Street Crane ZX6 Installation, Operation And Maintenance Instructions Download Page 7

Page: 7 / 103

VII

5.10.8

Brake

rectifier

...........................................................................................................................

5.11

INSPECTION

AND

MAINTENANCE

–

TRAVERSE

BRAKE

......................................................................

5.11.1

Traverse

Brake

Components

....................................................................................................

5.11.2

Checking

Adjusting

the

Air

Gap

..............................................................................................

5.11.3

Changing

the

Brake

Disc

(brake

rotor)

Inspecting

the

brake

hub

..........................................

5.11.4

Fitting

the

Traverse

Drive

Hand

Release

..................................................................................

5.11.5

Fitting

the

brake

seal

kit

(optional)

..........................................................................................

5.12

INSPECTION

AND

MAINTENANCE

–

HOOK

BLOCK

.............................................................................

5.13

INSPECTION

AND

MAINTENANCE

–

HOIST

DRIVE

COUPLING

............................................................

FAULT

FINDING

..................................................................................................................................

6.1

GENERAL

.................................................................................................................................................

6.2

BRAKES

....................................................................................................................................................

6.3

MOTOR

UNITS

.........................................................................................................................................

6.4

GEARBOXES

.............................................................................................................................................

TECHNICAL

DATA

................................................................................................................................

7.1

CONDITIONS

USE

...............................................................................................................................

7.2

PROCEDURE

FOR

ESTIMATING

REMAINING

SERVICE

LIFE

......................................................................

7.3

HOIST

MODEL

CODE

...............................................................................................................................

7.4

NOISE

LEVELS

..........................................................................................................................................

7.5

HOIST

MOTOR

DATA

...............................................................................................................................

7.5.1

ZX06

Hoist

Motor

Data

–

3:1

SPEED

RATIO

‐

400V,

3Ph,

50Hz

......................................................

7.5.2

ZX08

Hoist

Motor

Data

–

4:1

SPEED

RATIO

‐

400V,

3Ph,

50Hz

......................................................

7.5.3

ZX06

Hoist

Motor

Data

–

3:1

SPEED

RATIO

–

460V,

3Ph,

60Hz

.....................................................

7.5.4

ZX08

Hoist

Motor

Data

–

4:1

SPEED

RATIO

‐

460V,

3Ph,

60Hz

......................................................

7.5.5

ZX06

Hoist

Motor

Data

–

3:1

SPEED

RATIO

‐

575V,

3Ph,

60Hz

......................................................

7.5.6

ZX08

Hoist

Motor

Data

–

4:1

SPEED

RATIO

‐

575V,

3Ph,

60Hz

......................................................

7.5.7

ZX06

Hoist

Motor

Data

–

3:1

SPEED

RATIO

‐

380(±10%)V,

3Ph,

60Hz

.........................................

7.5.8

ZX08

Hoist

Motor

Data

–

4:1

SPEED

RATIO

‐

380(±10%)V,

3Ph,

60Hz

.........................................

7.5.9

Dual

Wound

‘WU’

Type

Traverse

Motor

Data

‐

400V

50Hz

......................................................

7.5.10

Dual

Wound

‘WU’

Type

Traverse

Motor

Data

‐

460V

60Hz

.................................................

7.5.11

Dual

Wound

‘WU’

Type

Traverse

Motor

Data

‐

575V

60Hz

.................................................

7.5.12

Dual

Wound

‘WU’

Type

Traverse

Motor

Data

‐

380V

60Hz

.................................................

7.5.13

Traverse

Motor

Data

for

use

with

Frequency

Inverter

........................................................

7.6

CABLE

CROSS

SECTION

AND

LENGTH

SUPPLY

CABLE

........................................................................

7.7

RESULTS

PERIODIC

TESTS

..................................................................................................................

7.8

RECORD

REPLACEMENT

PARTS

(ropes,

brakes,

sheaves

etc.)

...........................................................

FIGURES

Figure

–

Hoist

Nameplate

Location

....................................................................................................................

Figure

–

Single

Girder

Fall

Traverse

End

Stops..........................................................................................

Figure

–

Double

Girder

Traverse

End

Stops

.......................................................................................................

Figure

–

Single

Girder

Runway

Tolerances

.........................................................................................................

Figure

–

Double

Girder

Runway

Tolerances

.......................................................................................................

Figure

–

Low

Headroom

4&8

Fall

Lifting

Points

.................................................................................................

Figure

–

Double

Girder

Crab

Lifting

Points

–

fall

units

.............................................................................

Figure

–

Foot

Mounted

Lifting

Points

.................................................................................................................

Summary of Contents for ZX6

Page 1: ... INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS 65656defgh Street Crane Company Limited reserves the right to alter or amend the details given in this publication without prior notification Street Crane Company Limited 2014 Document Ref D3256 rev B ...

Page 2: ......

Page 3: ...r ensuring that the equipment is properly inspected and maintained and is safe to use NOTE Other national regulations may apply for other countries In Great Britain codes of practice exist for the Safe Use of Cranes This standard BS 7121 also covers inspection testing and examination The user should be familiar with its contents and it is advisable to have a copy of this standard kept alongside th...

Page 4: ...defgh Street Crane Co Ltd IV THIS PAGE IS INTENTIONALLY BLANK ...

Page 5: ...heel running surfaces and guidance surfaces 18 3 3 HOIST WEIGHTS AND LIFTING POINTS 18 3 3 1 Low Headroom 18 3 3 2 Double Girder Crab 19 3 3 3 Foot Mounted 20 3 4 INSTALLATION OF LOW HEAD 4 8 FALL SINGLE GIRDER HOIST 21 3 4 1 Setting the Reaction Roller 23 3 5 INSTALLATION OF FOOT MOUNTED HOIST 24 3 6 SETTING THE UPPER AND LOWER LIMIT SWITCHES ROPE GUIDED 25 3 6 1 Setting the lower limit 25 3 6 2 ...

Page 6: ...ER FAILURE 46 5 INSPECTION AND MAINTENANCE INSTRUCTIONS 47 5 1 REPORTING OF DEFECTS AND INCIDENTS 47 5 2 SPECIAL KNOWLEDGE 47 5 3 KEEPING OF RECORDS 47 5 4 DAILY PRE USE INSPECTIONS at the start of each day shift 47 5 5 HOISTS THAT HAVE BEEN UNUSED FOR AN EXTENDED PERIOD 48 5 6 INSPECTION AND MAINTENANCE INTERVALS 49 5 7 LUBRICATION 52 5 7 1 Lubrication Schedule 54 5 8 INSPECTION AND MAINTENANCE W...

Page 7: ...SPEED RATIO 460V 3Ph 60Hz 87 7 5 5 ZX06 Hoist Motor Data 3 1 SPEED RATIO 575V 3Ph 60Hz 88 7 5 6 ZX08 Hoist Motor Data 4 1 SPEED RATIO 575V 3Ph 60Hz 88 7 5 7 ZX06 Hoist Motor Data 3 1 SPEED RATIO 380 10 V 3Ph 60Hz 89 7 5 8 ZX08 Hoist Motor Data 4 1 SPEED RATIO 380 10 V 3Ph 60Hz 89 7 5 9 ZX Dual Wound WU Type Traverse Motor Data 400V 50Hz 90 7 5 10 ZX Dual Wound WU Type Traverse Motor Data 460V 60Hz...

Page 8: ... 31 ZX6 Gearbox oil fill level plug locations 52 Figure 32 ZX8 Gearbox oil fill level plug locations 53 Figure 33 Correct Uncoiling of Wire Ropes 57 Figure 34 Incorrect Uncoiling of Wire Ropes 57 Figure 35 Winding of new wire ropes 57 Figure 36 Fleet angle 58 Figure 37 Reeving Diagrams for ZX6 ZX8 4 8 Fall Low Head Crab Hoists 59 Figure 38 Reeving Diagrams for Foot Mount Hoists ZX084 FTM ZX088 FTM...

Page 9: ...efgh Street Crane Co Ltd IX Figure 57 Traverse Drive Brake Seal 73 Figure 58 Hook Throat Admittance 74 Figure 59 4 Fall Bottom Block Hook Nut Grubscrew Grease nipple 75 Figure 60 Sound Pressure Levels 85 ...

Page 10: ...2006 Also ISO 15513 gives competency requirements for crane drivers operators slingers signallers and assessors In the text of this manual the following definitions apply User person or organisation that has control of both the lifting operation and the crane operator and has the responsibility to ensure the equipment is properly maintained and thoroughly examined by a competent person Competent P...

Page 11: ...Number of personnel who require access at high level Total weight of any parts to be removed replaced Provision of safety harness anchor points 1 5 WARRANTY REPLACEMENT PARTS The warranty will become invalid if the instructions for installation operation and maintenance instructions contained in this manual are not followed Where replacement components are required use only genuine Street Crane pa...

Page 12: ...acity or Safe Working Load SWL The rated capacity is clearly marked on the hoist nameplate and the bottom block 1 Hoist motor 6 Control panel 11 Upper level limit switch 2 Hoist brake 7 Travel drive 12 Lower level limit switch 3 Wire rope 8 Reaction roller LH only 13 Rope guide 4 Bottom block 9 Travel wheels 14 Rope clamps 5 Hoist gearbox 10 Rated capacity limiter 15 Sheave assembly ZX8 4 FALL LOW...

Page 13: ...defgh Street Crane Co Ltd Ref D3256 rev B Page 13 of 103 ZX8 4 FALL CRAB ZX6 4 FALL CRAB ZX8 8 FALL CRAB ZX8 4 FALL FOOT MOUNT ZX6 4 FALL FOOT MOUNT ...

Page 14: ...mation The hoist model code The manufacturers name The serial number The year of manufacture Hoist classification Mechanism classifications The information on this nameplate will be required when ordering replacement parts and when assessing the remaining service life of the hoist Further information on the hoist model code can be found in section 7 3 Figure 1 Hoist Nameplate Location ...

Page 15: ...quire the hook block to be lowered manually and the limit re set If the second hoist upper limit operates the hoist should be taken out of service until the reason for the normal upper limit switch failure has been investigated The failure should be rectified before putting the hoist back into service The second hoist upper limit when tripped will prevent movement from all hoist and traverse motio...

Page 16: ...rry out any alterations or modifications to the hoist either prior to or during installation If the hoist is located outdoors we recommend that a small cover roof is fitted to the runway beam to protect the hoist at its parking position 3 1 TRAVERSE END STOPS Single girder 4 8 fall low head hoists require end stops to be mounted on either end of the runway and include rubber buffers as shown Weld ...

Page 17: ...ge shall not deviate from the nominal by more than 3mm The difference in rail height shall not exceed 3mm for gauges up to and including 2000mm or 5mm for gauges greater than 2000mm Rail height should be a minimum of 30mm 3 2 3 Tolerances on Single Girder Runway Flange Width The variation in the width of a single girder runway flange should be no greater than 3mm over its entire length 3 2 4 Toler...

Page 18: ... than 0 5mm Lateral misalignment in double girder rail joints L1 should not exceed 1mm NOTE Runway joint splice plates on the bottom flange are not possible with ZX6 ZX8 single girder low headroom hoists because of the hoist reaction roller Figure 4 Single Girder Runway Tolerances Figure 5 Double Girder Runway Tolerances 3 3 HOIST WEIGHTS AND LIFTING POINTS 3 3 1 Low Headroom Figure 6 Low Headroom...

Page 19: ... hoist cover top section and tighten setscrews to 15Nm 3 3 2 1 Table of weights Double Girder Crab Ø8 Rope Ø13 Rope 4 Fall 8 Fall 4 Fall NB LB ELB NB LB ELB NB LB ELB ZX6 405 441 499 ZX8 PARALLEL ARRANGEMENT CRB 1400 GAUGE 973 1045 1237 1064 1163 1373 1015 1121 1303 ZX8 PERPENDICULAR ARRANGEMENT CRE 1400 GAUGE 965 1056 1008 2000 GAUGE 1003 1056 1209 1094 1174 1345 1045 1133 1276 2600 GAUGE 1040 10...

Page 20: ...able of weights Foot Mounted Ø8 Rope Ø13 Rope 4 Fall 8 Fall 4 Fall NB LB ELB NB LB ELB NB LB ELB ZX6 288 314 361 ZX8 656 714 875 731 812 985 699 790 941 Weights shown for each model in kg do not include any optional extras 1 The lifting lugs fitted to the hoist unit are designed for lifting the mass of the hoist unit ONLY ...

Page 21: ...the reaction roller assembly from the wheel support casting by removing the circlip and washer on the end of the pin Withdraw the reaction roller assembly from the wheel support casting see Figure 10 Figure 10 Withdrawing the Reaction Roller Raise the hoist to runway level use the lifting lugs provided see Figure 6 Push the barrel side trolley onto the runway flange until the hoist side guide roll...

Page 22: ...in turn and tighten until a centre pop indent is made in the hoist legs Using a 10mm diameter drill drill a full cone of 10mm diameter into both legs at four positions see Figure 12 Remove any swarf from the holes using a magnet Replace cone point setscrew in its storage position securing with the locknut Figure 12 Setting the Low Headroom Legs Replace each of the four M12 locking grub screws and ...

Page 23: ... underside of the runway beam directly below the traverse drive wheel If the roller assembly has not been replaced rotate the assembly until the location pin aligns with the hole in the body casting red adjusting spring facing horizontally outwards Push the pin into the hole and attach the washer and circlip the washer sits directly behind the circlip Figure 14 Reaction Roller Ensure that the trav...

Page 24: ...n Figure 15 Installation of Foot Mounted Hoist Foot mounted hoist units are supplied with four mounting feet On 4 8 fall units each foot has a single 22mm diameter hole They should be secured to a suitable supporting structure using four M20 fixings with minimum grade of 8 8 1 The supporting structure should be suitably designed to support both the mass of the hoist unit together with its rated ca...

Page 25: ...se the grub screws that secure the holding arm to the limit bars and slide the switch towards the end of the hoist Lower the hook to the desired lowest operating position Do not let the hook touch the floor such that it would cause the ropes to go slack NOTE The clearance between the rope guide and the rope clamps should not be less than 10mm when the hook is at its lowest position Slide the limit...

Page 26: ...tion as the Ultimate limit option Open barrel TVL hoists do not have a Rotary Ultimate Limit option 3 7 1 Setting the Hoist Upper limit Raise the hook to the desired operating position at slow speed with no load attached allowing an additional 50mm for a fast speed approach 1 The upper hook level for low headroom hoists vary with the runway flange width The hoist will be seriously damaged if the h...

Page 27: ... 18 Ultimate Upper Limit Switch Rotary Type 3 8 1 Setting the ultimate upper limit 1 Extreme care must be exercised when testing the ultimate limit switch as it is necessary to by pass the normal upper limit Reposition the normal upper limit such that the ultimate limit is the first to operate Raise the hook to the desired operating position at slow speed with no load attached allowing an addition...

Page 28: ...defgh Street Crane Co Ltd Page 28 of 103 Ref D3256 rev B Figure 19 Setting the Ultimate Upper Limit Switch Rotary Type ...

Page 29: ...ating position at slow speed with no load attached allowing an additional 50mm for a fast speed approach 1 The upper hook level for low headroom hoists vary with the runway flange width The hoist will be seriously damaged if the hook is set higher than the values indicated in section 3 10 Remove the bottom block trigger fixings such that the bottom block trigger can be split in two Position the bo...

Page 30: ... ZX8 4 FALL Ø13 1 To prevent accidental damage to the hoist unit all low headroom hoists are despatched from Street Crane with upper and lower limit switches set to suit a 500mm runway flange As part of the commissioning procedure the upper and lower limit switches should be adjusted to achieve the optimum C DIMENSION for the runway flange width see 3 6 ...

Page 31: ...OUNT HOIST FALLS ROPE Ø BARREL C DIMENSION mm DATASHEET ZX6 4 8Ø NB LB ELB 479 DZX 1244 ZX8 FOOT MOUNT HOIST FALLS ROPE Ø BARREL C DIMENSION mm DATASHEET ZX8 4 Ø 8 NB LB ELB 461 DZX 1377 ZX8 4 Ø13 NB LB ELB 714 DZX 1385 ZX8 8 Ø 8 NB LB ELB 991 DZX 1393 3 12 DOUBLE GIRDER PARALLEL CRAB HIGHEST HOOK POSITION ZX6 ZX8 ...

Page 32: ... GAUGE HOIST FALLS ROPE Ø BARREL C DIMENSION mm DATASHEET ZX8 4 Ø8 NB LB ELB 169 DZX 1329 ZX8 4 Ø13 NB LB ELB 217 5 DZX 1337 ZX8 8 Ø8 NB LB ELB 535 DZX 1361 3 13 DOUBLE GIRDER PERPENDICULAR CRAB HIGHEST HOOK POSITION ZX8 ZX8 DOUBLE GIRDER PERPENDICULAR CRAB 1400 2600mm GAUGE HOIST FALLS ROPE Ø BARREL C DIMENSION mm DATASHEET ZX8 4 Ø8 NB LB ELB 169 DZX 1345 ZX8 4 Ø13 NB LB ELB 217 5 DZX 1353 ZX8 8 ...

Page 33: ...ear of the floor with the test load attached The limit does not require any adjustment if the hoist picks up its rated capacity SWL but does not lift the rated capacity 10 SWL 10 If the limit trips either below or above these limits adjust the limit by turning the grub screw 3 14 1 Adjusting the Rated Capacity Limiter for Proof Loading For proof load testing of a hoist or crane at a load greater t...

Page 34: ... two stage limit employs two actuating arms at each end of travel NOTE On each of the above when the limit is tripped normal operation is available in the opposite direction Reversing away from the stop is at the speed selected by the operator slow or fast 3 15 1 Setting traverse limits To ensure reliable operation of the switch the actuating arm should be positioned to strike the limit bar as sho...

Page 35: ...ement See Figure 21 for setting dimensions When setting the point of operation for the limit switch account should be taken of the hoist speed and the stopping distance The point of operation should be set to allow a fully loaded crane hoist to stop from fast speed before reaching the required position ...

Page 36: ...olator supply switch by others The main isolator supply switch must disconnect all phases of the supply to the hoist must be clearly marked and located in an easily accessible position The switch should be capable of being locked in the OFF position whilst any maintenance work is being carried out The main isolator if reasonably accessible may also be used for emergency stop or emergency off purpo...

Page 37: ...B Page 37 of 103 Figure 24 Delay Timers Figure 25 Phase Failure Relay POTENTIOMETER SETTINGS Supply H1 H2 380V 50Hz 12 5 12 5 380V 60Hz 15 15 400V 50Hz 12 5 12 5 415V 50Hz 12 5 12 5 440V 50Hz 12 5 12 5 460V 60Hz 12 5 12 5 575V 60Hz 12 5 12 5 ...

Page 38: ...16 5 Connecting the Pendant controller Low Headroom Where a control pendant is to be attached directly to a low headroom hoist it must be supported by the two strainer wires on either side of the pendant cable The electrical cable or terminals must not support any load Connect the two pendant strainer wires to the M6 screws on the suspension bracket as shown Tighten the M6 fixings to 9Nm Connect t...

Page 39: ...ion see the instructions for by pass of the RCL in section 3 14 1 Run the hoist several times under light load approx 10 of SWL and at slow speed to allow the wire rope to bed down and improve its service life After the running in period check that the wedge and rope has seated correctly in the socket Remove any twist imparted in the rope during installation see section 5 8 2 6 The hoist is now re...

Page 40: ...ne or hoist if any defects are found which may compromise safety The following information serves as a guide for safe hoisting practices and an operator adhering to these will quickly find that he she is able to work both smoothly and quickly without prejudicing safety and equipment 1 Know where the safety fire and first aid equipment is located and how to use it 2 Ensure that no one is working on...

Page 41: ...here necessary 3 Do not move the loads over the heads of other personnel 17 Do not run the hoist or crane into the travel stops at full speed Ensure that the rubber buffer is in place and not damaged 18 Ensure that adequate clearance is maintained between the load or lifting attachment and the hoist or crane structure See Figure 28 Figure 28 Clearances to consider when lifting 19 Ensure that you c...

Page 42: ...switch and for short periods retain the key in their possession For longer periods or when the crane is not in use the transmitter should be deposited in a designated safe storage place When the transmitter is fitted with a belt or harness the operator should be wearing the harness before switching the transmitter on This will prevent accidental operation of the crane hoist whilst fitting The tran...

Page 43: ...egends To improve safety in operation there are directional identification legends on the crane that correspond to the legends on the controller 4 4 2 Switch ON Establish power supply to the conductors via the main isolator this may be located on a wall or supporting column Release the emergency stop button on the controller Momentarily depress the ON pushbutton This will energise the crane hoist ...

Page 44: ...n Speed When the motion is active press the button in to the first stage Change Speed Slow to Fast To change from slow speed to fast speed push the pushbutton fully in to the second stage The motion will accelerate toward maximum speed Hold Speed To maintain desired speed reduce pressure on the pushbutton and allow it to come out to the first stage Reduce Speed From Fast speed To reduce speed rele...

Page 45: ... fast speed move the joystick fully to the second stage The motion will accelerate toward maximum speed Hold Speed To maintain desired speed reduce pressure on the joystick and allow it to come out to the first stage Reduce Speed From Fast speed To reduce speed release pressure on the joystick completely and re engage to first stage when the motion decelerates to the desired speed The motion will ...

Page 46: ... periods the key should be placed at the authorised storage point 6 For long periods and for out of service conditions switch the mains isolator to the OFF position 7 For outdoor cranes hoists attach the storm anchors 4 6 POWER FAILURE The appointed person should establish a safe operating procedure in the event of a power failure If the appointed person does not have such a procedure the followin...

Page 47: ...unctions requiring adjustments or repairs and the need to bring these to the attention of the competent person for corrective action The crane hoist and associated equipment should undergo daily visual and functional checks to ensure that they operate correctly These can be executed by the operator from floor level 1 In the event of a malfunction of equipment or unusual occurrences the operator sh...

Page 48: ...s depends on the length of time the crane has been out of service and the location of the crane during that period As a minimum the pre use checks should include the daily pre start inspections mentioned above plus the following 1 Check all ropes for signs of corrosion degradation and damage and that there is still adequate rope lubricant Check the entire length of the rope 2 Check that the RCL ra...

Page 49: ...ss of the wedge fitting Check the security of the rope anchors on the barrel Replace any damaged parts M3 M4 M5 M6 M7 M8 ROPE GUIDE Examine for signs of wear or damage particularly around the rope exit entry point Check security of guide bar and other fixings Ensure that the guide bush travels freely and operates the upper and lower hoist limit switches correctly M3 M4 M5 M6 M7 M8 BOTTOM BLOCK Che...

Page 50: ... and rubber buffers Replace if damaged M3 M4 M5 M6 M7 M8 HOIST STRUCTURE Visually inspect overall structure for damage and unusual rubbing marks Check rail for wear or localised damage Check security of a reasonable quantity of the bolts in particular those that are not pen marked or where the pen mark has been disturbed Check security of the grub screws on the hoist low head frame trolley legs se...

Page 51: ...EARTH CONTINUITY AND INSULATION RESISTANCE Carry out earth continuity and insulation resistance tests on the installation M3 M4 M5 M6 M7 M8 HOIST AND LOWER LIMIT SWITCHES Inspect for wear or damage Check for correct operating position Check that the limit bush travels satisfactorily along the limit bush bar see section 3 6 Check the operation of the second upper limit where fitted see section 3 7 ...

Page 52: ...low Wear eye protection Always wash hands thoroughly after use Obtain first aid treatment for any injury however slight Dispose of the lubricant and its containers in the recommended manner Do not allow the lubricant to contaminate water supplies General All gearboxes must be at standstill when oil filling Use only fresh oils greases Do not mix oils and greases of different types and manufacturers...

Page 53: ...defgh Street Crane Co Ltd Ref D3256 rev B Page 53 of 103 ZX8 Hoists with angled position gearbox ZX8 Hoists with horizontal position gearbox Figure 32 ZX8 Gearbox oil fill level plug locations ...

Page 54: ... C Drop point 180 C Operating temperature range 10 to 120 C M4 M5 M6 M7 M8 HOIST ROPE Clean the rope surface before applying new lubricant This is particularly important in environments containing abrasive particles For maximum effect the lubricant is best applied to the rope where it opens up as it travels over a sheave or winds on the barrel Intervals of lubrication are given for general guidanc...

Page 55: ...ange is due at 500 hours of operation Thereafter replace the oil every 3000 operating hours or every 5 years Fill to the level plug See table below for lubricant quantity Traverse Drive Gearbox Ref see nameplate Lubricant Qty litres SK01 0 25 SK172 0 35 SK250 1 4 SK373 0 55 SK2282 1 65 M3 ISO VG220 mineral oil for ambient operating temperatures of 10 to 40 C ISO VG220 synthetic oil for ambient ope...

Page 56: ... carried out 5 8 2 Replacing the Wire Rope 1 Removal and replacing the wire rope is most effectively carried out with the power to the hoist unit switched ON so all work must be carried out with extreme care Suitable safety precautions should be made to ensure that other motions are not accidentally activated i e isolate any travel motions It may be necessary to adjust the lower limit to allow the...

Page 57: ...spool and the tail end away from the hoist together until the spool is empty note that the distance you need to travel with the spool will be half the total rope length You should now have two equal length tail ends and the centre of the rope over the compensating sheave With the bottom block positioned under the hoist in the correct orientation bring both tail ends back to the hoist ensuring that...

Page 58: ...that represents the HOL of the hoist Pull the tail end from the spool and pass through the first sheave of the bottom block Then back to the hoist and over the outer most of the twin sheave assembly closest to the spool side of the hoist Back to the bottom block and through the inner sheave on the opposite side to that of which is already reeved Back to the hoist and over the compensating sheave s...

Page 59: ...of 103 Figure 37 Reeving Diagrams for ZX6 ZX8 4 8 Fall Low Head Crab Hoists Low Head Hoists ZX064 LHR ZX084 LHR ZX088 LHR Crab Hoists ZX064 CRB ZX084 CRB ZX084 CRE ZX088 CRB ZX088 CRE Figure 38 Reeving Diagrams for Foot Mount Hoists ZX084 FTM ZX088 FTM ...

Page 60: ...defgh Street Crane Co Ltd Page 60 of 103 Ref D3256 rev B Figure 39 Reeving Diagrams for Foot Mount Hoists ZX064 FTM ...

Page 61: ...t and untwist by letting the rope hang freely or laying the rope out on the floor 1 Remove any twist before the hoist is subject to any further load The rope may otherwise be permanently damaged 5 8 3 Fitting the Rope Guide Fit the top and bottom halves of the rope guide inner band over the rope ensuring correct orientation NOTE the reduced diameter of the Band faces TOWARDS the end of the drum Fi...

Page 62: ...one or both plastic washers from the inner band joint Figure 42 Rope Guide Inner Band Fitted Lightly lubricate the location groove on both halves of the outer band see section 5 7 1 Fit the bottom half of the outer band tapped joint holes over the inner band and rotate until it is on the underside of the barrel ensuring that the slot collects the rope which leaves the barrel see Figure 43 Figure 4...

Page 63: ...t pen marked or where the pen mark has been disturbed 5 9 1 Sheaves Check all rope sheaves for wear and for free running The sheaves should rotate freely when rotated without load The sheave must be replaced if the wear on the groove side wall or the groove base is significant Measure the thickness of the side wall and groove depth as shown and replace the sheave if the wear exceeds the values giv...

Page 64: ...eaction roller for wear When the diameter has reduced to the value given in the table below replace the wheels roller Wheel Low Head Hoist Reaction Roller Guide Roller Original diameter mm Replacement diameter mm Original diameter mm Replacement diameter mm Original diameter mm Replacement diameter mm 100 96 75 72 40 37 160 152 If a trolley wheel or roller needs replacing consult Street Crane 5 9 ...

Page 65: ... code see 7 3 When inspecting the brake particular attention should be made to checking the air gap and the condition of the rotor brake disc spline 5 10 1 Hoist Brake Components Figure 47 Hoist Brake Components Ref Description Ref Description 1 Armature plate 8b Stator brake seal optional kit 2 Brake hub 9 Hand release mechanism 3 Brake disc rotor 10 Hand release spring 4 Mounting Flange 11 Washe...

Page 66: ...r supply to the hoist and to the brake 5 10 3 Brake Disc Rotor Spline Check the brake disc and hub for wear on the spline teeth The end of the spline can be viewed from the end of the brake shaft If the brake is fitted with the seal end cap 8b this will have to be removed before inspection For a more detailed inspection the brake disc will have to be removed If the spline appears replace the brake...

Page 67: ...in the Hoist Brake Data table 5 10 2 the brake disc should be replaced Figure 50 Inspecting the Brake Disc Remove the outer brake seal where fitted and clean any brake dust from around the brake Loosen the assembly fixings evenly and remove them taking care to support the brake body Remove the brake body taking note of its orientation The brake rotor brake disc will now be exposed Withdraw the bra...

Page 68: ...sion springs 10 into the holes of the armature plate 1 Fit the washers 11 onto the hand release fixings 12 and assemble through the compression springs 10 and the stator 5 Fit the barrel nuts 13 into the holes provided in the hand release 9 Position the hand release 9 over the stator and tighten the hexagon screws 12 into the barrel nuts 13 until the armature plate moves towards the stator Adjust ...

Page 69: ...9 Brake rectifier type Normal full wave 14 630 32 016 BEG 161 270 OR B3 18464 CSA approved Force voltage full half wave B3 69500 CSA approved Testing the normal rectifier types 14 630 32 016 and B3 18464 With the brake connected to the rectifier check that the input voltage to the rectifier is correct at 220V The output measured at the brake coil terminals should be approximately 198V DC Testing t...

Page 70: ...ake rectifier is located in the motor terminal box 5 11 1 Traverse Brake Components Figure 53 Traverse Brake Components Ref Description Ref Description 1 Armature plate 8b Stator brake seal optional kit 2 Brake hub 9 Hand release mechanism 3 Brake disc rotor 10 Hand release spring 4 Mounting Flange 11 Washer 5 Stator 12 Hand release fixing 6 Hub circlip 13 Barrel nuts 7 Assembly screws 14 Adjustme...

Page 71: ...ll screw the adjustment tubes out of the stator Adjust the air gap until a gap of 0 2 0 3mm is reached around the brake Re tighten the assembly fixings to 3Nm Re check the air gap and repeat the adjustment procedure if necessary Test the brake for correct operation before replacing the outer brake seal where fitted the fan cowl and returning the drive into service Figure 55 Adjusting the Traverse ...

Page 72: ...ration before returning into service 5 11 4 Fitting the Traverse Drive Hand Release For safety reasons the hand release is spring loaded and returns to its original position brake applied automatically Insert the compression springs 10 into the holes of the armature plate 1 Fit the washers 11 onto the hand release fixings 12 and assemble through the compression springs 10 and the stator 5 Fit the ...

Page 73: ...ling ring Drop the outer brake seal 8a over the hand release lever and push the sealing ring over the stator Press the lips of the seal into the grooves into the stator 1 and the mounting flange 4 see Figure 57 Tap the stator brake seal 8b into the hole in the front of the stator Press the motor fan onto the motor shaft and replace the motor fan cowl Figure 57 Traverse Drive Brake Seal ...

Page 74: ...gure 58 Replace the complete bottom block where t max has been exceeded Figure 58 Hook Throat Admittance Example from hoist model code ZX064 3EoNM5K031 LHR0002 40050E14X HOIST MODEL TYPE NO FALLS Rope Ø t t max w ref only New Hook mm mm mm ZX06 4 Ø8 50 55 38 ZX08 4 Ø8 50 55 38 4 Ø13 56 61 6 73 8 Ø8 56 61 6 73 Check that the safety catch operates and springs fully closed against the hook point Chec...

Page 75: ...defgh Street Crane Co Ltd Ref D3256 rev B Page 75 of 103 Figure 59 Bottom Block Hook Nut Grubscrew Grease nipple ...

Page 76: ... the four retaining nuts and spring washers that fasten the motor to the gearbox 1 NOTE A hoist motor can weigh up to 120kg see HOIST MOTOR DATA 7 5 Carefully withdraw the motor noting the orientation of the motor terminal box Remove the motor complete and replace the coupling element with new If the coupling body is damaged or loose on the shaft and has to be changed consult the manufacturer befo...

Page 77: ...heck that the power supply is correct and the equipment is switched ON Phase monitoring relay not set correctly Check settings on relay as section 3 16 3 Emergency stop activated Release emergency stop First ensure that the emergency stop button has not been depressed because of a fault Pendant or switchgear fault Check condition of pushbuttons pendant wiring and switchgear After a long period out...

Page 78: ...nt temperature is within the design range Consult Street Crane Voltage to the brake coil is too high Check function of the rectifier and supply to the rectifier Brake slow releasing Faulty rectifier or air gap too large Check the air gap and function of the rectifier Brake does not hold the load or excessive run through when stopping Air gap too large Check the working air gap Brake lining worn Ch...

Page 79: ...list Fuses blow or circuit breaker trips immediately Short circuit in the cable Repair the short circuit Short circuit in the motor or short circuit to earth Motor must be repaired by service specialist Motor overheats and thermal protection device trips Overload Ensure the motion is free and clear of all obstructions Inadequate cooling Ensure the cooling air passage is clear Ambient temperature t...

Page 80: ...e or irregular gearing Check oil and condition of gears and bearings Call customer service if noise persists Polluted oil or not enough oil Check oil oil level Oil is leaking from gearbox Defective seal Call customer service Oil is leaking at breather plug Excessive amount of oil in gearbox Correct the oil level Breather plug fitted incorrectly Fit breather plug correctly ...

Page 81: ... Mechanisms occasionally subjected to their maximum load and normally to rather light loads L3 heavy Mechanisms frequently subjected to their maximum load and normally to loads of medium magnitude L4 very heavy Mechanisms regularly subjected to their maximum load 2 Ascertain the classification of the hoist M The group classification of your equipment can be found on the equipment nameplate See sec...

Page 82: ... and when assessing the remaining service life of the hoist HOIST MODEL TYPE ZX06 or ZX08 NUMBER OF FALLS OF ROPE 1 2 4 6 or 8 HOIST MOTOR SPEED RATIO 1 Dual speed 10 1 inverter 2 Dual speed 20 1 ratio inverter 3 Dual speed 3 1 ratio 4 Dual speed 4 1 ratio 8 Dual speed 8 1 ratio GEARBOX So 99 1 ratio ZX6 139 1 ratio ZX8 Fo 80 1 ratio ZX6 115 1 ratio ZX8 Xo 64 1 ratio ZX6 97 1 ratio ZX8 Xa 97 1 rat...

Page 83: ...8 ZX08 H8 09 ZX08 H9 10 ZX08 H10 HOIST BRAKE SIZE 1 Type 12 46 20 180 2 Type 14 60 20 180 3 Type 14 60 25 180 4 Type 14 60 25 103 5 Type 16 80 25 103 6 Type 18 150 25 103 7 Type 20 315 35 103 8 Type 20 170 25 103 9 Type 20 315 25 103 HOIST GEARBOXES S Single gearbox BARREL ARRANGEMENT T Non Rope guided TVL R Rope Guided TVL S Standard reeving HOIST CONSTRUCTION FTM Foot mounted LHR Low head with r...

Page 84: ... AC SUPPLY FREQUENCY 50 50Hz 1 60 60Hz 1 COMPLIANCE E European directives CE U North America N Canada CSA Imperial D Canada CSA Metric C China CCL B Brazil CONTROL POTENTIAL 4 48V AC 1 110V AC MAX AMBIENT TEMPERATURE 4 40 C 5 50 C SPECIAL FEATURES X Consult Street Crane V Galvanising environment A Aggressive environment NAMEPLATE MAJOR REVISION REFERENCE DETAILS Revision Rv 1 for details of change...

Page 85: ... For measurement purposes the hoist unit was operated under normal loading conditions for a full operating cycle Distance from Sound Source metres Mean Sound Level dB A ZX6 ZX8 1 80 80 2 77 77 4 74 74 8 61 61 16 68 68 Figure 60 Sound Pressure Levels The sound pressure level is reduced by approx 3dB A each time the distance from the sound source is doubled ...

Page 86: ...0 8 0 53 7 5 2 ZX08 Hoist Motor Data 4 1 SPEED RATIO 400V 3Ph 50Hz Example from hoist model code ZX084 4EoN3AM6K071 SR LHR0002 40050E14X Hoist Motor Speed Ratio Motor Mass kg Motor Ratings at 400V 10 50Hz BS Class CDF S h Power FLC LRC Main Fuse Cos kW A A 06 4 50 110lb M3 17 8 50 100 9 1 2 3 21 0 8 8 61 17 5 32A 0 87 0 59 M4 20 10 60 120 8 4 2 1 18 9 8 3 0 87 0 56 M5 27 13 80 160 7 6 1 9 16 7 8 0...

Page 87: ... 5 4 ZX08 Hoist Motor Data 4 1 SPEED RATIO 460V 3Ph 60Hz Example from hoist model code ZX084 4EoN3AM6K071 SR LHR0002 46060U14X Hoist Motor Speed Ratio Motor Mass kg Motor Ratings at 460V 6 60Hz BS Class CDF S h Power FLC LRC Main Fuse Cos kW A A 06 4 50 110lb M3 17 8 50 100 10 9 2 8 21 0 8 8 61 17 5 32A 30A 0 87 0 59 M4 20 10 60 120 10 1 2 5 18 9 8 3 0 87 0 56 M5 27 13 80 160 9 1 2 3 16 7 8 0 0 87...

Page 88: ...6 ZX08 Hoist Motor Data 4 1 SPEED RATIO 575V 3Ph 60Hz Example from hoist model code ZX084 4EoN3AM6K071 SR LHR0002 57560N14X Hoist Motor Speed Ratio Motor Mass kg Motor Ratings at 575V 6 60Hz BS Class CDF S h Power FLC LRC Main Fuse Cos kW A A 06 4 50 110lb M3 17 8 50 100 10 9 2 7 18 3 8 0 62 17 25A 0 77 0 55 M4 20 10 60 120 10 0 2 5 17 0 7 8 0 77 0 53 M5 27 13 80 160 9 1 2 3 15 8 7 6 0 75 0 50 M6 ...

Page 89: ...atings at 380V 10 60Hz BS Class CDF S h Power FLC LRC Main Fuse Cos kW A A 06 4 50 110lb M3 17 8 50 100 9 1 2 3 22 2 10 9 86 25 9 40A 0 86 0 49 M4 20 10 60 120 8 4 2 1 20 1 10 6 0 80 0 48 M5 27 13 80 160 7 6 1 9 18 9 10 2 0 78 0 42 M6 34 17 100 200 6 8 1 7 16 6 10 2 0 80 0 40 M7 40 20 100 200 6 1 1 5 15 4 10 2 0 76 0 37 07 4 58 128lb M3 17 8 50 100 11 2 2 8 25 7 12 1 100 28 40A 0 83 0 53 M4 20 10 ...

Page 90: ...OWING HOIST MODELS ZX064 xxxxxxxxxx LHRxxx2 40050xxxx ZX064 xxxxxxxxxx CRBxxx2 40050xxxx Traverse Motor Motor Ratings at 400V 10 50Hz Motor Mass Classification CDF S h Power FLC LRC Cos Frame kg kW A A 80LWU 2 8 13 M3 M4 M5 20 10 80 160 0 60 0 13 1 63 0 74 4 85 1 18 0 9 0 7 29lb M6 27 13 100 200 0 55 0 13 1 47 0 74 M7 40 20 120 240 0 55 0 13 1 47 0 74 ABOVE MOTOR IS USED ON THE FOLLOWING HOIST MOD...

Page 91: ...LOWING HOIST MODELS ZX064 xxxxxxxxxx LHRxxx2 46060xxxx ZX064 xxxxxxxxxx CRBxxx2 46060xxxx Traverse Motor Motor Ratings at 460V 10 60Hz Motor Mass Classification CDF S h Power FLC LRC Cos Frame kg kW A A 80LWU 2 8 13 M3 M4 M5 20 10 80 160 0 65 0 15 1 39 0 68 4 52 1 09 0 9 0 7 29lb M6 27 13 100 200 0 63 0 15 1 37 0 68 M7 40 20 120 240 0 63 0 15 1 37 0 68 ABOVE MOTOR IS USED ON THE FOLLOWING HOIST MO...

Page 92: ...LOWING HOIST MODELS ZX064 xxxxxxxxxx LHRxxx2 57560xxxx ZX064 xxxxxxxxxx CRBxxx2 57560xxxx Traverse Motor Motor Ratings at 575V 10 60Hz Motor Mass Classification CDF S h Power FLC LRC Cos Frame kg kW A A 80LWU 2 8 13 M3 M4 M5 20 10 80 160 0 65 0 15 1 2 0 58 5 28 1 17 0 88 0 69 29lb M6 27 13 100 200 0 63 0 15 1 16 0 58 M7 40 20 120 240 0 63 0 15 1 16 0 58 ABOVE MOTOR IS USED ON THE FOLLOWING HOIST M...

Page 93: ...LOWING HOIST MODELS ZX064 xxxxxxxxxx LHRxxx2 38060xxxx ZX064 xxxxxxxxxx CRBxxx2 38060xxxx Traverse Motor Motor Ratings at 380V 10 60Hz Motor Mass Classification CDF S h Power FLC LRC Cos Frame kg kW A A 80LWU 2 8 13 M3 M4 M5 20 10 80 160 0 65 0 15 1 69 0 82 5 45 1 31 0 9 0 7 29lb M6 27 13 100 200 0 63 0 15 1 65 0 82 M7 40 20 120 240 0 63 0 15 1 65 0 82 ABOVE MOTOR IS USED ON THE FOLLOWING HOIST MO...

Page 94: ...1 xxxxxxxxx ZX084 xxxxxxxxxx CRBxxx1 xxxxxxxxx ZX084 xxxxxxxxxx CRExxx1 xxxxxxxxx ZX088 xxxxxxxxxx CRBxxx1 xxxxxxxxx ZX088 xxxxxxxxxx CRExxx1 xxxxxxxxx ZX088 xxxxxxxxxx LHRxxx1 xxxxxxxxx ZX084 xxxxxxxxxx LHRxxx4 xxxxxxxxx ZX084 xxxxxxxxxx CRBxxx4 xxxxxxxxx ZX084 xxxxxxxxxx CRExxx4 xxxxxxxxx ZX088 xxxxxxxxxx CRBxxx4 xxxxxxxxx ZX088 xxxxxxxxxx CRExxx4 xxxxxxxxx ZX088 xxxxxxxxxx LHRxxx4 xxxxxxxxx Tra...

Page 95: ...7 05 2 5 25 2 5 29 2 5 37 2 5 9 2 5 11 2 5 14 4 0 40 4 0 46 4 0 59 4 0 14 4 0 17 4 0 22 6 0 60 6 0 69 6 0 88 6 0 21 6 0 25 6 0 33 10 0 36 10 0 43 10 0 56 06 4 0 38 4 0 44 4 0 56 4 0 13 4 0 16 4 0 21 6 0 56 6 0 65 6 0 83 6 0 20 6 0 24 6 0 31 10 0 34 10 0 40 10 0 52 16 0 55 16 0 64 16 0 83 07 6 0 51 6 0 59 6 0 74 6 0 19 6 0 22 6 0 28 10 0 86 10 0 99 10 0 125 10 0 32 10 0 37 10 0 47 16 0 50 16 0 59 1...

Page 96: ...defgh Street Crane Co Ltd Page 96 of 103 Ref D3256 rev B 7 7 RESULTS OF PERIODIC TESTS HOIST SERIAL No Page No Date Defects found Remedial actions Estimated remaining service life see 7 2 Signature ...

Page 97: ...reet Crane Co Ltd Ref D3256 rev B Page 97 of 103 7 8 RECORD OF REPLACEMENT PARTS ropes brakes sheaves etc HOIST SERIAL No Page No Date Hours In Service Reading Part description Reason for replacement Signature ...

Page 98: ...defgh Street Crane Co Ltd Page 98 of 103 Ref D3256 rev B HOIST SERIAL No Page No Date Hours In Service Reading Part description Reason for replacement Signature ...

Page 99: ...defgh Street Crane Co Ltd Ref D3256 rev B Page 99 of 103 NOTES ...

Page 100: ...defgh Street Crane Co Ltd Page 100 of 103 Ref D3256 rev B NOTES ...

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Page 103: ...656565656565656565565656565656565656565656565656565656565656565656 Street Crane Company Limited Chapel en le Frith High Peak SK23 0PH UK email admin streetcrane co uk web www streetcrane co uk Telephone 44 0 1298 812456 Certificate No FM13635 ...

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