i {

1.

IMPORTAilT POINTS TO BE GHECKED BEFORE TNSTATLATION

(i)

Before instaffation fiil uptheoirin Hoist GearBoxandc. T.GearBox. Thisis veryimportant otherwise it willlead to failure ot g"";. . rope, drumgrooves, c. T. Runner wheelgears, C.T.Wheeldriving pinion.

(ii) Apply lightlayerof grease on wire

(iii) Motors andbrakes usedon sAFEX

wire RopeHoist aresuitabfe for 415 t 6% Volts,50 Hz,3 phase power A.C. supply. Check incomming vortage prevent to burning of motors andbrake coirs..

2.

IMPORTANT POINTS TO BE GHECKED DURING GOMlUIISSIONING

(i) Firstcheckthe hoistingmotorrotation. rt shourd run in rightdirection. i.e. when the hoist button is pressed the hoist is actuarty hoisting. lf notthiscan be corrected by reversing onepairof reads fromincomming suppry. Fairure to do this may resurt in damage to the hoistdue to timit switchnot operating.

(ii) Limitswitch operationfor overhoisting and over rowering shourdbe checked.rf neededrimitswitchto be adjustedby shiftingthe rimitswitch. (iii) The'brakes are adjusted at-factoryto its rated t{rque. sripage of road to be checkedduringcommissioning, and it requirecto be adjusted as per procedure givenon page "BrakeAdjustment." (iv) At the time of commissioning of the hoistput someroadon hook in orderto giveinitiaf tension to the rope.srackening of rope*iil ;;;"; damage to ropeguideand wire rope.

3.

INSTALLATIOffi (i)

OF HSIST

BLOCK

ON BEAM

wheelplate top boltsconnected withsideplateand Openthe runner loosen the lowerboltsbutdo not remove it.

(ii) Turnthe runner wheelassembly on outward side. (iii) Insert the hoistblockon to beamand reposition the runnerwheel . assembly.

(iv) Fixandproperly wheel tighten thebolts& nutsof sideplates andrunner platefixingbolts.

Note : Before Installationof Hoist Block on Beam. Check the Joistsizeand runner wheelwidth.lt Should be 5 to 6 mm morethanflangewidthof the beamsize,lf not please adjustrunner wheels runner wheelspacers frontsideor rearsideequally by changing plates. wheeladjustment on boththe runner OneSide runner should notbe donesinceit willdisturb the hoist linefrombeamcentreline. centre

4.

OILING AND GREASING POINTS

Hoist GearBox Travers Cross GearBoxes WireBope Geared runner Wheel
Fillup to the oil levelplug Fillup oilto the levelplug Smearwith lightgrease greased KeepSlightly

Note For Lubrication

GearBoxes GreaseNipples Wire Rope Drainoil once in every6 monthsand replace grade. with relevant gun. grease .Should applying cleanbefore be wiped Mustbe free fromdust and dirt and shouldbe kept lightlygreased. OIL - SAE- 140OR Equivalent - AP3 No - 2 / Spheerol Grease- Mobilple - Mobilple No. 1 / Gr ease - 33 OR Eq. No.2/Groppo IndexCompound S. 140OREQ Tr ansfor m er OilB.

R e c o m m e n d e dL u b r i c a n t s
(i) GearBoxes (ii) WheelBearing (iii) Wire Rope (iv) ThrustorBrake

lmportant
(i) Keep Load directlybeneaththe block and do not attemptto lift the loadat an angle. to lift. (ii) Makesureload is securelyslungbeforeatternpting Instructions. (iii) Obeyloading :The (iv) Hoistmustnot be usedout of doorsunlessweatherproofed.

5. A.

BRAKE INSTALLATION & ADJUSTMENT E. M. Shoe Type Brake :

(i) isenergised principle. Whenthesolenoid workson thesotenoid Thisbrake pulls apart levers shoe whichis linkedwith shoe levers, an armature to returns the brake.Whensupplyis cut off the mechanism to release Thisbrake andbrakeis applied. underspringaction its originalposition 'Fail brakeis power the off it cut the when to Safe'typebecause is and whenthe poweris on the brakegets released. applied

Brake Adjustment & Maintenance

to get required the torquesprings brakecoilsand compress Energise anychattering plateshouldbe attracted smoothlywithout Armature torque. andwhen be free shall shaft on, the motor the supply.is When noise. Repeat'ON'& off, the brakeshouldbe applied. the sqpplyis switched 'OFF'.2/3 timesto ensurefree movementof Afteradjusting Armature the torque,lock mainspringnut and locknut firmly. the wornout liners for,brake linerwear.Remove (ii) Checkperiodically the brake new and adjust with ones and replace incomming supplyleadsandremove (iii) To replace brakecoils,disconnect plate plate.Replace the brakecoilsand refitthe magnate magnate suPPly. incomming andconnect (i)

E. M. $HOE BRAKE

---..:-T

lt{a!

lLf

Type

BrakeTorque Size Rating A N.M. t01.6 13.6

'

73.2 177.866.6 31.8 139.7 77.7 9.8 16.0 73.2 6.4 s51/Ss2139.734.0/48.0 101.6239.8 88.9 50.8 212.9104.6 11.1 25.4 124.0s.7

s42

69.9 41.2 41.2

,79.344.5 76.21

82.6 50.8 50.8 79.3 95.3 79.3 108.0 53.9 76.2 79.3 120.779.3

s71/S721n.8 68.0nA2.0 127.0290.6 111.3 63.5 241.3127.0 14.3 25.4 152.4

B.

Disc Type Brake

(i) end of motorshaving Discbrakesare fitteddirectlyon non-driving to the motor is keyed hub(Normalty Squared) shaft.A driving extended shaft.Linerplatesfullyfloaton drivinghub,The brakeis springloaded iseasilyadjustable. Thebrakingtorque by Electromagnets. andis released

BrakeAdjustment& Maintenance
(i) threemainsprings breaking torqueby compressing Adjustthe required by tightening mainspringnut.Thenadjustairgap(0.5to 1mm. equalty all max.)with the helpof magnetplatenuts.Gap shouldbe uniform gap plate. Afterchecking magnetbodyand Armature aroundbetween In anycaseair gap magnetplatenutsfirmly. withfillergauge,tighten coilsmayburnoff. shouldnot be morethan 1 mm. otherwise and remove the coilclamps the Brakecoils,bendupwards To replace burntcoils.Fit new coilstakingcare that all leadsare exactlyas before.

6.

LIIIIT SWITGH ADJUSTMENT

(i) the limitSwitchFixingbolt and slide,lt on guidestripin sucha Loosen way that limitswitchstrikershouldoperatethe limitswitchat highest position of the bottomblock.

its operation. (ii) Tighten the limitSwitchFixingbolt and recheck (iii) Similarly limitswitchsuchthat bottomblock adjustthe overlowering shallremain50 mm. abovethe groundlevel. at lowermostposition, blockhookshouldnottouchthe ground NOTE: Bottom of ropeguide. wire ropewill get loosenedresultingin breakage Otherwise

OF DISCTYPEA.C. BRAKE(SlNGtEDISC) ASSEMBLY

PART LIST
HUB 1 . D R I VIN G PLATE 2. MOUTING 3. LINER PLATE 4. ARMATUREPLATE 5. ARMATURE 6. COTLS 7. MAGNET 8. MAGNETPLATE 9. LOCKINGNUTS 1 0 . SP R I N G 11.STUDS

DISC) OF DISCTYPEA.C. BRAKE(DOUBLE ASSEMBLY

PART LIST
HUB 1 . D R I V IN G PLATE 2. MOUTING SPRING 3. BALANCING 4. FRICTIONPLATE 5. LINERPLATE 6. ARMATUREPLATE 7. ARMATURE 8. MAINSPRING 9. COIL 1 0 . ' M AGN E T NUT 1 1 . L O C K IN G 12. MAGNETPLATE 1 3 . ST U DS

VARIOUS SUBASSEMBLIES (r)HorsTtNG GEAR BOX ASSEMBLY

PARTLIST
1. 2" 3. 4. 5. 6. 7. 8, 9. M OT ORP IN ION lST GEAR 2 N D P IN ION 2ST GEAR 3 R D P IN ION 3RD GEAR ROPEDRUM GEAR BOX COVER COVERGASKET

(ii) c.T. GEARBOXASSEMBLY

PART LIST

:
16. STUDMlO 17. NYLOCKNUT 18. SOCKET HEADCAP SCREW 19. WASHER 20. HEX. HEAD BOLT 21. HEX:HEAD BOLT 22. SOCKETHEADEDCAP SCREW 23. HEX. HEADEDBOLT 24. REC. KEY 25. SQ. KEY 26. SO. KEY MOUNTEDMOTOR 27. FLAGE, 28. EXTERNAL CIRCLIPLIGHT 29. BALL BEARING 30 BALL BEARING

1 . M O T OR P IN ION 2 . 1 S T GE A R 3 . z N D P IN ION 4 . 2 N D GE A R 5. DRIVING PINION 6. OUTPUTSHAFT 7. OIL SEAL 8. SPACER 9. SPACER 1 0 . BE A R IN G H OU S IN G 11. BEARINGCAP 12. RETATNG PLATE(FORW.D. PINION) 13. MOTORADAPATOR 14. GASKETFOR OIL SEAL HOUSING 15. GASKETFOR MOTORSIDE

(iii)c.T.wHEELASSEMBLY

C.T. WI.IEELASSLY
Orcascllipplc UDrlc.ts the bcerings pcriodically

e
6
I

t
F I tozrnrndcrmce \l/hccl ste can bc a{stcd
by clrangtrg bcfitg !9.cct I

s
I

+
I

(arcEARED WHEELASSLY WHEELASSLY GEARED lvlornunoHolc positionfor l{0 nm b 210 rm iirt citc lloh po:itin b 73 nwr b t4O rm

PARTLIST
I. 2. 3. 4. 5. 6.

GEARED WH E E L W HE E LS P IN D L E LOCKINGSPACER BEARING BE A R IN G C OV E R P L AN E .WH E E L

8.

TROUBLE SHOOTING GHART

TROUBLE CAUSE PROBABLE 1 Voltage/ Brake /lnsufficiant Overloading not opening up or too tight / Winding defective. / Womoutbearing/ Misalign Singlephasing ment. detective Inconectphaseconnection/Spdng / Ropeguidebroken. intercbnnection Insufficientvoltage/Wrong inching. coils/ Frequent between Oil on brake linings/ Wornout brake linings. Dust or carbon particles between Magnet 'E' Bloekfaces/ Alignment of with respectto magnetyoke liftinglever not correct/ Magnetyoke mountingbolts loose. Contactor'notworking / Push button wrongly. defective/Limit Switchconnected Cbntactor not functioning properly/ Contactor coil defective / Contactor defective/ Looseconnections.

Motornot runningat full RPM, does not lift load at raled speed.

2.
3. 4. 5.

Noisein motor.
Limit switch does not operate. coilsburningout. Magnet Brakedose not operate.

2. 3. 4. 5.

6.

MagnetChatter(Shoetype A.C. Brake)

6.

7. 8.

Hoist moves up or down one way. Contactorchatter.

7. 8.

9.

SPARE FOR TWO YEARS LIST OF REGOMTUIENDED NORMAL MAINTAINTACE

1 . Brake Coil---2 . BrakeLiner 3 . Wire RoPe 4 . RopeGuide (Hoisting) 5 . Contactor 1 Set ---, --1 Pair 1 Length 1 Set 1 No. 1 No.

(C.T-) 6 . Contactor
7.

---

PLEASE NOTETHATTHE

^c SPARESARE SUPP'LIED oM' dnn!1-1v' R crLYF E IR ^o]jl :.Y3slJx J D FRoM PRocURED ilr'XF;ii+t';il;ei ii spnREs
usED' diiEc souRcES'ARE

PRODUCTS OTHER
?K t( t( )k * ELECTRIC WIRE ROPE HOISTS CHAIN PULLEY BLOCKS CHAIN HOISTS CAGE H0ISTS cRANES (D0UBLE GIRDER, STNGLE GIRDER, E.0.T., H.0.T., JtB CRANES, GOLTATH CRANES) FOR SAFE & ALSO FOR HAZARDUS AREA AREA

,fifx
ELECTROMECH PRIVATELIMITED
Regd. : 0ffice & Works - 382 -lV, 445. Plot G.|.D.C., Vatva, Ahmedabad No. Phase : 7608, Ph. No. 25840513, 32918913 : 25841915, -Fax No. 25840124 : (079) E-mail : info@safexelectromech.com Web. : www.safexelectromech.com