Planeta PKB Series Operation And Maintenance Manual Download Page 1

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Operation and maintenance manual for

Low headroom trolley hoist PKB

Installation - Operation - Maintenance

01-06-02-0000-0515-00-BA-EN-PLA

IMPORTANT - READ BEFORE USE!

PLANETA-Hebetechnik GmbH

•

Resser Str. 17 & 23 • D-44653 Herne

Tel. +49 2325 9580-0 • Fax +49 2325 77077 • [email protected] • www.planeta-hebetechnik.de

Summary of Contents for PKB Series

Page 1: ...Maintenance Reprint also in extracts only with written permission of PLANETA Hebetechnik GmbH 01 06 02 0000 0515 00 BA EN PLA IMPORTANT READ BEFORE USE PLANETA Hebetechnik GmbH Resser Str 17 23 D 44653 Herne Tel 49 2325 9580 0 Fax 49 2325 77077 info planeta herne de www planeta hebetechnik de ...

Page 2: ...ing transportation to PLANETA After inspection damaged items must be repaired or replaced before installation and commissioning Assembly installation commissioning tests and maintenance may only be executed by competent persons Each operator must have read the entire manual and fully understand its contents Copyright 2015 by PLANETA All rights reserved No parts of this document may be reproduced o...

Page 3: ... Safe Working Load 9 3 4 Areas of application 9 3 5 Trolley nameplate designation 10 3 6 Trolley model designation 10 3 7 Hoist nameplate designation 11 3 8 Hoist model designation 11 3 9 Product overview and dimensions 12 3 9 1 Standard headroom 12 3 9 2 Low headroom 15 3 9 3 Ultra low headroom 17 4 Transport and Storage 19 5 Installation 20 6 Commissioning 23 7 Operation 24 8 Maintenance 26 8 1 ...

Page 4: ...4 11 1 Standard headroom 35 11 1 1 Model K hoist 38 11 1 2 Model N hoist 43 11 2 Low headroom 48 11 3 Ultra low headroom 49 Appendix I Logbook 51 Appendix II Technical specifications 52 4 ...

Page 5: ...ring operation and incorrect usage Operators are well aware of the precautions prevailing conditions and applicable regulations They have proven their ability by experience and are authorised to control the product Competent person s Competent persons have a theoretical basis as well as a practical experience in the field of lifting equipment They possess excellent knowledge of the product safety ...

Page 6: ...rning of an imminent danger to health and life Ignoring these warning notices will lead to severe injuries possibly resulting in death Warning Gives warning of situations which are potentially dangerous to health and life Ignoring these warning notices may lead to severe injuries Caution Gives warning of situation which can lead to minor injuries or damage to the device or its surrounding Suspende...

Page 7: ...that is properly designed and dimensioned 2 4 Inappropriate use Use in areas with potentially explosive atmospheres Using the hoist trolley unit to transport people is strictly forbidden Using the hoist trolley unit with people walking moving underneath the load Exceeding the safe working load of the trolley and or hoist under the specified conditions Operation exceeding the allowed operating circ...

Page 8: ...lace illegible or damaged plates The hoist and trolley shall be tested and inspected by a relevant authority before commissioning 2 6 Proper load attachment suspension Use only tested and approved slings to attach the load Never use the hoist trolley unit when the load chain is damaged Ensure a load is always suspended above the centre of gravity The load must always be suspended from the base of ...

Page 9: ...d low headroom hoist trolley units can optionally be executed with an overload protection device Ultra low headroom hoist trolley units always have the overload protection device built in If equipped with an overload protection device the slipping clutch will be activated between 125 and 150 of the safe working load When activated the hoist can only be lowered to reduce the load below the safe wor...

Page 10: ...ed through the table below Type 33 2 5 MRS NC Non corrosive Headroom S Standard L Low U Ultra Low Model execution P Push G Geared W Worm geared H Helical geared S Swinging beam C Articulated for curved beams R Rack and pinion F Friction wheel system T Personal transportation Drive model M Manual E Electric P Pneumatic H Hydraulic Capacity in tons 1 ton 1000 kg Chassis type in Kilo Newton kN Trolle...

Page 11: ...roduct 3 8 Hoist model designation The model description describes how the hoist is executed The execution parameters can be converted through the table below Type 3 3 N032 NC Non corrosive Model execution K N Lifting height Capacity in tons 1 ton 1000 kg Chain hoist For example the above model description describes a 3 tons Chain hoist The hoist has 3 meters of lifting height and is executed in m...

Page 12: ...main components of a standard headroom hoist trolley unit Component description 1 Single flange wheel 2 Side plate 3 Wheel shaft 4 Adjustable support bolt 5 Adjustable bended suspension bolt 6 Hexagon lock nut 7 Adjustment washers 8 Hoist body 9 Hand chain hoist control 10a Load hook 10b Load hook in highest position 11 Safety latch load hook 12 Load chain 13 Hand chain trolley control 14 Top hook...

Page 13: ...ugh your contact person at PLANETA upon request Standard headroom model K dimensions kg Chassis mm No of falls Weight 3 meters lift Dimensions G A B C E F F1 R L N O 500 6 kN 55 102 1 13 337 Ø45 Ø60 15 15 31 1 27 75 150 105 152 1 000 11 kN 55 102 1 17 5 355 Ø60 Ø75 18 20 34 6 29 99 190 90 Ø100 105 152 156 203 206 254 1 500 22 kN 74 127 1 26 5 425 Ø80 Ø100 22 27 38 8 34 123 255 90 Ø100 127 180 190 ...

Page 14: ...5 102 1 20 360 Ø60 Ø75 18 20 36 29 99 190 90 Ø100 105 152 156 203 206 254 1 600 22 kN 74 127 1 30 420 Ø80 Ø100 22 27 39 31 123 255 90 Ø100 127 180 190 243 254 305 2 000 22 kN 74 127 1 36 455 Ø80 Ø100 22 27 39 31 123 255 90 Ø100 127 180 190 243 254 305 3 200 33 kN 90 143 1 53 525 Ø100 Ø120 25 35 48 39 144 300 95 Ø100 149 203 203 254 251 305 5 000 52 kN 106 156 3 70 690 Ø125 Ø150 30 40 56 47 174 375...

Page 15: ...Single flange wheel 2 Side plate 3 Wheel shaft 4 Suspension bolt 5 Hoist body 6 Hand chain hoist Control 7a Load hook 7b Load hook in highest position 8 Safety latch load hook 9 Load chain 10 Hand chain trolley control 11 Hand chain wheel assembly 12 Drive shaft assembly 13 Rubber buffer Optional 14 Single flange geared wheel 15 ...

Page 16: ...55 95 Ø100 5 000 52 kN 106 300 2 100 530 Ø125 Ø150 30 40 50 46 5 174 65 590 130 Ø135 7 500 104 kN 115 300 3 220 670 Ø160 Ø190 35 42 79 5 72 5 220 82 800 134 Ø270 10 000 104 kN 115 300 4 220 640 Ø160 Ø190 35 42 79 2 72 5 220 82 800 134 Ø270 Dimension table 3 Low headroom model N dimensions Capacity Chassis Monorail width BW No of falls Weight 3 meters lift Headroom Dimensions kg mm kg G A B C E F F...

Page 17: ...ingle flange wheel 2 Single flange geared wheel 3 Wheel shaft 4 Fixed end point of load chain 5 Suspension bolt 6a Load hook 6b Load hook in highest position 7 Bottom hook block 8 Load chain 9 Hand chain trolley control 10 Hand chain hoist control 11 Hand chain wheel assembly 12 Hoist body 13 Drive shaft assembly 14 Rubber buffer Optional 17 ...

Page 18: ...257 Ø160 Ø190 35 36 40 38 430 894 208 196 Ø300 10 000 124 kN 134 300 4 410 270 Ø160 Ø190 35 35 50 47 630 1 100 208 196 Ø375 Dimension table 5 Ultra low headroom model N dimensions Capacity Chassis Monorail width BW No of falls Weight 3 meters lift Headroom Dimensions kg mm kg G A B C E F F1 R L N U O 1 000 22 kN 74 300 2 45 130 Ø80 Ø100 22 21 36 29 226 466 140 104 Ø100 2 000 33 kN 90 300 2 86 162 ...

Page 19: ...be clean and dry If necessary the hoist trolley unit shall be cleaned The hoist trolley unit shall be kept free from excessive vibrations The hoist trolley unit shall be protected against excessive water wind and salt The hoist trolley unit shall be stored in a closed and or sealed packing Observe environmental protection laws do not allow oil etc to leak Model K Temperature not colder than 20 C o...

Page 20: ...e of monorail widths For reference see pos 4 5 and 7 of chapter 3 9 Product overview To adjust the width of a standard headroom hoist trolley unit follow below steps in sequence Detach the hoist from the trolley and put it down on a stable underground Unscrew the support and suspension bolts Pos 4 and 5 on both sides of the trolley and take off the hexagon lock nuts and washers Pos 6 and 7 Slide o...

Page 21: ...ension bolts Pos 4 and 5 on one side of the trolley Unscrew the support and suspension bolts on the other side of the trolley and take off the hexagon lock nut and washers Pos 6 and 7 Slide off the side plate Pos 2 Be careful not to damage the threaded ends of the support and suspension bolts Lift the trolley half containing the support and suspension bolts onto the monorail flange Attention Watch...

Page 22: ... trolley until the monorail web is in between the wheels and the underside of the wheels are just above the bottom flange of the monorail Attention Watch for the orientation of the hoist trolley unit Push the hoist trolley unit onto the monorail Reinstall the end stops on the monorail just beyond the removed section Option B4 For low headroom and ultra low headroom hoist trolley units a special de...

Page 23: ...hapter 8 4 Tightening torques Check if the end stops are properly mounted onto the monorail Visually check if monorail is clean and without obstacles Checks during commissioning During commissioning perform test and check the following steps Always ensure that there is enough space for travelling lifting and lowering without the risk of collision with obstacles Check all movements All movements mu...

Page 24: ...peration Each operator must have read the entire manual and fully understand its contents It is the responsibility of the operator to observe and follow everything that is described in this manual Pulling force hand chain in kilograms The hand chain pulling force of pulling force table 1 and 2 does not comply with NEN EN 13157 chapter 5 1 6 Operating effort Capacity Standard headroom Low headroom ...

Page 25: ...ng the left hand chain part down causes the trolley to drive forwards as shown in detail A of the illustration below Pulling the other chain part down will result in driving the trolley backward Hoists shall always be operated by hand Any other drive mechanism is not allowed Pulling the right hand chain part down causes the hoist to lift the hook as shown in detail B of the illustration below Pull...

Page 26: ...use Monthly 3 monthly Yearly K N K N K N K N Visually check if the load chain is clean and not twisted x x Visually check if the hand chain is clean and not twisted x x Check operation of hoist brakes x x Check pinions and gears for wear x x Lubricate pinions and gears x x Check the load chain and lubricate if necessary x x Check the guide rollers and lubricate if necessary x x Check the hoist and...

Page 27: ...y with oil x x Lubricate wheels guide wheels and pillow block bearings x x Lubricate pinions and gears x x x x Visually check if the load chain is clean x x Visually check if the hand chain is clean x x Lubricate the load chain x x Lubricate the hand chain corrosion prevention x x Clean off any lubrication of the hand chain x x Check condition and suspension of the chain bag or box x x Check for a...

Page 28: ...Dropping point C 1 Oil Shell Tellus S2 M 46 20 100 46 46 230 30 2 Oil Shell Omala S2 G 320 0 100 320 320 250 15 3 Oil Shell Omala S4 GX 320 25 120 320 312 7 252 42 4 Oil Shell Omala S4 WE 220 20 100 220 222 278 39 5 Oil Shell Omala S4 WE 320 20 100 320 321 270 39 6 Oil Shell Omala S4 WE 460 20 100 460 460 268 36 7 Oil Shell Omala S4 WE 680 20 100 680 664 262 39 8 Oil Shell Omala S4 GX 220 30 120 2...

Page 29: ... quality unless otherwise noted Torque Nm 8 8 10 9 12 9 A4 70 A4 80 M3 2 1 3 5 3 8 1 5 1 7 M4 4 4 7 7 6 3 3 6 M5 8 12 5 13 6 5 5 6 7 M6 13 2 20 1 21 8 8 1 11 2 M8 30 44 47 18 21 M10 49 73 93 26 34 M12 83 121 151 41 62 M14 131 188 232 68 101 M16 167 281 342 108 157 M18 275 388 467 157 224 M20 382 534 638 223 318 M22 517 719 852 310 438 M24 652 902 1 064 397 558 M27 945 1 297 1 519 589 823 M30 1 286...

Page 30: ...0 30 2 9 27 25 000 N250 10 30 2 30 000 K300 9 27 32 000 N320 10 30 2 40 000 N400 K400 10 30 2 9 27 50 000 N500 K500 10 30 2 9 27 Hand chain hoist 5 24 5 25 2 5 24 5 25 2 Hand chain trolley 5 18 5 5 18 5 5 18 5 5 18 5 Load chain table 1 Capacity Ultra Low Headroom Model N K kg N K Ød 1P Ød 1P 1 000 N005 K005 5 15 5 15 2 000 N010 K010 6 3 19 1 6 3 19 3 000 K015 7 1 21 2 3 200 N016 7 1 21 2 5 000 K02...

Page 31: ...f the hook If tip of the hook is subjected to load an increase of value a2 is likely to occur as a result of tensile or bending forces A hook can quickly wear due to improper load attachment and or overload In order to reduce wear and extending the service life of the hook read chapter 2 6 Proper load attachment suspension Capacity Standard Headroom Model N K kg N K a2 a2max h2 h2min a2 a2max h2 h...

Page 32: ...ing may only be greased in the factory of Inspection The both hooks and hook blocks must be checked for damage and wear using the following criteria Check for deformations cracks and or cuts caused by an impact The hook safety latch must close completely using its own spring without human assistance The hook pivot bearing of model N hoists with a capacity of 5 ton or larger must be able to rotate ...

Page 33: ...nd fails to lift the load The pawl has been improperly assembled If the pawl is assembled incorrectly it will not properly mesh with the ratchet disk Reassemble the pawl and its components The pawl is not moving smoothly Dirt has accumulated on the grease of the pawl and pawl shaft Movement will become sluggish or the pawl remains stuck in the kicked out position Reassemble the pawl and its compon...

Page 34: ...g Dismantling may only be carried out by competent persons Attention Before dismantling Read chapter 2 Safety instructions Read chapter 7 Operation for use of personal protective equipment Depending on the situation the hoist trolley unit can be dismantled in two ways If the ends of the monorail aren t accessible due to a wall or other obstacles follow option B instead of option A Option A Driving...

Page 35: ... is modified or non original spare parts are used 11 1 Standard headroom Below illustration shows the spare part of an manual push and geared standard headroom hoist trolley unit and shall be used in combination with spare parts table 1 and 2 Tip The shown position numbers are in accordance with chapter 3 9 1 Standard headroom headroom hoist trolley unit Request for spare parts can be issued at yo...

Page 36: ...lt Suspension bolt Adjustment washer Hexagon lock nut 8 1 Hoist See chapter 11 1 1 Model K hoist or 11 1 2 Model N hoist 17 4 Buffer Hex head bolt Spare parts table 1 Only in combination with an adjustable suspension set Standard headroom manual geared 81200 Pos Qty Consisting of 6 kN 11 kN 22 kN 33 kN 52 kN 64 kN 1 2 Single flange push wheel Bearing Circlip 3 4 Wheel shaft Hexagon lock nut Circli...

Page 37: ...ort bolt Suspension bolt Adjustment washer Hexagon lock nut 8 1 Hoist See chapter 11 1 1 Model K hoist or 11 1 2 Model N hoist 17 4 Buffer Hex head bolt 13 1 Hand chain 15 1 Hand chain wheel Hand chain guide 16 1 Drive shaft Pinion Spring pin 18 2 Single flange geared wheel Bearing Circlip Spare parts table 2 Only in combination with an adjustable suspension set ...

Page 38: ...3BA015 5101 C3BA020 5101 C3BA025 5101 12 1 Name plate F C3BA005 9806 13 1 Side plate B assembly C3BA005 5102 C3BA015 5102 C3BA025 5102 14 1 Load sheave C3BA005 9116 C3BA010 9116 C3BA015 9116 C3BA020 9116 C3BA025 9116 15 1 Ball bearing J1GR002 06006 J1GR002 06007 16 1 Ball bearing J1GR002 06005 J1GR002 06006 J1GR002 06007 17 1 Pinion C3BA005 9111 C3BA010 9111 C3BA015 9111 C3BA020 9111 C3BA025 9111 ...

Page 39: ...plate C3BA005 9151 C3BA020 9151 38 1 Ratchet disk C3BA005 9152 C3BA020 9152 C3BA005 9152 39 1 Bushing C3BA005 9154 C3BA020 9154 40 1 Hand wheel C3BA005 9115 C3BA015 9115 C3BA020 9115 C3BA025 9115 41 1 Wheel stopper C1FA005 9159 C1FA015 9159 42 1 Wheel stopper pin C3BA005 9167 43 1 Split pin J1PW01 020008 44 1 Wheel cover assembly C3BA005 5171 C3BA015 5171 C3BA020 5171 C3BA025 5171 45 3 Nut J1NA001...

Page 40: ...2 06006 J1GR002 06007 16 1 Ball bearing J1GR002 06006 J1GR002 06007 17 1 Pinion C3BA015 9111 C3BA025 9111 18 1 Roller bearing C3BA005 9130 C3BA020 9130 19 1 Snap ring C3BA005 9118 C3BA020 9118 20 2 Guide roller C3BA015 9161 C3BA025 9161 21 1 Stripper C3BA015 9162 C3BA025 9162 22 1 Anchorage C3BA015 9176 C3BA025 9176 23 1 Stopper pin C3BA015 9177 C3BA025 9177 24 1 Splint pin J1PW01 025015 J1PW01 02...

Page 41: ...C3BA075 9011 C3BA100 9011 C3BA150 9016 59B 1 Top yoke B C3BA075 9012 C3BA100 9012 C3BA150 9017 60 1 Socket bolt J1BE1 120404 5 J1BE1 120404 61 1 Lever nut C2BA400 9074 5 C2BA400 9074 2 Socket bolt J1BE1 1606060 2 U nut C3BA100 9087 62 2 Top suspension shaft C3BA150 9010 C3BA200 9010 63 2 Top yoke C3BA200 9011 64 1 Top plate A assembly C3BA150 5012 C3BA200 5012 1 Top plate B C3BA150 9014 65 4 Guide...

Page 42: ...A050 90411 107 1 Slotted nut C2BA015 90491 C3BA020 90492 108 1 Split pin J1PW01 020014 J1PW01 020014 109 1 Nameplate B C3BG030 9800 C3BG050 9800 C3BG075 9800 C3BG100 9800 C3BG150 9800 2 C3BG200 9800 110 1 Load chain K7UN071 00000 K7UN090 J00000 111 1 Hand chain K7NA050 00000 2 K7NA050 00000 114 1 Stopper assembly ER1ES10411 2 ER1ES10411 115 1 Washer C3BG005 9158 116 1 Nameplate C C3BA030 9805 Spar...

Page 43: ... GHH5A022T JHH5A022T KHH5A022T LHH5A022T NHH5A022T KHH5A022T 24 1 Wheel side plate assembly GHH5024U JHH5024U KHH5024U LHH5024U NHH5024U KHH5024U 25 1 Hand wheel GHH5A025 JHH5A025 KHH5A025 LHH5A025 NHH5A025 KHH5A025 27 1 Gear cover GHH5A027T JHH5A027T KHH5A027T LHH5A027T NHH5A027T KHH5A027T 28 1 Hand wheel cover GHH5028 JHH5028 KHH5028 LHH5028 NHH5028 KHH5028 32 1 Top hook assembly GHH5032U JHH503...

Page 44: ...44 10 ton N100 16 ton N160 44 ...

Page 45: ...45 20 ton N200 25 ton N250 45 ...

Page 46: ... Side plate for yoke UHH5A0381 VHH50381 WHH50381 XHH50381 38 4 Top cross UHH5A0384 VHH50384 WHH50384 XHH50384 38 5 Stay bolt A for yoke UHH5A0385 VHH50385 WHH5006A 38 6 Stay bolt B for yoke VHH50386 WHH5006B WHH5009B 38 7 Stay bolt C for yoke VHH50387 38 8 Stay pipe for yoke VHH50388 WHH50388 WHH5010 38 9 Chain guide roller UHH5A0389 VHH50389 WHH50389 VHH50389 38 11 Joint plate UHH5A03811 38 12 Ce...

Page 47: ...12X35 114 Nylon nut HNNIM12 115 Spring nut HUNIM12L 121 Hexagon socket bolt CBM16X40 122 Nylon nut HNNIM16 123 Thrust BT51110 BT51112 BT51115 124 Bottom holder bolt SHH5048 125 Hexagon U nut HUNIM12L HUMIM12L 131 Hexagon nut HNIM20 HNIM24 132 Spring washer SWM20 SWM24 133 Hexagon nut HNIM16 134 Spring washer SWM16 135 Hexagon nut HNIM16 136 Spring washer SWM16 137 Cotter pin SP8X70 140 Hexagon nut...

Page 48: ...Tip The shown position numbers are in accordance with chapter 3 9 2 Low headroom Low headroom manual push 81300 model N 81310 model K Pos Qty Consisting of 6 kN 11 kN 22 kN 33 kN 52 kN 104 kN 1 4 Single flange wheel Bearing Circlip 3 4 Wheel shaft Hexagon lock nut Circlip 5 1 Hoist See chapter 11 1 1 Model K hoist or 11 1 2 Model N hoist 13 4 Buffer Hex head bolt Spare parts table 9 48 ...

Page 49: ... N hoist 10 1 Hand chain 11 1 Hand chain wheel Hand chain guide 12 1 Drive shaft Pinion Spring pin 13 4 Buffer Hex head bolt 14 2 Single flange geared wheel Bearing Circlip Spare parts table 10 11 3 Ultra low headroom Below illustration shows the spare part of an geared ultra low headroom hoist trolley unit and shall be used in combination with spare parts table 11 Tip The shown position numbers a...

Page 50: ...le flange geared wheel Bearing Circlip 3 4 Wheel shaft Hexagon lock nut Circlip 7 1 Bottom hook block Load hook 9 1 Hand chain 11 1 Hand chain wheel Hand chain guide 12 1 Hoist See chapter 11 1 1 Model K hoist or 11 1 2 Model N hoist 13 1 Drive shaft Pinion Spring pin 14 4 Buffer Hex head bolt 14 2 Single flange geared wheel Bearing Circlip Spare parts table 11 50 ...

Page 51: ...51 Appendix I Logbook The following table can be used to write down the results of installation commissioning maintenance repairs etc Date Inspected by Results 51 ...

Page 52: ...52 Appendix II Technical specifications If applicable the technical documentation will be included as a separate document 52 ...

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