Check list prior to start-up
Visually inspect for obvious signs of defects such as mechanical damage to components, paint flaking, cable damage or oil leaks/spills on the following items:-
- Hoist Frame
- Hoist Motor
- Crab Frame
- End Carriages
- Travel Motor Gearbox Units
- Control Panel
- Bottom Hook Block
- Festoon Cables
- Pendant and Pendant Cables
- Mains Isolator and Fixed Cabling
- Check crane beam running rails are free of obstructions
- Check downshop beam running rails are free of obstructions
Start-up, shut-down abnormal operating condition and special maintenance instruction
Start-up
Unlock and switch in the mains isolator switch, located approx.1.5m above floor.
Re-set Emergency Stop Button on control pendant – twist to re-set.
Check list after start-up but prior to commencing normal operations
Before starting normal operations the following checks should be performed:-
With No Load
- Check correct function of all motions in both operating speeds; hoist, lower, cross traverse-left/right, long travel-forward/reverse.
- Check correct function of limit switches; hoist upper and lower limit positions, travel limit switches for hoist traverse and crane long travel.
- Change over limit switches travel speeds fast and slow.
- Operation of emergency stop button on pendant.
- Check condition of bottom hook block, is the safety catch operational and the hook is free to swivel.
- Check that Hoist rope is correctly reeved and the wire rope is good condition.
With Load
- Operation of brakes – hoist, traverse, long travel. Note: only hoist/travel the load a small distance in the first instance to check that the brakes are working correctly/brake is holding the load.
Shut Down | Normal Condition
- Hoist the unloaded bottom hook block to a safe height position (clear of personnel).
- Drive hoist to parking position (if nominated).
- Activate emergency stop on pendant unit by depressing button.
- Switch off power at mains isolator.
Shut Down | Abnormal Condition
- Lower load (manual brake release available for use in emergency no power situation).
- Depress Emergency Stop button.
- Activate emergency stop on pendant unit by depressing button.
- Switch off power at mains isolator.
Operating Safety
During operation of the hoist it is essential that the following specific rules be strictly adhered to:
- There should always be a tension applied to the hoist rope to ensure that the rope maintains its optimum reeved position. A slack rope could result in rope lift and incorrect spooling into drum grooves.
- Do not allow hoist bottom block to touch the floor i.e. taking tension off the load ropes. If this does occur examination of the rope guides is necessary before allowing the crane to re-enter service.
During operation of the hoist it is essential that the following general rules are strictly adhered to:
- It is imperative that crane operators are Trained/Experienced personnel.
- Local, national regulations and recommendations should be considered, we especially recommend BS5744 Code of Practice for Safe Use of Cranes and The Accident Prevention Regulations VBG9.
Duties of Crane Operator
Please take the following recommendations for Crane Safety into consideration:-
When working with electric wire rope hoists and cranes, the accident prevention regulations on Cranes must be observed. Listed below are the most important points, which must be observed to ensure safety at work.
- Inspect brakes and limit switches daily
- When commencing work the crane operator must check to ensure that the brakes and emergency end position stopping devices are functioning properly. He must inspect the condition of the crane for visible defects.
- The crane operator must shut down the crane in the event of faults, which endanger operational safety.
- Do not move suspended loads above personnel
- The crane operator must ensure that loads are easily and away from other personnel.
- Do not leave suspended loads unattended
- Whenever a load is suspended form a crane, the crane operator must keep the control facilities within reach.
- Do not approach emergency limit switch during normal operation
- Emergency limit switches must not be approached during normal operation.
- Do not load excess of nominal load-bearing capacity
- Cranes must not be loaded beyond their maximum permissible load.
- Adjustable load torque limiters (overload device) must be matched to the current crane configuration.
- Do not pull loads at angles, do not haul or pull loads
- Pulling at angles overhauling of loads as well as moving vehicles with load or load-bearing equipment are prohibited.
- Do not heave up any loads which are jammed
- Heaving up of jammed loads is not permitted.
- Approach limit positions for hoisting, lowering and travel during operation only when operational end position stopping device is fitted
- Operational approach of limit positions defined by means of emergency end position stopping devices is only permitted when operational end position stopping devices are provided ahead of any such equipment.
- Avoid frequent inching operation (briefly switching on motor to achieve small movements) as far as possible, as otherwise the switchgear may be destroyed by fusion welding of the contact parts and the motor become overheated
- Overhead Cranes and Hoists are intended solely for lifting and travelling freely movable loads
Do not carry out any alterations or modification without manufacturer`s permission
Operational interruption, malfunctions and irregularities
Hoist does not start (no motion available)
- No power available.
- Check mains isolator is switched on and that the emergency stop button on pendant is re-set.
If power is connected and switched on correctly, then the following checks should be carried out by properly qualified personnel (please refer to Maintenance Instruction and take all necessary safety precautions before beginning work).
- Check fuses
- Check supply cables
- Check control pendant unit
- Check switchgear in control panels
Hoist does not start (power available)
- Check hoist limit switches have not been activated
- Check hoist upper and lower limits
- Check over load limit switch
- Check travel limit switches
Hoist does not start after a long period of not being used (motor emits humming noise).
- Hoist brake may be stuck – remove hoist motor fan cowl, may be freed by giving a firm blow to brake hood and then switching on the motor. Take care to use timber or similar protective material to strike against to prevent mechanical damage.
Loud click when switching on
- Brake lifting path is too long – adjust brake according to Maintenance Instructions.
Hoist starts but will not lift load
- Overload cut-off device has been actuated or is defective – refer to Maintenance Instructions.
Braking path too long (hoist and travel motors)
- Brake lining worn or needs adjustment – refer to Maintenance Instructions
Limit Switches
- All limit switches are self re-setting.
- Hoist overload switch will activate in an overload condition but will allow load to be lowered off.
- Hoist top and bottom limit switches, travel limit switches will activate but allow reverse function enabling the limit switch to be reactivated for further normal use of the hoist. Fast to slow travel limit switches will cut-out fast speeds on approach of extents of travel but allow travel in same direction until ultimate travel limit switch is activated/tripped.
IF IN DOUBT CONTACT THE EQUIPMENT MANUFACTURER