Professional Documents
Culture Documents
CONTENT
FOREWARD
NOTES BEFORE INSTALLATION
2-1 General Examination
2-2 Insulation
2-3 Rail
2-4 The notes of power feed system installation
2-5 Distribution of the control box
INSTALLATION OF HOIST
3-1 Mono rail
3-2 Double rail
3-3 Lifting hoist (Cargo elevator)
TESTING
4-1 Confirmation before running
4-2 Confirmation before un-loading running
4-3 Confirmation before full loading running
4-4 Confirmation after testing
IMPROPER OPERATION
5-1 Correct Operation
5-2 Improper Operation
5-3 Operated by two peoples
MAINTENANCE
6-1 Notes when maintenance
6-2 Limitations of Use
6-3 Items examined daily
6-4 Items examined monthly
6-5 Items examined quarterly
6-6 Items examined yearly
TROUBLESHOOTING AND MAINTENANCE
7-1 Notes of Maintenance
7-2 Mechanism
Circuit Diagram
Annex
1
1
1
1
1
2
2
3
3
3
3
4
4
4
5
5
6
7
12
13
17
17
18
18
22
28
I FOREWARD
Dear Customers:
Now you are the master of FITOP Electric Wire Rope Hoist, and we believe that it will
meet your expectation. It is a best tool of automation for carriage purpose, and is
produced by us under careful design and strict quality control. Before leaving the factory,
every set is tested to be qualified to meet CNS regulation for domestic and overseas
markets. It is surely safe.
However, in order to perform it with the maximum function, this manual is prepared by
us to let you fully understand the operation and maintenance. Please read carefully
before operation, and we will serve you with satisfactory instructions. The prosperity and
development of your business is our happiness!
2-2. Insulation
Examine the resistance of insulation system: Use of 500V high- impedance Meter to
measure if the resistance of each individual part is above 1.
2-3. Rail
2-3-1. Stop device shall be set on the rail.
2-3-2. The gap between each rail connection shall not over 0.8 cm.
2-3-3. The installation of rail shall be complied with the regulation and be sure to keep
level at transversal and horizontal direction to avoid any unstable condition
when operating.
Gap
3-1-2. When one end of girder is opened, the hoist and trolley could be combined and
install them from the opening end.
3-1-3. When both ends of grider are closed or the end of girder cant be opened to
cause hoist to fail to enter in, please release the trolley plates than install it.
-2-
IV TESTING
4-1. Confirmation before running
4-1-1. The auxiliary supporting line of the button switch should be tie firmly and
correctly, to avoid the cable being deformed under force.
4-1-2. The position of button switch shall at 1 M distance from the floor.
V IMPROPER OPERATION
5-1. Correct Operation
5-1-1. When hoisting, be sure the wire rope is fastened at correct position for safety
purpose. Otherwise, loosened hook, the cargo hoisted will be fallen down to
cause damage.
5-1-2. Gradually loosen the tight wire rope; on the contrary, the loose wire rope shall be
tightened by gradual process.
5-1-3. Before hoisting, please make sure the wire rope orderly.
5-1-4. A sharp angle would be damaged wire rope, make use of a smooth object to
protect the wire rope at that position.
5-1-5. Keep opening of hooks wire rope degreed within at 60 shown as below fig.
Max. 60
5-1-6. When operation, be careful not to impact to the cargo , to avoid loading falling
down.
5-1-7. Lift one cargo by two hoists, please pay attention to keep a balance for the center
of gravity.
-4-
Prepare
Raise arm over the head,
open five fingers,
Palm forward not moving
Lifting
Raise arm over the
head
forefinger point sky ,
and Draw a circle
horizontal rotation
Stop
Extend the arm , let palm
down, not moving .
Descending
Lower the arm,
forefinger point
ground and Draw a
circle horizontal
rotation
-5-
Emergency Stop
(at emergency condition)
Quickly stretch out both arms,
not moving.
Runway Moving
Arm protrusion,
open palm and
Move hand back
and forth to the
desired direction.
Traversing
Palm up and clench
fist ,
Thumb point to the
desired direction
VI MAINTENANCE
6-1. Notes when maintenance
6-1-1. Periodically clean the rail of trolley.
6-1-2. Periodically check the function of limit switch.
6-1-3. Periodically lubricate. Please refer the the below table for the
recommendation lubricant applied.
Standard lubricant
Lubricating
Place
Lubricating
Method
Interval
(Temp.10-60)
Recommended
CPC
www.cpc.com.tw
Lubricant
JIS
Standard
Gear box
Oil bathing
Every year
K-2219(1983)
Gear oil
Wire Rope
Smearing
Check it monthly,
Apply lubricant, If
necessary
GEAR
COMPOUND
K-2220(1980)
Grease
Bearing
Oil filling
Every year
Grease for
Ball bearing
K-2220(1980)
Grease
Opened gear
Smearing or
spraying
Check it monthly ,
Apply lubricant, If
necessary
GEAR
COMPOUND
k-2220(1980)
Grease
Oil filling
Check it monthly ,
Apply lubricant, If
necessary
GEAR
COMPOUND
Oil filling
Check it monthly ,
Apply lubricant, If
necessary
GEAR
COMPOUND
Up sheave &
shaft
sheave &
shaft
-6-
K-2220(1980)
Grease
K-2220(1980)
Grease
The broken thread number shall not over 10% of total thread number in one
unit.
One Unit
6-2-2. Hook
H1
H2
Normal Hook opening
Serious opening
(Dont use it)
-7-
6-2-3. Sheave
The wear and tear limitation of cast iron sheave is under 30% of wire ropes
O. D., but the wear and tear limitation of inner wall of sheave shall depend
on it condition.
6-2-4. Gear
The wear and tear limitation of gear depends on thickness above the pitch
circle.
Thickness
Blank
diameter
Pitch circle
diameter
Wearing
Gap
Dedendum
diameter
6-2-4-1. The wear and tear limitation of driving gear for trolley is at 40%.
6-2-4-2. The part of winding up shall not over 30% of original size.
6-2-4-3. The first section of gear shall not over 10% of original size.
6-2-4-4. Shaft coupler shall not over 20% of its original size.
6-2-5. The wear and tear condition of electrical connection shall be below 65% of
original thickness.
6-2-6. The wear and tear of lining shall not over 50% of original thickness.
6-2-7. Wheel
6-2-7-1. The wear and tear limitation of flange thickness is 50% of original size.
6-2-7-2. The wear and tear limitation of wheel groove is 5% of original dia.
6-2-7-3. The tolerance of roundness on groove dia. Shall not over 1mm
6-2-7-4. the tolerance of Left/right dia.:
Driving (Active) wheel shall not over 0.2%.
Follow (Passivle) wheel shall not over 0.5%.
6-2-8. The wear and tear of lining shall not over 50%. (The original thickness:
3.5mm)
-8-
6-2-9. The SOP of Brake Disk Replacement and Brake Gap Adjustment
6-2-9 -1. The SOP of 6HP Motor Brake Disk Replacement and Brake Gap Adjustment
The steps of release as below:
1 (pay attention to brake line and
Step 1 - Remove the the end cover of brake
spring)
2
Step 2 - Remove the brake plate
3
Step 3 - Remove the brake disk
4
Step 4 - Remove the Brake plate
6 and brake column
5 if they have any
Step 5 - Check the brake seat
loosened.
The steps of installation as below:
4
Step 1 - Install the Brake plate
3
Step 2 Install the brake disk
2
Step 3 Install the brake plate
Step 4 Mesure the gap of brake. (The gap about 0.5mm)
.
1 (pay attention to brake line and
Step 5 Install the the end cover of brake
spring) and Test and check the function of brake in normal.
-9-
6-2-9-2. The SOP of 10HP Motor Brake Disk Replacement and Brake Gap
Adjustment the steps of release as below:
1
Step 1 - Remove the fan cover
2
Step 2 - Remove the nut
3 (pay attention on brake line and spring)
Step 3 - Remove the brake coil assembly
4
Step 4 - Remove the nut
5
Step 5 - Remove the brake plate
6
Step 6 - Remove the first of brake disk
7
Step 7 - Remove the retaining ring
8
Step 8 - Remove coupler
9
Step 9 - Remove the Brake plate
10 if it has been broken or missed.
Step 10 - Check the washer
11 and brake column
12 if they have any loosened.
Step 11 - Check the brake seat
The steps of installation as below:
9 (put the washer between brake seat
11 and
Step 1 - Install the Brake plate
9 )
brake plate
8
Step 2 - Install the coupler
7
Step 3 - Install the retaining ring
6
Step 4 Install the brake disk
5 and nut
4 at the right position (the plane side of nut
Step 5 - Install brake plate
face up).
3 and nut
2
Step 6 - Install brake coil assembly
.
Step 7 - Using adjustment plate to adjust the gap of brake. (The gap between coil
column and brake plate is 0.5mm)
.
Step 8 Reverse the screw tight and fix the brake coil seat. Test and check the
function of brake coil. If the brake discs have been engaged and released
averagely, be sure if the gap of brake is appropriate.
1
Step 9- Install the fan cover
- 10 -
6-2-9-3. The SOP of 15HP Motor Brake Disk Replacement and Brake Gap
Adjustment the steps of release as below:
1
Step 1 - Remove the fan cover
2
Step 2 - Remove the nut
3 (pay attention on brake line and spring)
Step 3 - Remove the brake coil assembly
4
Step 4 - Remove the washer and nut
5
Step 5 - Remove the brake plate
6
Step 6 - Remove the first of brake disk
7 and coupler
8
Step 7 - Remove the retaining ring
Step 8 - Check the teeth of coupler, if the teeth have been abraded, if so, we
strongly suggest the brake disc and coupler should be replaced together,
otherwise the brake disc will have big problem.
9
Step 9 - Remove the middle brake plate
10
Step 10 - Remove the second of brake disk
11
Step 11 - Remove the Brake plate
12 if it has been broken or missed.
Step 12 - Check the washer
13 and brake column
14 if they have any loosened.
Step 13 - Check the brake seat
The steps of installation as below:
11
Step 1 - Install the Brake plate
8 and retaining ring
7
Step 2 - Install the coupler
10
Step 3 Install the second of brake disk
9
Step 4 - Install the middle brake plate
6
Step 5 - Install the first of brake disk
5
Step 6 - Install the brake plate
Step 7 - Install the nut
4 at the right position (the plane side of nut should be up).
3
Step 8 - Install the washer and brake coil assembly
2 and use the retaining ring
15 to adjust the brake gap.
Step 9 - Install the nut
(The gap between coil column and brake plate is 0.5mm)
Step 10 - Reverse the screw tight and fix the brake coil seat. Test and check the
function of brake coil. If the brake discs have been engaged and released
averagely, be sure if the gap of brake is appropriate.
1
Step 11 - Install the fan cover
- 11 -
Item
Prolonged
Worn out
Deformed
Corroded
Broken
Judgment Standard
Abnormal prolong condition.
The thread wiring is over the limitation.
Visible for continuous deformation.
Clearly to see corroded part.
Over the limitation for broken.
Hook
Widen opening
Deformed
Other damaged
defects
Performing
Safe latch
Up limited switch
Up and upper
limited switch
assembly
Motor
The function of
hoist, Trolley and
end carriage
Brake
The function of
hoist, Trolley and
end carriage
Push Button
Outlook and
Operation
Hanging tool
- 12 -
Place
Main hoisting
Sub-hoisting
Inspected by
Charged by
Crane No.
Date of inspection
Span
Lift
Operator
Safety supervisor
Area
Sidewalk
Traveling
mechanism
device
Item examined
Good
Bad
Area
Item examined
Gear Device
12. Abnormal sound, heating,
vibration, and lubricating.
13. Loose condition of bolt
mounting for gear box.
14. Gear cover and bolt
deformed, damaged.
Shaft coupler
4. Mounting of bolt, key,
non-turn.
5. Loosen or deformed
washer, rubber
cushion.
6. Lubricating & oil
leaking of gear, shaft
coupler
Bearing
15. Cracked, damaged,
deformed or loosened
bolt.
16. Lubricating condition.
Traveling motor
17. Loosened bolt
Traveling
mechanism
device
Brake
7. Performance.
8. Wear and tear
condition of brake
lining.
9. Contact condition, gap
between brake lining
and brake body when
starting.
10. Contact condition, gap
between brake lining
and brake body when
braking.
11. Suitable gap for brake.
Wheel
18. Wear and tear or
deformed wheel base.
19. Wear and tear of wheels
groove surface.
20. Cracked wheel.
21. Noisiness or lubricating
Wheels bearing.
- 13 -
Good
Bad
Area
Item examined
Good
Bad
Area
Gear Device
41. Abnormal sound,
heating, vibration, and
lubricating.
42. Loose condition of bolt
43. Mounting for gear box.
Gear cover and bolt
deformed, damaged.
Shaft coupler
22. Mounting of bolt, key,
non-turn.
23. Loosened or deformed
washer, rubber
cushion.
24. Lubricating & oil
leaking of gear, shaft
coupler
Hoisting motor
25. Loosened bolt
Hoisting
Mechanism
device
Item examined
Brake
26. Performance.
27. Wear and tear
condition of
brake lining.
28. Contact condition, gap
between brake lining
and brake body when
starting.
29. Contact condition, gap
between brake lining
and brake body when
braking.
30. The slide is too much.
31. Wear and tear, broken,
and dusted surface of
brake Body.
32. The condition of brake
torque adjustment
device.
33. Performance of
electro-magnet brake
magneto and abnormal
sound.
34. Drum type brake oil
pipe leakage
35. The status of Electric
hydraulic disc brake.
36. Electric hydraulic brake
disc , oil leakage and
the oil volum
37. Rod, bar, pin, screws
and other parts of
operating mechanism.
38. All pins of the
lubrication.
39. Piping, joints of oil
spills
40. Abnormal noise,
abnormal vibration,
Hoisting
Mechanism
device
- 14 -
Bearing
44. Cracked, damaged,
deformed or loosened
bolt.
45. Lubricating condition.
Winding drum
46. Crack.
47. Gear of winding drum,
loosened condition of
bolt.
48. Winding drum groove.
49. After rope is fallen off.
50. Deformation, loosened
condition of key plate,
shaft.
51. Bearing.
Wire Rope
52. Wire rope.
53. Knotted.
54. Lubricant & surface
polluted.
55. Other contacts and intercontacts point.
56. Thread cut.
57. Disordered & curved
part.
58. Caved, grooved, swelled
and corroded.
59. Rope end processing,
rope end parts, fixing
condition.
60. Knitted part.
61. Wear and tear and
broken condition of
equilibrium sheave.
62. After replacement of
wire rope.check that
monthly.
Good
Bad
Area
Item examined
Good
Bad
Sheave
Gear
84.
68.
Condition of return-run
Damaged, cracked flange.
Wear and tear condition
of sheave groove.
Crack of spider hub.
Wear and tear and
deformation of Bearing
chain plate, locking Pin.
Proper sheave groove and
Rope dia.
85.
86.
69.
70.
71.
72.
73.
74.
87.
Traveling
mechanism
device
Damaged condition of
hook.
Loosened condition of
screw thread.
Falling protective device
of hook nut.
Deformed, loose
condition of key plate,
locking pin.
Deformed, loose
condition of bolt, nut,
splitting pin, etc.
Cracked, wearing,
damaged condition of
side plate.
77.
80.
81.
82.
83.
Cracked, damaged,
deformed, loosen condition
of bolt.
Lubricating condition.
Traversing Wheel
90.
91.
92.
Wearing, deformation of
Flange.
Wearing of wheels pedal
Face.
Crack of wheel.
Abnormal lubricating of
Wheels bearing.
93.
94.
95.
Security
check
Brake, etc.
78.
79.
88.
89.
Shaft coupler
75.
76.
Bearing
Hook
Traveling
mechanism
device
Item examined
63.
64.
65.
66.
67.
Hoisting
Mechanism
device
Area
Performance
Wearing of brake lining,
etc.
Contact, gap between
brake Lining & brake body
when starting.
Equable contact of brake
Lining & brake body when
braking, wearing, cracked,
dusted, Condition of
brake body surface.
Stroke distance is too long
Others
- 15 -
Good
Bad
Place
Crane No.
Date of
inspection
Area
Electric motor
Main hoisting
Sub-hoisting
Hook path
Lift
Item examined
Good
Bad
Control panel
or
Distributor
Interior wiring
Push button
station
(pendant)
Area
Power
feed
system
Inspected by
Operator
Charged by
Safety supervisor
Item examined
Safe rail
21. Wear and tear of safe
rail.
22. End tension device.
23. Anti-conduction
device.
24. Abnormal insulating
object & insulation.
Current Collector
25. Wear and tearof
collector.
26. Oiler mechanism.
27. The status of
insulation.
28. Fix terminal, bolt and
screw.
Power-supply cable
29. Wear and tear of
exposed insulation.
30. Expansion of cable.
31. Terminal, Bolt and
screw tightly.
32. Performance of cable
leading mechanism.
Signal lamp
33. Fixing part of terminal.
Lightening device
34. Fix the terminal.
35. Mounting part &
break proof bulb.
Other
devices
- 16 -
Limit switch
36. Contact point of
contactor.
37. The spring of
contactor point.
38. Limit lever deformed?
39. Performance & its
position.
40. Bolt mounting.
Good
Bad
- 17 -
7-2. Mechanism
Trouble
1. Steel wire rope is not in
the drum groove when
rolling.
Possible cause
(1)
(2)
Troubleshooting
(1)
(2)
2. Loud noise.
(1)
(1)
Adjust gap.
(2)
(1)
(2)
4. Disc brake takes too long
time to function.
(1)
(2)
(3)
(4)
(3)
(4)
Loosen bolt.
Change lining.
(1)
(2)
(3)
(1)
(2)
(3)
(1)
(1)
(2)
(2)
(3)
7. End carriage will slide
and running un- even
(1)
(2)
(3)
- 18 -
(2)
(3)
(1)
(2)
(3)
Trouble
8. Noise & abnormal
vibration produced when
wheel is running.
Possible cause
(1)
(2)
(3)
9. No working
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
10. Hoisting up doesnt work
(1)
(2)
(3)
(4)
(5)
(1)
(2)
(3)
(1)
(2)
(3)
(1)
(2)
(3)
(4)
Troubleshooting
(1)
(2)
(3)
Clean it.
(1)
(2)
(2)
(3)
(4)
(5)
(1)
(2)
(3)
(1)
(2)
(3)
(1)
(2)
(3)
(4)
- 19 -
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(1)
Trouble
14. Trolley cant move
WEST
Possible cause
(1) check up west limited switch
(2) The west current of hoisting has
broken.
(3) Push buttom WEST malfunction.
(4) Contactor of WEST function
malfunctions.
(1) The brake of trolley motor doesnt
open.
(2) Burned-out trolley motor.
(1) Check South limited switch
(2) The SOUTH current has broken.
(4)
(1)
(2)
(3)
(4)
(1)
(2)
(3)
(1)
(2)
(1)
Battery no power
(1)
(2)
(1)
(2)
(1)
(1)
(2)
(3)
(4)
(1)
(2)
(1)
(2)
(3)
(1)
(2)
(2)
23. Releave push button
but hoist doesnt stop
(1)
(3)
(4)
(3)
Troubleshooting
(1)
(2)
- 20 -
(2)
(1)
(2)
(2)
(1)
(2)
(1)
(2)
Trouble
24. Motor burned
(main hoist , trolley end
carriage)
Possible cause
(1)
(1)
(2)
(7)
(1)
(1)
(1)
(1)
(2)
(3)
(1)
(2)
(1)
(2)
(2)
(3)
(3)
(1)
(1)
(2)
(2)
(2)
(3)
(4)
(5)
(6)
(7)
(2)
(3)
28. Abnormal sound
when the end carriage is
traveling
(1)
(2)
(3)
(4)
Troubleshooting
- 21 -
(3)
(4)
(5)
(6)
(3)
(4)
(1)
Circuit Diagram 1.
- 22 -
Circuit Diagram 2.
- 23 -
Circuit Diagram 3.
- 24 -
Circuit Diagram 4.
- 25 -
Circuit Diagram 5.
- 26 -
Circuit Diagram 6.
- 27 -
Annex 1.
Year
month
Manager:
Date
Item
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Remarks:
Inspection result, the good one is marked ' ', no need to check mark ' /' ,bad one is marked '' and note in item 8.
25
26
27
28
29
30
31
Annex 2.
Check item
Monthly
and
End
carriage
Rail
3. Any crack on the welding
4. Any damage on stopper or buffer
1.
button
- 29 -
Quarterly
Yearly
Monthly
Wire
rope
4.
- 30 -
Quarterly
Yearly
Monthly
1. Any crack
2. Visual check and find deformation
3. Opening width same as original size.
4. Opening width under 5% as standard
Hook
Sheave
groove
Hoist case
1. Any cracks
1. The states of gearbox
Lubrication
Inner
power
cable
Power
feed
Current
Collector
Motor
- 31 -
Quarterly
Yearly
Safety
device
Contactor
Cable
Monthly
1.
2.
Handrail is firmly
3.
4.
5.
6.
7.
8.
9.
10.
Loudspeaker
11.
Lighting
1.
Action confirmed
2.
3.
Fixed terminal
1.
2.
Quarterly
Yearly
and
Cable reel
The state expresses symbols: Good O , Normal , Bad X , Doesnt have that device N
Suggestion
Manager :
Inspector 1:
Inspector 2:
- 32 -