spacemaster sx wire rope hoist free sample

2.1 FEM Hoist Duty Service Classification ............................................................................................................... 7

2.2 ASME Hoist Duty Service Classification............................................................................................................. 8

4.2 Hoist Speed Accuracy ...................................................................................................................................... 10

4.5 Rope Type Code .............................................................................................................................................. 10

4.6 Hoist Duty Rating ............................................................................................................................................. 10

6.1 Hoist Motor Features ........................................................................................................................................ 31

6.2 Optional Hoist Motor Features ......................................................................................................................... 31

6.10 Hoist Motor Brake ............................................................................................................................................ 32

7.1 Hoist Gear Reducer ......................................................................................................................................... 52

7.2 Hoist Gear Lubricant ........................................................................................................................................ 52

8.3 Rope Clamps ................................................................................................................................................... 54

8.4 Rope Guide ...................................................................................................................................................... 54

9.4 Rope Anchor .................................................................................................................................................... 57

10.1 Wire Rope Technical Data ............................................................................................................................... 58

10.2 Heavy Duty Wire Rope – RR09 ........................................................................................................................ 59

12.1 SX2-SX7 Hoists ............................................................................................................................................... 65

14.1 Low Headroom Hoist ........................................................................................................................................ 67

14.2 Normal Headroom Hoist ................................................................................................................................... 68

14.7 Cross Mounting Double Girder Hoist ................................................................................................................ 70

22.1 Monorail Hoist (Solo Hoist) ............................................................................................................................... 88

22.2 Crane Package Hoist ....................................................................................................................................... 88

25.1 HoistMonitor ® – HS11 ...................................................................................................................................... 90

25.4 HoistMonitor ® Select – HS12 ........................................................................................................................... 91

25.5 HoistMonitor ® Elite – HS13 .............................................................................................................................. 92

27.1 Hoist & Trolley Color Layout ............................................................................................................................. 95

27.3 Standard Painting Method for Hoist ................................................................................................................. 96

27.4 Special Painting Specification for Hoist ............................................................................................................ 96

29.1 Second Hoist Brake – BRA01 ........................................................................................................................ 100

29.11 Special Encoder on Hoist – EL20 ................................................................................................................... 101

29.12 Hoist Inverter Control Method – EL36 ............................................................................................................ 101

29.13 Hoist without Electrical Controls – ELE65 ...................................................................................................... 101

29.16 Hoist Motor, IP66 Protection – HM04 ............................................................................................................. 101

29.17 Hoist Motor, Thermal Protection – HM05 ....................................................................................................... 101

29.18 Hoist Motor, Class H Insulation – HM12......................................................................................................... 102

29.19 Speed Sensor on Hoist Motor – HM13 ........................................................................................................... 102

29.22 Rain/Dust Cover for Hoist – HS04 .................................................................................................................. 102

29.23 Hoist Drum Brake – HS07 .............................................................................................................................. 102

29.27 Synchro for Hoisting – HS27 .......................................................................................................................... 103

29.37 Nonstandard Voltage/frequency for Hoist....................................................................................................... 106

29.39 Hoist Motor External Fan – MOT08 ................................................................................................................ 107

29.45 IP-type of Hoist Panel (Add for IP66) – PAN01 .............................................................................................. 107

29.47 Stainless Steel Hoist Panel (IP55) – PAN03 .................................................................................................. 107

29.52 Stainless Wire Rope – RR08 .......................................................................................................................... 108

29.53 Heavy Duty Wire Rope – RR09 ...................................................................................................................... 108

33.4 Hoist Speeds and Controls ............................................................................................................................. 112

33.7 Two Similar Hoists Arrangement .................................................................................................................... 113

39.17 Pliotex Type Wire Marking – ELE48 ............................................................................................................... 118

We are committed to helping you rise above the challenges of your everyday business. The safety, reliability and reduced maintenance of the Spacemaster® SX wire rope hoist allows you to get the most out of your equipment. As a standard feature, this hoist includes hoist monitoring to provide real-time data about hoist operation.

Designed to maximize dimensional envelope and operational efficiency, the wide capacity range of this hoist is ideal for applications across industries. The Spacemaster SX wire rope hoist can be configured to your precise facility needs, from building headroom and workflow needs to environmental considerations.

Our innovative hoist design provides the best headroom in the industry while minimizing hook drift and maximizing end approaches. This means you get more floor coverage and easier operation of the equipment. Standard inverter controls on the trolley reduce load swing and minimize brake wear.

R&M offers load monitoring systems as standard with every wire rope hoist. The HoistMonitor and HoistWatch systems give you real information about your equipment use and service needs while preventing overloads to the crane. In addition, our regenerative braking system can ensure safe operation for your crane operators.

At R&M, all our equipment is designed in-house, specifically for lifting applications. The innovative gear case design reduces stress on drum bearings, lowering the need for maintenance and extending the life of the equipment. Our unique rope drum design, with 40:1 drum to rope diameter and motor inside the drum, provides the least hook drift in the industry while improving motor cooling efficiency.

Our RX Program has a selection of wire rope hoists ranging from 1 to 40 tons, available in 2-5 business days! Ask a R&M Distributor for more information on this program.

Have an upcoming project? Use our Crane Designer for an instant recommendation of crane and hoist components that will help you rise above your competition.

1 UPDATE HISTORY ............................................................................................................................ 42 GENERAL INTRODUCTION .............................................................................................................. 5 2.1 Foreword: About this manual............................................................................................................5 2.2 Symbols used in this manual ............................................................................................................5 2.3 Safety Alert Symbols and Signal Words ...........................................................................................5 2.4 Questions and Comments ................................................................................................................6 2.5 Manual Use.......................................................................................................................................6 2.6 Service personnel .............................................................................................................................6 2.7 Terminology ......................................................................................................................................7 2.8 Standards and Directives .................................................................................................................73 SAFETY FIRST! ................................................................................................................................. 8 3.1 Personal protective equipment (PPE) ..............................................................................................8 3.1.1 Fall Protection ...................................................................................................................................8 3.2 Fire Safety ........................................................................................................................................9 3.3 Main isolation switch .........................................................................................................................9 3.4 Safety during maintenance ...............................................................................................................9 3.4.1 Lockout - Tagout Procedure ...........................................................................................................114 IDENTIFICATION............................................................................................................................. 12 4.1 Manufacturer ...................................................................................................................................12 4.2 Hoist series .....................................................................................................................................13 4.3 Hoist Identification Data ..................................................................................................................14 4.4 R&M code example (R&M: SX, Factory: Q) ...................................................................................15 4.5 Motor Identification Data .................................................................................................................165 GENERAL ABOUT MAINTENANCE ................................................................................................ 18 5.1 Service process ..............................................................................................................................18 5.2 Periodic inspections and actions ....................................................................................................19 5.2.1 Daily inspections .............................................................................................................................19 5.2.2 Periodic inspections and maintenance tasks .................................................................................19 5.3 Approaching Theoretical Calculated Lifetime .................................................................................21 5.3.1 General Overhaul ...........................................................................................................................216 MAINTENANCE PROGRAM ............................................................................................................ 23 6.1 Periodic inspections and maintenance tasks .................................................................................23 6.2 Lubrication ......................................................................................................................................34 6.2.1 General Lubrication Instructions .....................................................................................................34 6.2.2 Lubrication Charts (Low headroom trolley) ....................................................................................36 6.2.3 Lubrication Charts (Normal headroom trolley) ...............................................................................37 6.2.4 Lubrication Charts (Double girder trolley) .......................................................................................38 6.2.5 Lubrication Charts (Fixed hoist) ......................................................................................................39 6.2.6 Lubrication Charts (Machinery Hoist) .............................................................................................40 6.2.7 Lubricant volumes, hoisting gears ..................................................................................................44 6.2.8 Lubricant volumes, drum rim gear ..................................................................................................44 6.2.9 Lubricant volumes, traveling gears .................................................................................................447 MAINTENANCE INSTRUCTIONS.................................................................................................... 45 7.1 Hoisting machinery .........................................................................................................................45 7.1.1 Hoisting machinery .........................................................................................................................45 7.1.2 Rope drum ......................................................................................................................................53 7.1.3 Rope clamps ...................................................................................................................................56 7.1.4 Rope guide .....................................................................................................................................58

7.1.5 Hoisting gearbox ............................................................................................................................. 82 7.1.6 Hoisting motor ................................................................................................................................ 88 7.1.7 Hoisting brake................................................................................................................................. 93 7.1.8 Second brake, Frame size: SX1, SX2, SX3, SX4, SX5. ................................................................ 98 7.1.9 Drum Brake .................................................................................................................................. 100 7.1.10 Manual brake release for hoisting motor ...................................................................................... 119 7.1.11 Manual crank ................................................................................................................................ 122 7.1.12 Hoisting limit switch ...................................................................................................................... 125 7.1.13 Hook operated limit switch ........................................................................................................... 134 7.2 Rope reeving system .................................................................................................................... 141 7.2.1 Standard reevings (one rope from drum) ..................................................................................... 141 7.2.2 True vertical reevings (two ropes from drum)............................................................................... 145 7.2.3 Machinery reevings ...................................................................................................................... 148 7.2.4 Rope sheave maintenance ........................................................................................................... 150 7.2.5 Sheave support and rope anchorage support .............................................................................. 151 7.2.6 Wire rope ...................................................................................................................................... 152 7.2.7 Hook-block .................................................................................................................................... 160 7.2.8 Overload protection ...................................................................................................................... 175 7.2.9 Rope anchorage ........................................................................................................................... 180 7.3 Trolley ........................................................................................................................................... 185 7.3.1 Trolley ........................................................................................................................................... 185 7.3.2 Trolley buffers ............................................................................................................................... 187 7.3.3 Traveling machinery ..................................................................................................................... 188 7.3.4 Traveling motor ............................................................................................................................. 191 7.3.5 Traveling brake ............................................................................................................................. 195 7.3.6 Trolley wheels ............................................................................................................................... 201 7.4 Electrics ........................................................................................................................................ 210 7.4.1 Push-button controller .................................................................................................................. 210 7.4.2 Condition monitoring unit .............................................................................................................. 211 7.4.3 Frequency converters ................................................................................................................... 212 7.4.4 Cubicles and wiring ...................................................................................................................... 215 7.4.5 Contactors .................................................................................................................................... 2158 DISMANTLING .............................................................................................................................. 216 8.1 Dismantling the Product ............................................................................................................... 216 8.2 Disposal of Waste Material ........................................................................................................... 2179 APPENDIX: TIGHTENING TORQUES .......................................................................................... 218

2.1 Foreword: About this manualThis manual offers guidance to enable safe and efficient service.Taking the time to read this manual will help you to prevent damage to the product, and, most importantly,personnel situated close to it. The product is designed to be safe when used correctly. However, there are manypotential hazards associated with incorrect operation and these can be avoided when you know how to recognizeand anticipate them.This manual is not intended as a substitute for proper training but provides recommendations and methods for safeand efficient service.

2.4 Questions and CommentsAny questions or comments relating to the content of this manual and/or the operation, maintenance and/or serviceof manufacturer products should be directed to: www.rmhoist.com

ANSI American National Standards InstituteISO International Organization for StandardizationAuthorized personnel Persons who are authorized by the owner and who have the necessary training to carry out operation or service actions.Experienced service person authorized by A person with service experience who is properly trained to perform service actions.the manufacturerCE marking The CE-marking indicates that the product complies with the appropriate CE regulations.Check A visual and functional assessment (not a test) of the product without dismantling.Emergency brake A brake that can be applied by the operator, or automatically upon loss of power.Electric panel Power is controlled to the motors and components through the electric panel.Parking brake (storm lock) A brake that can be applied either automatically or manually and prevents horizontal movement of the trolley or bridge. Used when movements need to be prevented in windy conditions.Main brake A brake that stops motion and prevents movements.Second brake (Holding brake) A brake that supports the load if the main brake fails.Operator Person operating the product for the purpose of handling or moving loads.Inching Making very small movements by repeatedly and momentarily pressing the direction control.Bridge The bridge (main girder) moves along the runwayMain girder The main girder (bridge) is connected to the bridge end carriages.Main isolation switch The main isolation switch is the power switch which the operator should normally use to turn off the power.Hoist Drive mechanism for lifting and lowering the load.Inspection (Visual) Looking for defects and checking the operation of the controls, limiting and indicating devices without loading the product. This is much more than a check but does not normally require any part of the product to be dismantled other than for removal or opening of covers or housings.Power supply Power is supplied to the components via the power supply.Controller The pendant or other type of controller is used by the operator to give commands to the product.Qualified personnel One with necessary qualification based on theoretical and practical knowledge of hoists or/and cranes. The person must be in a position to assess the safety of the installation in conjunction with the application. Persons with the authority to undertake certain maintenance work on products of manufacturers include manufacturers’ service engineers and trained fitters with corresponding certification.Maximum capacity Load that the product is designed to lift for a given operating condition (e.g. configuration, position of the load).Runway The product rides on or under the runway.Trolley (hoisting unit) The trolley (hoisting unit) moves along the main girder.Sling A sling is used to attach the hook to the load when the load cannot be lifted directly by the hook.

2.8 Standards and DirectivesThis state of the art product has been designed and manufactured to conform to European and internationalstandards and directives. The product also fulfils the requirements of the following standards (if applicable): CSA,UL, RoHS, OSHA, CCC.

While personnel are performing inspection or maintenance work at heights, they must follow fall protectionprocedures as required by local regulations. Fall prevention practices and fall protection equipment aim to protectpersonnel working on or around the equipment from exposure to falls.If the equipment does not have a service platform or handrail, personnel must use a properly fitted safety harnessthat is attached to the dedicated fixing points on the building or equipment in order to prevent falls.If the product does not have dedicated fixing points for fall protection, it is the owner’s responsibility to make surethat there are suitable fixing points in the building structure.If ladders must be used, personnel must practice setting and securing the ladders before using them for actualwork.A typical fall protection program may include: Documented and established site policies and procedures. Conducting site assessments for fall hazards. Selection of the proper fall protection system and equipment. Training on fall protection procedures and the proper use of fall protection systems. Inspection and proper maintenance of fall protection equipment. Measures to prevent falling objects. Rescue Plans.If necessary, contact your supplier or service organization for assistance with designing your fall protectionprogram.

Inform that equipment will be undergoing maintenance 3 Before starting maintenance, people must be properly informed that the equipment is being removed from operation.

Ensure that there is no load on the lifting device 4 Before starting maintenance there should be no load on the hook or lifting device. Park the hook on the ground if there is any chance that the hoisting brake will be opened during maintenance. A raised empty hook will fall to the ground if the hoisting brake is opened.

Use hand lines for lifting and lowering tools 8 Hand lines, securely attached to the building structure, should be used for lifting or lowering materials and tools. Use proper safety equipment to prevent objects from falling when working in high places.

Pay special attention to all safety-critical components 13 The brakes, limit switches, hook, rope and controller are all safety-critical items which must always be kept in good order. Ensure that safety devices (overload protectors, limit switches, etc.) work properly so that they provide protection against human error.

This manual contains information for several hoist types, components and options. The information in this manualis identified by individual feature of hoist or by product code or by part of product code. Identification data is onhoist data plate or component data plate.

12/218 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.4.2 Hoist seriesThe series of hoist covers a lot of variants with load capacities ranging from 400 kg to 80 000 kg. It covers a wholerange of modular hoists with numerous options under hoist components. The following illustration and the tableafter show in brief different modules/components available.

Pos. Module or component Description of modules of hoist series Electrics Several control device, driving device and measuring/monitoring device variants and combinations. A • Controlling devices: push button pendant, remote controls etc. 1 • Measuring and monitoring devices: condition monitoring, overload indication etc. B • Driving devices: contactor controls, frequency controllers etc. C 2 A Traveling machinery • Several machinery sizes. Several motor and gear size variants and combinations.

13/218 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice. Pos. Module or component Description of modules of hoist series B • Several quantity variants on applications. C Hoisting machinery Several machinery frame sizes. Several motor, gear and drum size variants and combinations. 3 A • From drum size Ø 243 mm. B • Up to drum size Ø 608 mm with two motor drive. Rope drum length Several drum length variants. 4 A • Short drum lengths for short lifting hights. B • Long drum lengths for long lifting hights. Trolley Single girder trolley variants: A • Low headroom trolley B • Normal headroom trolley Double girder trolley variants: C • Double girder trolley C • Double girder trolley ,Low 5 C • Double girder trolley ,Medium C • Double girder trolley ,High D • Two hoist trolley Fixed connection variants: E • Fixed hoist E • Machinery hoist Reeving system Several reeving system variants: A • Standard reeving 6 B • True vertical reeving C • Machinery reeving

1 Product Exact model of the product, product code.2 Duty class Duty group defined based on the expected use of the product3 Load Maximum load which can be lifted with the product4 Height of lift Maximum lifting height of the hook5 Approvals and standards Directives and approvals which the product complies to. Refer to the chapter “Standards and directives”.6 Serial number A unique number which identifies the product7 Manufacturing month Manufacturing month/year8 Manufacturer’s reference Factory work number9 Frequency Supply frequency which the product is designed for10 Hoisting speed High/low hoisting speed11 Trolley speed High/low trolley travelling speed12 Main voltage Supply voltage which the product is designed for13 Control voltage Control circuit voltage

4.4 R&M code example (R&M: SX, Factory: Q) SX 2 041 0020 P 1 5 F A L0 N (GE09) (DES27) (LOA01) (HM01) HM02 (DIM01) HS06 GE08 (DES01) 1,2 3 4-6 7-10 11 12 13 14 15 16,17 18

Feature Pos. Code Feature Available properties code Short product 1,2 SX SX SX product name GE09 value GE09 value 1 243 mm rope drum diameter Z 6 608 mm rope drum diameter D 2 303 mm rope drum diameter A 7 608 mm rope drum diameter 3 2 (GE09) Frame size E 3 303 mm rope drum diameter A (2 hoisting motors) 4 355 mm rope drum diameter B 5 406 mm rope drum diameter C 1-roped DES27 value 2-roped DES27 value 010 01 022 22 021 02 042 24 Rope reeving 031 03 062 26 4-6 041 (DES27) code 041 04 082 28 061 06 M1 081 08 A2 B2 7-10 0020 (LOA01) Capacity Capacity x 100 (units: kg or Lbs.), 0020 x 100 = 2 000 kg, 2000kg = LOA01 HM01 value HM01 value 11 P (HM01) Hoist motor type P Pole change motor P I Frequency converter motor T 50 Hertz 50 Hertz 1 1.8 kW 7 18 kW 2 3.6 kW 8 23 kW 12 1 HM02 Hoist motor size 3 4.5 kW 9 28 kW 4 7.5 kW A 35 kW 5 9 kW X 1.5 kW 6 15 kW Z 2.5 kW ASME / ISO Duty class DIM01 value ASME / ISO Duty class DIM01 value 13 5 (DIM01) Hoist duty group 3 H2 / M3 M3 5 H4 / M5 M5 4 H3 / M4 M4 6 H5 / M6 M6 Hoist speed for 4-roped, 50 Hz E 4 m/min F 5 m/min Hoisting gear 14 F HS06 G 6.3 m/min type H 8 m/min J 10 m/min Hoist gear options listed are not available for all hoist frame sizes. A 310 mm rope drum length (if frame size 1, 394 mm) J 1600 mm rope drum length B 340 mm rope drum length (if frame size 1, 394 mm) K 1900 mm rope drum length C 440 mm rope drum length (if frame size 1, 504 mm) L 2250 mm rope drum length D 540 mm rope drum length M 2500 mm rope drum length 15 A GE08 Hoist drum length E 660 mm rope drum length N 2800 mm rope drum length F 810 mm rope drum length Z 1400 mm rope drum length G 1000 mm rope drum length X Special drum length H 1250 mm rope drum length Drum lengths are available for hoist frame sizes indicated. DES01 value DES01 value NP Normal headroom perpendicular L0 Low headroom L DH Double girder (Height above rail is N0 Normal headroom N 16,17 L0 (DES01) Trolley type taller than standard, improves HR) H D0 Double girder (standard) M DL Double girder (Height above rail is F0 Foot mounted F lower than standard, increases HR) W Special N Standard hoist without any options S Special hoist 18 N properties F Options selected from option list

Do not allow the product to be used if it is not in proper condition. The usage WARNING of a defective product can result in serious damage, injury or death.

Never wash the crane or hoist with chemical products or high pressure water CAUTION jets, as they can cause problems like detaching of the stickers and water entering inside the electrical components.

5.1 Service processService process should include following steps. 1 Preliminary actions This may include: • Prepare schedules, process plans and documentation. • Reserve sufficient resourses like properly trained personnel, enough time and apporiate tools. • Plan safety actions and reserve proper safety equipment.

5.2.1 Daily inspectionsDaily inspection items are listed in Hoist Operator’s Manual. In most cases these checks will be performed byoperators on start of each work shift.Check if there is need for other daily checks caused by application, usage, product options, environment or someother reasons. Update Operator’s instructions if needed.

5.2.2 Periodic inspections and maintenance tasksCarry out the inspection and servicing procedures for the hoist in accordance with the maintenance program.Check if there is need for other periodical maintenance tasks or need to shorten the intervals caused byapplication, usage, product options, environment or some other reasons. Update Owner’s and Operatorsinstructions if needed.19/218 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice. R&M Materials Handling, Inc. 4501 Gateway Boulevard Springfield, Ohio 45502

In order to ensure safe operation of cranes, the proper working and operational condition shall be maintainedaccording to standard ISO 9927.This requirement covers also special assessments to be carried out by an expert engineer at regular intervals tocheck the remaining Safe Working Period (SWP) of the hoist as stated in standard ISO 12482-1.The condition monitoring unit (CID) provides two different SWP values: the runtime-based SWP (CID parameter 2-12 SWPRT% ) and the working cycle-based SWP (CID parameter 2-15: SWPHC%).The CID display of the data counter SWP always shows the lesser value of two parameters.

5.3.1 General OverhaulIn the GO service, the product is assigned with a new, runtime-based SWP, provided that it is safe to continue theoperation. The runtime-based SWP means the lifetime of the interchangeable rotating components of the hoist likehoisting gear, hoisting motor, and rope sheaves. Note that in case of hoists with a smaller drum size, it is oftenmore cost-efficient to replace the hoist with a new one.

When the Safe Working Period (SWP) of the hoist has decreased to zero or is counting in the negative, the hoist may only be used after a GO service has WARNING been conducted, or the hoist must be replaced with a new one. Any usage of a defective hoist can result in serious damage, injury, or death.

When performing General Overhaul, the construction of the hoist may not be changed or the supporting structures repaired without permission from the CAUTION manufacturer. If there are any deformations, cracks or corrosion in the supporting structures of the hoist, the parts have to be replaced or repaired according to the instructions given by the manufacturer.

21/218 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.The same hoisting machinery can undergo no more than two GOs before it must be replaced completely:

22/218 R&M Materials Handling, Inc. reserves the right to alter or amend the above information without notice.6 MAINTENANCE PROGRAMThe lifetime of the hoist is divided into Safe Working Periods (SWPs). At the beginning of the Safe Working Period,a new hoist has an SWP% of 100. A Safe Working Period ends when the SWP% of the hoist is zero. When a SafeWorking Period ends, a General Overhaul (GO) must be conducted, after which the hoist is assigned a new SafeWorking Period, refer to the section "General Overhaul, GO".During the SWP, the safe and efficient operation of the hoist is contingent on regular servicing.

For the safety carry out the inspection and servicing procedures for the hoist CAUTION in accordance with maintenance task list.

To avoid any risk of spark with explosive proof hoists due to the friction of two CAUTION mechanical parts, it is important to follow strictly the maintenance intervals. The safety of the equipment could be compromised if not.

6.1 Periodic inspections and maintenance tasksThe servicing intervals for the hoist are defined as SWP% periods. The actual operation of the hoist is taken intoaccount in SWP%. If the hoist is provided with a condition monitoring unit, the SWP value can be read from the unitdisplay. Refer to the more detailed instructions that are given in the separate operating instructions for the conditionmonitoring unit.The following table shows the service intervals for the hoist in SWP% periods and in calendar months. Theservicing procedure must be carried out at the end of SWP% period latest, or after the stated number of calendarmonths. Hoists without a condition monitoring unit must follow a servicing procedure guide by calendar months. Forensuring the usability of the hoist, the servicing intervals can be shortened.

Hoists used under harsh conditions may require a shorter servicing interval CAUTION than stated in the table. Consult with a representative of the manufacturer for a tailored service agreement.

If the hoisting machinery is used outdoors, the lubrication of all the hoisting CAUTION machinery parts, as a general rule, should be carried out on a quarterly basis (every three months).

Periodical inspecting and servicing procedure may only be carried out by a WARNING serviceman authorized by the hoist manufacturer, or by the service personnel that are adequately trained by the hoist manufacturer.

Note: Intervals on the following table are SWP% periods or a stated number of calendar months. For ensuring the usability of the hoist, the servicing intervals can be shortened.

Hoist 10% Test-run the hoist first to see that all movements (hoisting, traveling) 12 function smoothly without any unusual noise or vibration.

Inspect the general condition and cleanness of the hoist. Visually check the general condition and accumulation of dust or dirt. Pay special attention to: • Hoist motor body. Remove dust or dirt to eliminate insulating factor, as the motor heat must be able to dissipate • All parts that need cooling • Parts that wear if the surfaces are not clean • Optical and other sensors. 10% Inspect the condition and fixing of covers. 12 Test by hand that all covers are fixed. Visually check that covers are not bent or cracked. Fix or replace if needed.Stickers and 10% Inspect the condition and readability of warning stickers and other See sections:markings 12 stickers and markings. Hoist identification data Visually check that all type plates and stickers exist and are readable. Motor identification data Replace all missing and unclear stickers.Capacity labeling Check that the capacity load of a hoist is readable on the hook block.

Hoisting limit 10% Verify the condition and operation of hoisting limit switches. Construction of hoisting limit switch forswitches 12 hoist frame size: SX1Up Limit Operate the hoist in the up direction and slowly drive to the Up Limit Construction of hoisting limit switch for Switch Activation point. Check that it works. hoist frame size: SX2, SX3, SX4,Slow Down Up SX5, SX6, SX7Limit Run the hook block down at a short distance and drive at high speed Maintenance task for hoisting limit and check if the Slow Down Up Limit activates to override the high- switch, hoist frame size: SX1 speed command to slow down the speed before the Up Limit Maintenance task for hoisting limitDown Limit activates. switch, hoist frame size: SX2, SX3, SX4, SX5, SX6, SX7Hook limit (SafetyUp Limit/ Ultimate Operate the hoist in the down direction and drive to the Down LimitLimit) Switch Activation point.

Adjust or replace parts as required.Up Limit Distance 10% Verify Up Limit Distance. 12 Verify the Up Limit Distance to the frame of the trolley. It is important to adjust the C dimension according to the specification, to minimize rope and sheave wear.Down Limit 10% Verify Down Limit Distance.Distance 12 When the hook block is in the Down Limit Switch Activation point, verify that there is a minimum number of wraps of rope on the drum according to the standards (the absolute minimum is two full turns of a rope).Overload 10% Inspect the condition and operation of the overload protector. Overload protectionprotector 12 Maintenance of overload device Mechanical switch and load sensor overload device: Operation test of overload Test the free movements of mechanical parts. Test the mechanical overload limit switch by mechanically activating the switch and checking for a click. Clean and lubricate lever mechanism. Verify that the set screw is locked in its place. When required to confirm calibration, place a test weight of a nominal load plus 10%. Adjust mechanical overload to stop hoisting at 110% of capacity. Replace damaged parts.

Power measurement overload device: Conduct a test operation of the power measurement overload device according to the local regulations if necessary.Condition 10% Verify the operation of the condition monitoring unit. Service manual for hoist controlmonitoring unit 12 Test the condition monitoring unit by lifting a known load and verify device that the unit reads the load within 5% accuracy. If not reading properly, a new calibration of the unit required. Check for possible error codes and warnings.

Crane power Inspect the power collector shoes.supply collectors • Check for any signs of wear • Check that there is a proper contact between the shoes and the conductor bar • Check the spring tension of the collector Inspect the collector bar. • Check straightness • Verify that the fasteners are fixed properly • Check the bar for possible signs of wear: burn marks, oxidation, cracks, or any other general damage.Main isolation Inspect the main isolation switch (the main runway disconnectswitch (Main switch).runway Verify the following:disconnect • Main isolation switch is labeled to indicate what crane runway it controlsswitch) • Main isolation switch functions properly • Main isolation switch is lockable.

Bridge travel 10% Check the operation of Slowdown and Stop Travel Limits of thelimits 12 bridge.Bridge power 10% Check the festoon cable system.supply 12 • Check that the cable is not worn • Verify that the cable is running smoothly from one end of the bridge to the other end, indicating that the cable carrier is not damaged and the cable is not running into any obstacles • Check that the pull cable is secure and working properly, relieving strain on the cable when the trolley is pulling • Check that the festoon arm is secure.Bridge disconnect 10% Verify that the bridge disconnect switch on the bridge panel turns onswitch 12 and off the power.

Emergency stop 10% Check that the emergency button is clean and not damaged. 12 Push in the emergency button. Test that no movement activates. Verify that the main contactor is off. If the emergency stop is equipped with key locking, remove the key and test that it is not possible to release the emergency stop.Main switch for 10% Check that the main switch is clean, clearly marked and not Main isolation switchhoist 12 damaged. Test manually that the main switch switches off the hoist.Wiring 10% Inspect the condition of wiring and the connections. 12 • Follow the power supply and visually check the potential areas for damages • Pull on the wiring at the terminals • Check the wiring for any signs of wear, crushing, breaks, or cuts • Check visually that the cable bushings are tight • Check visually that the connectors are not damaged • Test by hand that the cable bushings are tight • Test by hand that the connectors are tight • Check randomly the tightness of screws at the terminal blocks and at the connections of other components. Note that the terminals can cause a heat damage to the insulation and/or to the connections.Hoist cubicle 10% Check that the electrical cubicle is securely fastened with a trolley or 12 a bridge. Verify that the doors are closing properly and the locking devices are functioning. Check the door sealing. Check that the cubicle is clean. Inspect the air conditioning and filters. Inside the electrical cubicle: • Check that the electrical components and their fastenings are secure. • Check that all the electrical protection guards are in place.

Contactors Control Check that all the movements are operational in the hoist, in the Contactors warning trolley and in the bridge. 12 Check visually that the contactors are clean and there are no visible damages.Condition When the condition monitoring unit indicates the “Control” warning, one ofmonitoring unit the start counters 2-7 (ST up), 2-8 (ST down) or 2-9 (ST fast), haswarning “Control" reached the set design limit (the default value is 640,000 operations) which is defined with parameter 6-19 (Max Control) that calculates the life- time of the contactors. When the design limit has been reached, replace the contactors (Up, Down, Slow, Fast and Brake Contactors). If a brake contactor contains an auxiliary contact block or a time delay auxiliary contact block, replace that part as well. After the replacement, calculate a new value for parameter 6-19. See instructions in chapter “Contactors”. If the condition monitoring unit is not used with the hoist, replace the contactors after six years of operation according to the designed duty cycle.Over-current 10% Check the adjustment of the over-current protectors.protectors 12Fuses 10% Inspect visually that the fuse holder and the fuses are clean and 12 there are no visible damages. Check the correct amperage rating.Braking resistors 10% Clean all dust or dirt from the braking resistors.(with some 12frequencyconverter models)Hoisting 10% Check that wires are securely fastened. See further instructions in thefrequency 12 Check fault code records. equipment-specific “Service Manualconverter for Frequency Control System” Inspect the operation and cleanliness of the cooling fan.

Traveling 10% Check that wires are securely fastened. See further instructions in thefrequency 12 Check fault code records. equipment-specific “Service Manualconverter for Frequency Control System”