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TROLLEY

OPERATION & MAINTENANCE

P/N: 11854801 REV. AC

September 2017

MOTOR BRAKES

Standard motor brakes are DC rectified solenoid activated, spring

set disc type brakes. Brake is intended to be used strictly as a

holding brake and does NOT have any torque adjustment for

decelerating and stopping the crane. Deceleration and stopping is

to be provided by the variable frequency (inverter) motor control.

BRAKE AIR GAP INSPECTION

To inspect brake air gap refer to figure 6:

1. Disconnect and lock out power supply

2. Remove brake cover

3. Carefully roll the o-ring back towards the magnet body

exposing the air gap between the armature plate and magnet.

Use feeler gauge and measure the gap between the armature

plate and magnet. If gap exceeds maximum allowed, replace

the brake.

Motor

Horsepower

Normal Air

Gap

Maximum

Air Gap

Brake Mounting Bolt

Torque

0.75

.55

0.2 mm

(.008 in.)

0.3mm

(.012 in.)

3 Nm

(2.2 ft. lbs.)

1.0

.75

1.5

1.2

2.0

1.5

0.4 mm

(.016 in.)

3.0

2.2

4. Roll o-ring back into place and re-install brake cover.

5. Turn power back on to crane and test brakes for proper

operation.

BRAKE RECTIFIER REMOVAL

AND REPLACEMENT

Rectifier is located inside the motor conduit box cover. To replace

follow these steps:

1. Disconnect and lock out power supply.

2. Unplug motor leads and open conduit box.

3. Remove rectifier and unplug wires.

4. Plug wires into replacement rectifier.

a. Connect brake leads to DC side of rectifier, terminals marked

“+” & “–”.

b. Connect leads from the plug to the AC side, two terminals

marked “~”.

5. Re-assemble in reverse order disassembly.

6. Turn power onto crane and test for proper operation.

BRAKE REMOVAL AND REPLACEMENT

If brake air gap exceeds the maximum allowed, or is not functioning

properly, the brake may need to be replaced. Follow these

instructions.

1. Turn power off to crane and lock out

2. Unplug motor leads, open motor conduit box and disconnect

brake leads from rectifier

3. Remove brake cover

4. Remove retaining ring and fan (if applicable).

5. Remove (3) mounting bolts holding brake magnet body in

place. Pull brake leads from motor, remove magnet, brake coil

and rotor.

6. Re-assemble in reverse order, and tighten mounting bolts to

specified torque.

7. Turn power back on to crane and test brakes for proper

operation.

Motor End Bell

Shroud Bolt

Brake Disc

O-Ring

Magnet Body

Retaining Rings

(where applicable)

Shroud

Brake Mounting Bolts

Air Gap

Plastic Fan

(where applicable)

Figure 6: Motor Brake

ELECTRICAL

Gearmotors

a. The gearmotors are inverter duty. If gearmotor requires

any service or repairs, other than what is described in this

manual, the complete gearmotor must be replaced.

b. For hoist and trolley motors, consult the hoist and trolley

literature.

Control Panel

a. All connections should be checked frequently for tightness.

Hoist and Trolley

Panel, brakes, limit switches, etc. Consult hoist and trolley

literature for maintenance and spare parts information.

Содержание Lodeking LT Series

Страница 1: ...OPERATING MAINTENANCE MANUAL MANUAL 11854801 REV AC Capacities from 10 to 25 Tons HIGH CAPACITY ELECTRIC WIRE ROPE HOISTS P N 11854801 REV AC September 2017 ...

Страница 2: ...tructions 6 Basic Suspensions 7 Hoist Maintenance and Inspection 7 9 Daily Inspection Monthly Inspection Quarterly Inspection Annual Inspection Function Testing After Repair WIre Rope Mainenance and Inspection Reeving 9 10 Lubricant Specifications 11 Inspection Schedule and Maintenance Report 12 Disassembly Reassembly 13 14 Troubleshooting 15 Hoist Gear Drive Information 16 17 Helical Bevel Reduce...

Страница 3: ...T02511072 Model Capacity Tons Suspension Or Mounting Lift Feet Lifting Speed FPM Gage In T for Top Runner or D for Deck Mount T for LODEKING LT 25 ton LODEKING LT Top running suspension 23 ft of lift 11 st min hoist speed 11 ft min hoist speed Gage is 72 in 1 3 1 3 3 2 11 072 T T 023 020 ...

Страница 4: ... stop signals 23 Never lift a load with the hoist until you and all other personnel are clear of load 24 Make sure load has proper clearance before moving 25 Inch the hoist slowly into engagement with a load but avoid excessive plugging inching and quick reversals of load 26 Do not lift load more than a few inches until it is well balanced in the sling or lifting device 27 Each time a load approac...

Страница 5: ...commended due to the possibility of stray voltage from the welding operation damaging the electrical components present on the hoist 7 The trolley mounting surfaces shall be flat and in the same plane within 0 015 8 Hoist frame loading in areas not approved by CMCO is prohibited 9 Deck mount angles to shear block mounting bolts shall be installed with Loctite and torqued to 300 325 ft lbs Bolts sh...

Страница 6: ...90 42 xxxx xxx et la douille de sortie Listed approprié et raccords QCRV 7 étanche aux liquides pour les modèles PF A90 67 xxxx xxx doit être installé dans domaine afin de maintenir l enceinte respectivement type1 et 3 votes Type 2 Le terminal de connexion rapide et le câblage en général sont appropriés pour le câblage en usine seulement 3 Cord Listed approprié ZJCZ 7 minimum type de cordon souple...

Страница 7: ...cant indicates a chemical change in the lubricant caused by excessive heat which in turn is caused by heavy duty cycles Lubricant that is very black in color must be replaced to prevent shortened life of drive components Lubricate wire rope and other points as required Refer to lubrication chart FOR OPTIMUM LUBRICATION AND COOLING OIL LEVEL MUST BE MAINTAINED AT THE SIGHT GAUGE LEVEL 3 HOOK Check ...

Страница 8: ...for excessive wear When the groove of a sheave or rope drum becomes worn excessively it should be replaced Worn grooves on the drum or sheave can greatly reduce the useful life of the hoisting rope 9 BEARING LUBRICATION The motor sheave and outer drum bearings are a pre lubricated sealed design and normally will not need to be lubricated 10 INSPECTION CHECKLIST Fill out inspection checklist at the...

Страница 9: ...HOULD BE INSPECTED ACCORDING TO THE ABOVE PARAGRAPH ON WIRE ROPE INSPECTION IF DAMAGED ROPE IS FOUND CHECK DRUM AND FRAME MEMBERS FOR DAMAGE HOW TO MEASURE WIRE ROPE The correct diameter of a wire rope is the diameter of a circumscribed circle which will enclose all the strands It is the largest cross sectional measurement The measurement should be made carefully with calipers The illustrations be...

Страница 10: ...5 Dimensional Units INCH Sheet Third Angle Projection Description 1 1 ECN Rev Description of change Date By Material Columbus McKinnon Corporation Hoist Rigging Americas Amherst NY USA Material No Standard Standard Dimensional Tolerances Unless Otherwise Specified 0 to 60 Over 60 X 020 025 XX 010 015 XXX 005 010 Ang 0 30 0 30 Columbus McKinnon Corporation CMCO claims proprietary rights in the mate...

Страница 11: ...d Normal Wear Points Viscosity 100º F 193 235 SUS 284 347 SUS Viscosity Index 60 Min 60 Min Pour Point 20ºF 29ºC 10ºF 12ºC Amoco Oil Co Rykon Oil 46 American Industrial Oil 68 Mobil Oil Corp Mobil DTE Oil Heavy Shell Oil Co Rotella 10W Rotella 10W 30 Sun Oil Co Sunvis 932 Sunvis 968 Texaco Oil Inc Rando Oil 46 Rando Oil 68 MPG NLGI Grease No 1 No 2 Multipurpose Grease Grease Lubricated Wear Points...

Страница 12: ...ch CONTROL PANELS PUSHBUTTON Trolley Panel Hoist Panel Pushbutton Wiring TROLLEY Motor Brake When so Equip Couplings Gears Shafts Bearings Frame Wheels Bumpers Guards Conductors Collectors RUNWAYS Monorail Joints Monorail Main Conductors Main Collectors MISC General Condition Load Attach Chains Rope Slings Connect Change Gearcase Lub Grounding Faults See text for daily weekly requirements Inspecti...

Страница 13: ...ashers that hold the limit switch assembly to the bracket Remove the limit switch assembly from the bracket b Upper Block Limit Switch 1 Disconnect all power from the hoist 2 Remove bolts holding the limit switch bracket to the hoist and remove the limit switch assembly 3 Loosen the clamping screw holding the hub on the limit switch shaft and remove the hub and lever assembly Note its position car...

Страница 14: ... and keeping it properly seated in the drum groove install the remaining two clamps to the speciﬁed torque above 2 With all personnel clear of hoist TURN ON POWER 3 Operate hoist UP guiding six 6 wraps of new rope into drum grooves with gloved hand 4 With outer lower block covers removed thread the wire rope through the sheaves of the upper and lower block as shown on Reeving Diagrams referenced o...

Страница 15: ... to see if points touch If not replace Defective push button cord Wire may be pinched broken or bare Check for lack of continuity or short to ground Motor brake coil burned Replace Check to make sure coil is proper coil for voltage applied Defective stator Rewind stator Rotor loose on shaft Replace MOTOR OVERHEATS EXCESSIVE AMPERAGE DRAW Possible Cause Remedy Defective stator Replace or rewind sta...

Страница 16: ...ry for different employs must be adopted and assured by the person responsible for the installation IMPORTANT the components supplied by Rossi must be incorporated into machinery and should not be commissioned before the machinery in which the components have been incorporated conforms to Machinery directive 2006 42 EC and subsequent updatings in particular possible safety guards for shaft ends no...

Страница 17: ...s and or bearings which may cause overheatings which may represent heavy danger for people Do not use motor eyebolts when lifting the gearmotors Position the gear reducer or gearmotor so as to allow a free passage of air for cooling both gear reducer and motor especially at their fan side Avoid any obstruction to the air flow heat sources near the gear reducer that might affect the temperature of ...

Страница 18: ...indication of the health of the oil additive packages Consult your local oil supplier for further details 7 COMMISSIONING Carry out an overall check making particularly sure that the gear reducer is filled with lubricant Where star delta starting is being used input voltage must match the motor lower voltage connection For asynchronous three phase motor if the direction of rotation is not as desir...

Страница 19: ...e brake is supplied with two series of thin spacer of different color yellow and red to allow two adjustment operations After several adjustments of air gap verify that brake disk thickness is not lower than the minimum value stated in Tab 3 if necessary replace the brake disk refer to Fig 9 Release lever rod is not to be left permanently installed to avoid dangerous or inappropriate use Tightenin...

Страница 20: ...e switchs thermostats flow indicators etc Anomalous noise One or more teeth with dents or spallings excessive flanks roughness Consult Rossi Worn faulty or badly lubricated bearings Consult Rossi Taper roller bearings with ex cessive clearance Consult Rossi Vibrations Check the fastening and the bearings Lubricant leaking Seal ring with worn bakelized damaged or false mounted seal lip Replace seal...

Страница 21: ...asurements should be checked against the corresponding crane measurements to insure correctness of fit After assuring that the crane fits the building determine orientation of crane position with respect to the runway In addition verify building and runway power supply to ensure it matches the power requirements of the crane These types of cranes are usually lifted into position on the runway in o...

Страница 22: ... adherence to proven safety rules and practices No person should be permitted to operate a crane or hoist 1 who does not possess the above characteristics 2 who is not qualified or has handicaps that could adversely affect such operation 3 who has not been properly instructed 4 who has not been informed and does not have a thorough knowledge of all applicable safe operating practices including tho...

Страница 23: ...vided controls is two step infinitely variable The motion buttons on the pushbutton for the crane typically labeled FWD and REV are two step buttons for this programming The first step is the initial starting speed of the crane and it also performs a speed hold function The second step of the button performs an acceleration function To operate the crane press the button for desired direction FWD o...

Страница 24: ...EVICES SHALL NOT EXCEED THE RATED CAPACITY OF THE HOIST AND OR CRANE STEP 3 Attach load to load hook Slowly raise the hook until the slack has been taken out of the below the hook devices When the floor man signals and the operator is satisfied the load is secure in the sling lift the load slowly until clear Now hoisting speed can be increased and maintained until the load is clear of all obstruct...

Страница 25: ...otionless in front of the hand giving the motion signal EXTEND BOOM TELESCOPING BOOMS ONE HAND SIGNAL One fist in front of the chest with the thumb tapping the chest RETRACT BOOM TELESCOPING BOOMS ONE HAND SIGNAL One fist in front of the chest with the thumb point ing outward and heel of fist tapping the chest STOP Arm extended and palm down move arm horizontally back and forth EMERGENCY STOP With...

Страница 26: ...The crane operator should STOP the crane and refuse to handle loads when 1 there is any doubt as to SAFETY 2 any unusual vibrations or sounds are noticed before or when starting the lift or traverse motions 3 there are arguments or disagreements with the floor man or hitchers 4 the operator feels ill or is not alert INSPECTION Overhead cranes are subject to four levels of inspection Initial Pre Sh...

Страница 27: ...cluding control contactors limit switches push button stations for signs of pitted contact points wear or deterioration 7 All hoists and trolleys installed on the crane in accordance with the manufacturer s recommendation ALWAYS LOCK MAIN SWITCH IN THE OPEN POSITION OFF BEFORE INSPECTION NOTICE CRANES THAT HAVE BEEN SITTING IDLE FOR SIX MONTHS OR GREATER SHALL RECEIVE A COMPLETE PERIODIC INSPECTIO...

Страница 28: ...e grease unless the severity of the duty cycle and or operating environment warrants otherwise Press bearings onto wheel axle ensure they are fully seated 11 Assemble both bearing caps onto bearings 12 Place wheel assembly onto runway rail and roll it into place in the endtruck Orient the grease fitting if provided on bearing cap pointing towards the rail sweep 13 Carefully lower endtruck ensuring...

Страница 29: ...to replacement rectifier a Connect brake leads to DC side of rectifier terminals marked b Connect leads from the plug to the AC side two terminals marked 5 Re assemble in reverse order disassembly 6 Turn power onto crane and test for proper operation BRAKE REMOVAL AND REPLACEMENT If brake air gap exceeds the maximum allowed or is not functioning properly the brake may need to be replaced Follow th...

Страница 30: ...30 P N 11854801 REV AC September 2017 HOIST MOTION 200 230 575V 15 20HP 200 575V 25HP WEG MOTORS ...

Страница 31: ...NY USA ELEMENTARY DIAGRAM MALE CONNECTOR WIRING SIDE VIEW 7 1 8 6 5 4 3 2 PIN 1 BLK 0VDC PIN 2 RED 10 TO 30 VDC PIN 3 WHT A CMCO ENCODER CABLE TO DRIVE LEADS PIN 4 BLK A PIN 5 GRN B PIN 6 BLK B PIN 7 NOT CONNECTED PIN 8 NOT CONNECTED 4 3 8 2 7 1 5 6 FEMALE CONNECTOR WIRING SIDE VIEW ENCODER CABLE AND CONNECTOR PINOUT PIN 1 BLK 0VDC PIN 2 RED 10 TO 30 VDC PIN 3 YEL A E3 ENCODER LEADS PIN 4 BLU A PI...

Страница 32: ...32 P N 11854801 REV AC September 2017 TROLLEY MOTION 200 460V 10 15T WITH 200MM WHEEL G MINI 1 5HP MOTORS 75 150FPM ...

Страница 33: ...33 P N 11854801 REV AC September 2017 TROLLEY MOTION 200 460V 20 25T WITH 260MM WHEEL G MINI 2 OR 3HP MOTORS 75 100FPM OR 100 150FPM ...

Страница 34: ...34 P N 11854801 REV AC September 2017 TROLLEY MOTION 200 460V 10 15T WITH 200MM WHEEL G SERIES 4 1 5HP MOTORS 575V ...

Страница 35: ...of change Rev ECN Drawn Approved Original Scale Design Authority Format Number Description Sheet Columbus McKinnon Corporation Hoist Rigging Americas Amherst NY USA ELEMENTARY DIAGRAM WARNING AVERTISSEMENT SYMBOL DESIGNATIONS 20 25T UNITS 2 x 3HP MOTORS w 260mm WHEEL ELECTROMOTIVE G SERIES 4 PROGRAMMING SPEED REFERENCE NOTE 20 25T UNITS 2 x 2HP MOTORS w 260mm WHEEL ELECTROMOTIVE G SERIES 4 PROGRAM...

Страница 36: ... for your hoist as spares for future use These parts are listed at the end of this manual The numbers assigned to parts of our various assemblies in our Parts List are the part numbers used in manufacturing Some of these itemized parts are not for individual sale but must be grouped with other related replacement items NOTICE WHEN ORDERING PARTS OR INFORMATION ON THIS EQUIPMENT ALWAYS INCLUDE MODE...

Страница 37: ...0T 15T 20T 25T 1 Trolley Frame Assembly 1 455122XX 455176XX 455169XX 455155X 2 Gearbox 1 454963XX 3 Motor 1 454964XX 4 Drive Shaft Splined 1 23601901 23623301 23604801 5 Key Drive Shaft 1 23569202 23569201 6 Outer Retaining Ring 1 10119449 11858101 7 Inner Retaining Ring 1 11852826 8 M16 Lockwasher 8 11852804 9 M16 Hex Head Bolt 8 C11852850 C11852851 FIGURE 7 ...

Страница 38: ... 15T 20T 25T 1 RCLS Spacers 2 11859101 2 RCLS Mounting Plate 1 23623601 23621201 3 RCLS Bracket Bolt Lock Washer 2 11852804 4 RCLSBracked Mounting Bolt 2 11852839 5 RCLS with Drive Coupling 1 236217XX 6 RCLS Flat Washer 2 11852828 7 RCLS Lock Washers 2 11852829 8 RCLS Mounting Bolt 2 11852827 A 1 4 3 2 5 DETAIL A SCALE 1 1 6 7 8 FIGURE 8 ...

Страница 39: ...rease Zerk 12 NO6099 6 Trolley Gear Motor 2 453191XX 451520XX 7 Bearing Cap SHCS 24 11802728 11802729 8 Bearing Cap Lockwasher 24 11803202 11803203 9 Rail Sweep 4 23488901 23601301 10 Rail Sweep SHCS 8 for 10T and 15T 16 for 20T and 25T 11802729 11 Rail Sweep Lockwasher 8 for 10T and 15T 16 for 20T and 25T 11803203 12 Rail Sweep Flatwasher 8 for 10T and 15T 16 for 20T and 25T 11803101 13 Bumper 4 ...

Страница 40: ...Retaining Ring 2 10119421 2 Washer Inner Spacer 2 11802001 3 Internal Retaining Ring 1 10008303 4 Ball Bearing 2 10377703 5 Sheave 12mm 1 33291501 6 Sheave Pin 1 23386901 7 External Retaining Ring 2 10119419 8 Yoke Pin 1 23387001 9 Hex Head Lock Nut 2 11803001 10 Upper Block Yoke 1 33291601 11 Hex Head Bolt 2 11802507 10 9 8 7 11 1 2 3 4 5 6 FIGURE 10 ...

Страница 41: ...Hex Head Nut 2 11802906 2 Lock Washer 2 11803401 3 SHCS M12 2 11852836 4 Staking Plate 1 1139401 5 Lock Washer 2 11852809 6 SHCS 2 11852808 7 Sheave Pin 1 23619602 8 Internal Retaining Ring 1 10008303 9 Ball Bearing 2 10377703 10 Sheave 12mm 1 33291501 11 Sheave Spacer 1 23577403 12 Sheave Spacer 2 23577401 6 5 4 7 11 12 1 2 3 10 8 9 FIGURE 11 ...

Страница 42: ...ation CMCO claims proprietary rights in the material disclosed hereon This drawing and or technical information is issued in confidence for engineering information only and may not be reproduced or used to manufacture anything shown or referred to hereon without direct permission from CMCO to the user This drawing and or technical information is loaned for mutual assistance and is subject to recal...

Страница 43: ...1 11852822 4 M20 LOCKWASHER 4 11852807 5 M20 HEX NUT 4 11852805 6 M20 SHOULDER BOLT 2 11852802 11852833 7 M16 FLAT WASHER 2 11803104 8 M16 HEX NUT 2 11852806 9 DRUM ASSEMBLY 1 236047XX 236194XX 10 ROPE CLAMP 6 23380301 23631401 11 LOCK WASHER 6 11803202 11803204 12 SHCS 6 11802705 11802713 13 M20 SHCS 2 11852822 11852833 14 OUTBOARD ROPEGUARD 1 33370201 15 M20 Flat Washer 2 18803502 12 SCALE 1 4 1...

Страница 44: ...GROUP ASSEMBLY Part Number Item Number Description Quantitiy 10T 15T 20T 25T 1 Limit Switch 1 11697002 2 Limit Switch Hub 1 23336501 3 10 32 SHCS 2 10264647 4 Limit Switch Rod 1 23600501 23600502 23615502 5 M5 Lock Washer 2 11852835 6 M5 SHCS 2 11852834 4 3 6 5 2 1 FIGURE 14 ...

Страница 45: ... 6 11803002 FIGURE 15 44 Part No 11353399 S4 REEVED Figure 9 4a Lower Block Assembly S4 Reeved B Frame Lower Block Components for Figure 9 4a S4 Reeved REF No Part Number Description Qty Req d 44931901C Lower Block Assembly Excludes Ref Nos 17 18 1 33290601 Sheave Assembly Incl Ref Nos 12 13 14 4X1309 Hook Latch Kit Not shown 23380691 Hook Assembly Incl Ref Nos 2 3 4 1 N A Trunnion Crosshead 1 2 N...

Страница 46: ... Amherst NY USA 8 7 6 5 4 3 2 1 8 7 6 5 B C D E F B C D E F A By Date Rev ECN 1 1 Description Third Angle Projection Sheet Standard Dimensional Tolerances Unless Otherwise Specified INCH Dimensional Units 2 13 2013 Hoist PDE Wadesboro Number C Format Original scale Original project Design Authority Approved Drawn Modeled RSMS 15T LOWER BLOCK ASSEMBLY 1 4 APCCE 2 10 2015 Description of change D6 RE...

Страница 47: ...PERSONS RECEIVING THIS DRAWING AND OR TECHNICAL INFORMATION Columbus McKinnon Corporation Amherst NY USA 8 7 6 5 4 3 2 1 8 7 6 5 B C D E F B C D E F A By Date Rev ECN 1 1 Description Third Angle Projection Sheet Standard Dimensional Tolerances Unless Otherwise Specified INCH Dimensional Units 2 13 2013 Hoist PDE Wadesboro Number C Format Original scale Original project Design Authority Approved Dr...

Страница 48: ...ct Original scale Format B Number Wadesboro 2 05 10 2016 Dimensional Units INCH Sheet Third Angle Projection Description 1 1 ECN Rev Description of change Date By RSMS Material Columbus McKinnon Corporation Hoist Rigging Americas Amherst NY USA Material No Standard 05 10 2016 Standard Dimensional Tolerances Unless Otherwise Specified 0 to 60 Over 60 X 020 025 XX 010 015 XXX 005 010 Ang 0 30 0 30 C...

Страница 49: ...P N 11854801 REV AC September 2017 DECK MOUNT EXPLODED VIEW Item Number Description Quantitiy Part Number 10T 15T 20T 25T 1 SHCS M20 X 2 5 40MM Long 8 C11865901 2 M20 Lock Washer HI Collar 8 11852807 3 Shear Block 4 C23658401 FIGURE 19 ...

Страница 50: ...NOTES ...

Страница 51: ...NOTES ...

Страница 52: ...REACH OF i SUCH WARRANTY WITH RESPECT TO THE ELECTRICAL COMPONENTS OF ANY GOOD SHALL BE VALID OR ENFORCEABLE UNLESS BUYER S WRITTEN NOTICE THEREOF IS RECEIVED BY SELLER WITHIN ONE 1 YEAR FROM THE DATE OF SELLER S DELIVERY TO THE CARRIER AND ii SUCH WARRANTY WITH RESPECT TO THE MECHANICAL COMPONENTS OF ANY GOOD SHALL BE VALID OR ENFORCEABLE UNLESS BUYER S WRITTEN NOTICE THEREOF IS RECEIVED BY SELLE...

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