Street Crane ZX6 User Manual (English)

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ZX6&ZX8

TRUEVERTICALLIFT

ELECTRICWIREROPEHOIST

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INSTALLATION,OPERATION

AND

MAINTENANCEINSTRUCTIONS

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StreetCraneCompanyLimitedreservestherighttoalteroramendthedetailsgiveninthispublicationwithoutpriornotification.

©StreetCraneCompanyLimited2014

DocumentRef:D3256rev.B

Table of Contents5
General Safety Instructions10
Symbols10
PERSONNEL - Definitions and Attributes10
Maintenance Safety Procedure10
Maintenance and Inspection Access11
Warranty / Replacement Parts11
Periodic Tests11
Storage11
Training and after Sales Service11
Description of Equipment12
Hoist Nameplate14
Figure 1 - Hoist Nameplate Location14
Limiting Devices15
Hoisting and Lowering Limits15
Rated Capacity Limiter (RCL)15
Travel / Traverse Limits (Optional)15
Installation and Commissioning Instructions16
Traverse End Stops16
Figure 2 - Single Girder 4 & 8 Fall Traverse End Stops16
Figure 3 - Double Girder Traverse End Stops16
Running & Mounting Surface Tolerances and Finishes17
Tolerances on the Inclination of the Running Surface17
Tolerances on Crab Rail Gauge & Rail Height17
Tolerances on Single Girder Runway Flange Width17
Tolerances on Mounting Surface for Foot Mounted Hoists17
Tolerance on Misalignment of Rail Joints, Wheel Running Surfaces and Guidance Surfaces18
Hoist Weights and Lifting Points18
Low Headroom18
Figure 4 - Single Girder Runway Tolerances18
Figure 6 - Low Headroom 4&8 Fall Lifting Points18
Double Girder Crab19
Foot Mounted20
Figure 8 - Foot Mounted Lifting Points20
Installation of Low Head 4&8 Fall Single Girder Hoist21
Figure 9 - Installing the Low Headroom Trolley21
Figure 10 - Withdrawing the Reaction Roller21
Figure 11 - Low Headroom Runway Clearance22
Figure 12 - Setting the Low Headroom Legs22
Setting the Reaction Roller23
Figure 13 - Low Headroom Hoist Transportation Feet23
Figure 14 - Reaction Roller23
Installation of Foot Mounted Hoist24
Figure 15 - Installation of Foot Mounted Hoist24
Setting the Upper and Lower Limit Switches - Rope Guided25
Setting the Lower Limit25
Setting the Upper Limit25
Figure 16 - Hoist Limit Switches - Standard Environment Rv-1 (See Hoist Nameplate for Revision)25
Setting the Upper and Lower Limit Switches - Open Barrel26
Setting the Hoist Upper Limit26
Figure 17 - Setting the Upper/Lower Limit Switch - Rotary Type26
Setting the Hoist Lower Limit27
Ultimate Upper Limit Switch - Rotary (Optional)27
Setting the Ultimate Upper Limit27
Figure 18 - Ultimate Upper Limit Switch - Rotary Type27
Ultimate Upper Limit Switch - Hook Block Operated (Optional)29
Setting the Ultimate Upper Limit29
Figure 19 - Ultimate Upper Limit Switch - Hook Block Type29
Low Headroom Highest Hook Position- 4 Fall & 8 Fall30
Foot Mount Highest Hook Position- Zx6 & Zx831
Double Girder Parallel Crab Highest Hook Position- Zx6 & Zx831
Double Girder Perpendicular Crab Highest Hook Position- Zx832
Checking / Adjusting the Rated Capacity Limiter33
Adjusting the Rated Capacity Limiter for Proof Loading33
Figure 20 - Rated Capacity Limiter33
Traverse Limits (Optional)34
Setting Traverse Limits34
Figure 21 - Setting the Traverse Limit - Single Girder Arrangement34
Figure 22 - Traverse Limit Double Girder Arrangement35
Connecting the Power Supply36
Supply Cables / Fuses36
Main Isolator - Supply Switch (by Others)36
Connecting to the Mains Supply36
Figure 23 - Hoist Electrical Connections36
Figure 24 - Delay Timers37
Figure 25 - Phase Failure Relay37
Electromagnetic Compatibility38
Connecting the Pendant Controller - Low Headroom38
Figure 26 - Control Transformer Connections38
Figure 27 - Strainer Wire Connections38
Commissioning Procedure39
Dismantling / Removal of the Hoist39
Operating Instructions40
Intended Use40
Duties of the Operator / Safe Hoisting Practices40
Figure 28 - Clearances to Consider When Lifting41
Remote Controlled Cranes / Hoists42
Figure 29 - Recommended Hand Signals42
Control Station Operating Instructions43
Legend Nomenclature43
Switch on43
Push Button Operation43
Figure 30 - Control Pendant Legends43
Joystick Operation44
Emergency Stop45
Leaving the Crane / Hoist Unattended46
Power Failure46
Inspection and Maintenance Instructions47
Reporting of Defects and Incidents47
Special Knowledge47
Keeping of Records47
DAILY PRE-USE INSPECTIONS (at the Start of each Day/Shift)47
Hoists that Have Been Unused for an Extended Period48
Inspection and Maintenance Intervals49
Lubrication52
Figure 31 - ZX6 Gearbox Oil Fill & Level Plug Locations52
Figure 32 - ZX8 Gearbox Oil Fill & Level Plug Locations53
Lubrication Schedule54
Inspection and Maintenance - Wire Rope56
Offloading and Storage56
Replacing the Wire Rope56
Figure 33 - Correct Uncoiling of Wire Ropes57
Figure 34 - Incorrect Uncoiling of Wire Ropes57
Figure 35 - Winding of New Wire Ropes57
Figure 36 - Fleet Angle58
Figure 37 - Reeving Diagrams for ZX6 & ZX8 4&8 Fall Low Head & Crab Hoists59
Figure 38 - Reeving Diagrams for Foot Mount Hoists: ZX084-FTM / ZX088-FTM59
Figure 39 - Reeving Diagrams for Foot Mount Hoists: ZX064-FTM60
Fitting the Rope Guide61
Figure 40 -Fitting Top and Bottom Halves of Rope Guide Inner Band61
Figure 41 - Rope Guide Inner Band Spring and Sleeve Arrangement61
Figure 42 - Rope Guide Inner Band Fitted62
Figure 43 - Fitting Rope Guide Outer Band62
Inspection and Maintenance- Hoist / Crab Frame63
Sheaves63
Figure 44 - Fitting Rope Guide Retainer - Standard Environments Rv-1 (See Hoist Nameplate for Revision)63
Figure 45 - Sheave Characteristics63
Single Girder Wheels64
Double Girder Crab Wheels (Double Flange)64
Figure 46 - Sheave and Barrel Groove Inspection64
Inspection and Maintenance - Hoist Brake65
Hoist Brake Components65
Figure 47 - Hoist Brake Components65
Hoist Brake Data66
Brake Disc (Rotor) Spline66
Checking / Adjusting the Air Gap66
Figure 48 - Checking Hoist Brake Air Gap66
Changing the Brake Disc (Brake Rotor) / Inspecting the Brake Hub67
Figure 49 - Adjusting the Hoist Brake Air Gap67
Figure 50 - Inspecting the Brake Disc67
Fitting the Hand Release68
Figure 51 - Hoist Brake Hand Release68
Fitting the Brake Seal Kit (Optional)69
Brake Rectifier69
Figure 52 - Brake Seal69
Inspection and Maintenance - Traverse Brake70
Traverse Brake Components70
Figure 53 - Traverse Brake Components70
Checking / Adjusting the Air Gap71
Changing the Brake Disc (Brake Rotor) / Inspecting the Brake Hub71
Figure 54 - Checking Traverse Brake Air Gap71
Figure 55 - Adjusting the Traverse Brake Air Gap71
Fitting the Traverse Drive Hand Release72
Figure 56 - Traverse Drive Brake Hand Release72
Fitting the Brake Seal Kit (Optional)73
Inspection and Maintenance - Hook Block74
Inspection and Maintenance - Hoist Drive Coupling76
Fault Finding77
General77
Brakes78
Motor Units79
Gearboxes80
Technical Data81
Conditions of Use81
Procedure for Estimating Remaining Service Life81
Hoist Model Code82
Noise Levels85
Hoist Motor Data86
ZX06 Hoist Motor Data - 3:1 SPEED RATIO - 400V, 3Ph, 50Hz86
ZX08 Hoist Motor Data - 4:1 SPEED RATIO - 400V, 3Ph, 50Hz86
ZX06 Hoist Motor Data - 3:1 SPEED RATIO - 460V, 3Ph, 60Hz87
ZX08 Hoist Motor Data - 4:1 SPEED RATIO - 460V, 3Ph, 60Hz87
ZX06 Hoist Motor Data - 3:1 SPEED RATIO - 575V, 3Ph, 60Hz88
ZX08 Hoist Motor Data - 4:1 SPEED RATIO - 575V, 3Ph, 60Hz88
ZX06 Hoist Motor Data - 3:1 SPEED RATIO - 380(±10%)V, 3Ph, 60Hz89
ZX08 Hoist Motor Data - 4:1 SPEED RATIO - 380(±10%)V, 3Ph, 60Hz89
ZX Dual Wound 'WU' Type Traverse Motor Data- 400V 50Hz90
ZX Dual Wound 'WU' Type Traverse Motor Data- 460V 60Hz91
ZX Dual Wound 'WU' Type Traverse Motor Data- 575V 60Hz92
ZX Dual Wound 'WU' Type Traverse Motor Data- 380V 60Hz93
ZX Traverse Motor Data for Use with Frequency Inverter94
Cable Cross Section and Length of Supply Cable95
Results of Periodic Tests96
RECORD of REPLACEMENT PARTS (Ropes, Brakes, Sheaves Etc.)97

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Street Crane ZX6 Specifications

General

Crane Type	Overhead crane
Ambient Temperature	-20°C to +40°C
Insulation Class	F
Protection Level	IP55
Application	Industrial and construction lifting
Control Method	Pendant control or radio control
Control System	Variable Frequency Drive (VFD)
Relative Humidity	Up to 95% (non-condensing)

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