Does the pilot valve return quickly when released after pressing the tip of the valve 7 lnspection of Air Motor Replace parts which show the following conditions The vanes are warped curved seized or cracked Wear on the vanes reaches the service Iimit The side face of the rotor is gouged or seized The vane slot of the rotor is worn beyond t...

Page 18: ...ct as indicated Check hoisting speed can be changed from low to high speed by controlling the pushing force on the push buttons Check the preventive device against reverse winding functions correctly See Chapter 5 Section 5 2 Check of the Preventive Device against Reverse Winding Overlowering Limit Switch Check the hoist is not abnormally noisy or vibrating Load Test Check for malfunctions while I...

Page 19: ...ged parts Brake does not work sufficiently Lining is worn Main valve does not return to the neutral position Replace with new Brake corn Check the darnage on 0 rings and Springs etc Hoist does not run in the lowering direction Preventive device against reverse winding works incorrectly Disassernble and check Hoist does not run in the Iifting direction after preventive device against reverse windin...

Page 20: ...e brake to stop and hold the Ioad without excessive dritt NOTE lf the set screw is over tightened the Iifting ability of the hoist will decline 10 Disassembly and Reassembly WARNING Always shut off the air supply before carrying out disassembly or reassembly Always disassemble or reassemble the holst on the floor Always employ specialists or weil trained persons for disassembly and reassembly CAUT...

Page 21: ... tubes 104 105 Pull out Nylon tubes 104 105 while pushing the collet of Elbow 81 See Fig 3 4 Loosen Cap screws 108 and remove Valve body 70 and Coil hose 103 together 5 Disassemble Valve body part 70 Remove Handle 82 Remove Spacers 78 then remove Spools 76 and Springs 75 Remove Elbow 81 and Adapter 74 Goilet Fig 3 Remove Plug 71 and press out Valve cone 72 to the adapter side NOTE Never hammer Val...

Page 22: ...oosen Gap screws 55 sequentially by 1 6 turns and remove Brake cylinder 48 Remove Retaining ring 54 and remove Brake cone 51 11 Remave Drums 36 40 and Wire rope 39 tagether from Casing 1 Remove Drum 40 from Drum 36 and remove Wire rope 39 12 Remave Planet shaft 25A or 258 Gear wheels 26 Shaft 30 and Brake wheel 32 together 13 Remave Retaining ring 29 remove Pins 28 and remove Gear wheels 26 from P...

Page 23: ... wheel 9 should not rotate freely 4 Before installing Valve body 14 in Casing 1 check the 0 5 air exhaust hole on Valve body 14 is open and Valve 16 returns quickly when released after pressing the tip of Valve 16 See Fig 5 Casing 1 Valve body 14 Valve seat 19 0 5 Air exhaust hole Liner 21 Fig 5 Valve 16 5 Reduction gear unit Apply about 3cm 3ml of grease to 63T intrenal gear 2 Also apply grease t...

Page 24: ... grease to the sliding anchoring position should be in this area Fig 7 surface of Bearings 5 44 where the drum contacts lnstall the drum into Casing 1 so that the wire rope anchoring position comes in the area shown in Fig 7 lf the gears do not engage weil rotate Shaft 30 a little 7 Brake unit Apply grease to 0 rings 49 53 and the grooves of Brake piston 52 and Brake cylinder 48 a little then inst...

Page 25: ...s 67 a little Use the same lubricant used for the lubricator See Chapter 8 Section 8 1 3 Recommended Lubricants 10 Valve body part 70 Check there are no flaws on the outer surface of Valve cone 72 and the inner surface of Valve body 70 the sliding surface where Valve cone 72 contacts lnstall 0 ring 73 to Plug 71 and install them in Valve body 70 Apply grease to the grooves of Valve cone 72 and ins...

Page 26: ...rn 72 Adapter 74 Fig 11 5 Take off the jig and install Adapter 74 11 For EHW 60 andEHW 120 lnstall Washer 90 and Steel ball 91 Tighten Setscrew 92 until it touches Steel ball 91 Then fix Setscrew 92 with Hex nut 13 For EHW 60R and EHW 120R lnstall Washer 92 and Steel ball 93 Tighten Setscrew 94 until it touches Steel ball 93 Then fix Setscrew 94 with Hex nut 13 12 Stopper For EHW 60 and EHW 120 96...

Page 27: ...is retracted approx 400 mm lf the air does not stop stop operation immediately and check Pin 38 is installed correctly and Valve seat 19 is sealed properly Air exhaust hole Fig 13 Operate the hoist in the lowering direction and check the preventive device against reverse winding functions correctly At the first time operate the hoist in the lowering direction slowly while paying attention to the a...

Page 28: ...ied individually Piease purchase a set or complete unit How to read parts Iist Ref Quantity Part No No EHW 60 EHW 120 Description LHP000073 1 Casing set 1 P2H100019c 1 1 Casing 2 P2H300141a 1 1 63T internal gear 3 KA42410412 1 1 Spring pin 4 KA42419812 1 1 Spring pin 5 1 Bearing 6 KA70501061 1 1 Grease nipple 7 P2H400190a 1 1 Shaft The mark indicates the range of the set or the complete unit ...

Page 29: ...te Brake cylinder 0 ring Spring Brake cone Brake piston 0 ring Retaining ring Cap screw Hookcompl Hook Hook latch set Hook latch Spring Rivet 60 61 62 63 64 3 65 66 67 68 69 70 115A 115B 71 72 73 74 75 76 77 78 110 73 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 97 101 109 98 57 58 59 99 100 102 103 103 1 103 2 104 105 106A 106B 107 108 111 112 113 114 LHP000149 KA00910516 KA00910525 P2H400136 LHP...

Page 30: ...ng Shaft Drum Set Drum 62T internal gear Spring pin Spring pin Name plate EHW 60 3 EHW 1 20 3 Different Part Ref No Part No Quantity EHW oO lEHW 120 l Description ompl ng 39 94 95 96 40 40 1 40 2 106 106 LHP000182 LHP000168 KA16410508 LHP000068 LHP000170 LHP001328 P2H401823 P2H300257 P2H300252 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 Wire rope c Wire rope Set screw Buffer spri Stopper Drum Drum Seal Na...

Page 31: ... 29 1 25A 25B 56 44 36 41 43 41 62 ...

Page 32: ... 29 ...

Page 33: ...g pin 91 38 P2H400268a 1 1 Pin 92 LHP000181 1 1 Wire rope compl 93 39 LHP000064a 1 1 Wire rope 94 96 KA16410508 2 2 Set screw 95 97 LHP000068 1 1 Buffer spring 98 LHP000151a 1 1 Stopper LHP000852b 1 1 Handle assembly P1R400323 3 3 Nipple LHP000992a 1 1 Valve body compl P2H200193a 1 1 Valve body P2H400293 2 2 Spring P2H300170 2 2 Spool KA50100080 6 6 0 ring P2H401220 2 2 Spacer LHP000851 1 1 Handle...

Page 34: ...ing Shaft Drumset Drum 62T internal gear Spring pin Spring pin Name plate EHW 60R 3 EHW 120R 3 Different Part Ref No Part No Quantity EHUR JEHW mR J Description LHP000182 1 1 Wire rope compl 39 LHP000168 1 1 Wire rope 96 KA16410508 2 2 Set screw 97 LHP000068 1 1 Buffer spring 98 LHP000170 1 1 Stopper 40 LHP001328 1 1 Drum 40 1 1 1 Drum 40 2 P2H401823 1 1 Seal 102 P2H300259 1 Name plate 102 P2H3002...

Page 35: ...IIEHW 60R IIEHW 120R 36 40 2 97 41 81 82 89 li 86 87 88 8 32 ...

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