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Warnings and symbols used in the manual to denote hazards and important information.
Defines the roles and required attributes for users, competent persons, and operators.
Procedures to ensure personnel safety during maintenance and inspection work.
Considerations for selecting appropriate access equipment for maintenance and inspection.
Information on warranty validity and the importance of using genuine replacement parts.
Requirements and frequency for periodic inspections and tests of the hoist.
Guidelines for storing the hoist when not in use to maintain its condition.
Information on training services provided by the manufacturer for technicians and operators.
Information on the hoist nameplate, including model code, serial number, and manufacturer details.
Details on upper/lower limits and rated capacity limiter for safe hoist operation.
Explains the function of hoisting and lowering limit switches and their safety role.
Describes the rated capacity limiter's role in preventing overloads and its operation.
Explains optional travel/traverse limit switches and their types.
Instructions for mounting traverse end stops on runways for single and double girder hoists.
Specifies tolerances for running surfaces, rail gauges, and mounting surfaces.
Defines acceptable angles of inclination for hoist running surfaces.
Specifies tolerances for crab rail gauge and rail height.
Details acceptable variations in single girder runway flange width.
Specifies tolerances for vertical misalignment of mounting holes for foot-mounted hoists.
Outlines tolerances for rail joints, wheel surfaces, and guidance for smooth operation.
Provides weights for different hoist models and details lifting point locations.
Lifting points and weights for low headroom hoist models.
Lifting points and weights for double girder crab hoist models.
Lifting points and weights for foot-mounted hoist models.
Step-by-step instructions for installing low head, single girder hoists.
Instructions for setting the reaction roller on the hoist trolley for correct runway contact.
Instructions for mounting foot-mounted hoist units onto a supporting structure.
Procedure for setting the upper and lower limit switches for rope-guided hoists.
Steps to set the lower limit switch for the hoist hook position.
Steps to set the upper limit switch for the hoist hook position.
Procedure for setting limit switches on open barrel hoists using a rotary limit switch.
Steps to set the upper limit on open barrel hoists with rotary limit switches.
Steps to set the lower limit on open barrel hoists with rotary limit switches.
Information on optional rotary ultimate upper limit switches for enhanced safety.
Procedure for setting the optional rotary ultimate upper limit switch.
Details on optional hook block operated ultimate upper limit switches for safety.
Procedure for setting the optional hook block operated ultimate upper limit switch.
Charts showing highest hook positions for low headroom hoists based on runway flange width.
Tables detailing highest hook positions for foot-mounted ZX6 and ZX8 hoists.
Highest hook positions for ZX6 & ZX8 double girder parallel crab hoists.
Highest hook positions for ZX8 double girder perpendicular crab hoists.
Procedures for checking and adjusting the rated capacity limiter (RCL).
Steps for adjusting the RCL specifically for proof load testing.
Explanation of optional traverse limit switch systems and their types.
Instructions for correctly setting traverse limit switches for reliable operation.
Guidelines for safely connecting the hoist to the main power supply.
Information on selecting appropriate supply cables and fuses for the hoist.
Requirements for the main isolator switch for safe power disconnection.
Instructions for connecting the hoist to the mains power supply via plug and socket.
Notes on ensuring the installation meets EMC requirements.
Instructions for connecting the pendant controller to low headroom hoists.
Step-by-step procedure for commissioning the hoist after installation.
Procedure for safely dismantling and removing the hoist unit.
Defines the intended applications and limitations for the hoist unit.
Outlines operator responsibilities and safe practices for hoisting operations.
Safety guidelines for operating hoists via remote control transmitters.
Instructions for operating the hoist via push buttons or joysticks on the control station.
Explanation of the legends used on control devices for identifying motion directions.
Steps to safely switch on the crane/hoist power supply and controller.
Detailed instructions for operating hoist and crane motions using push buttons.
Detailed instructions for operating hoist and crane motions using joysticks.
Instructions on the function and use of the emergency stop button for safety.
Essential precautions to take when leaving the crane or hoist unattended.
Recommended procedures for operating safely during a power failure event.
Procedure for reporting any defects, incidents, or dangerous occurrences found.
Notes on equipment requiring specialized knowledge for maintenance.
Importance and method of keeping accurate records for maintenance and parts.
Daily visual and functional checks to be performed by the operator before use.
Special pre-use checks required for hoists that have been out of service for an extended time.
Recommended intervals for various inspection and maintenance tasks for hoist components.
General safety precautions and procedures for lubricating hoist components.
A schedule detailing lubrication intervals and recommended lubricants for various hoist parts.
Guidelines for inspecting, maintaining, and replacing the wire rope.
Procedures for handling and storing new wire ropes to prevent damage.
Step-by-step instructions for removing and installing a new wire rope.
Steps for safely removing the old wire rope and rope guide components.
Detailed instructions for fitting a new wire rope onto the hoist drum and sheaves.
Specific reeving instructions for 4-fall hoist rope installation.
Specific reeving instructions for 8-fall hoist rope installation.
Procedure for running in a new rope to improve its life and seating.
How to remove twist from the wire rope after installation.
Instructions for fitting the rope guide components onto the hoist drum.
Inspection of the hoist and crab frame for damage and bolt security.
Inspection and replacement criteria for hoist sheaves based on wear.
Inspection and replacement of single girder hoist wheels, guide rollers, and reaction rollers.
Inspection and replacement of double girder crab hoist wheels.
Procedures for inspecting and maintaining the hoist's spring-applied disc brake.
Identification of the various components of the hoist brake assembly.
Technical data and specifications for different hoist brake sizes.
Inspection of the brake disc and hub spline teeth for wear.
Procedure for checking and adjusting the air gap in the hoist brake.
Steps for replacing the brake disc or inspecting the brake hub for wear.
Instructions for fitting the hand release mechanism for the hoist brake.
Procedure for fitting optional brake seal kits.
Information on brake rectifier types and testing procedures.
Procedures for inspecting and maintaining the traverse drive brake.
Identification of the various components of the traverse brake assembly.
Procedure for checking and adjusting the air gap in the traverse brake.
Steps for replacing the traverse brake disc or inspecting the brake hub.
Instructions for fitting the hand release mechanism for the traverse brake.
Procedure for fitting optional traverse brake seal kits.
Guidelines for inspecting and maintaining the hoist hook block.
Inspection of the coupling between the hoist motor and gearbox.
General troubleshooting guide for common hoist operational problems and their remedies.
Troubleshooting specific brake issues, including release, overheating, and noise.
Troubleshooting common problems related to hoist motor units.
Troubleshooting common problems related to hoist gearboxes, such as noise and leaks.
Specifies the standard operating conditions, temperature range, and environmental limits for the hoist.
Method for estimating the remaining service life of the hoist based on loading and classification.
Explanation of the hoist model code structure and its components.
Measured mean sound pressure levels for ZX6 and ZX8 hoists at various distances.
Technical data for hoist motors, including ratings at different voltages and frequencies.
Specific motor data for ZX06 hoists with 3:1 speed ratio at 400V, 50Hz.
Specific motor data for ZX08 hoists with 4:1 speed ratio at 400V, 50Hz.
Specific motor data for ZX06 hoists with 3:1 speed ratio at 460V, 60Hz.
Specific motor data for ZX08 hoists with 4:1 speed ratio at 460V, 60Hz.
Specific motor data for ZX06 hoists with 3:1 speed ratio at 575V, 60Hz.
Specific motor data for ZX08 hoists with 4:1 speed ratio at 575V, 60Hz.
Specific motor data for ZX06 hoists with 3:1 speed ratio at 380V, 60Hz.
Specific motor data for ZX08 hoists with 4:1 speed ratio at 380V, 60Hz.
Traverse motor data for ZX Dual Wound 'WU' type at 400V, 50Hz.
Traverse motor data for ZX Dual Wound 'WU' type at 460V, 60Hz.
Traverse motor data for ZX Dual Wound 'WU' type at 575V, 60Hz.
Traverse motor data for ZX Dual Wound 'WU' type at 380V, 60Hz.
Traverse motor data for use with frequency inverters.
Tables for selecting cable cross-section and maximum length based on motor and installation type.
A template for recording results of periodic tests, including defects and remedial actions.
Template for recording details of replaced parts, including date and reason.
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) |
