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Instruction Manual for ITM models including: TM9006-30030, TM9006-36060, TM9006-50030, TM9006-30030 Builders Hoist, TM9006-30030, Builders Hoist, Hoist
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DocumentDocumentBUILDERS HOIST OPERATOR'S MANUAL THIS MANUAL MUST BE READ BY EVERY PERSON BEFORE INSTALLING, OPERATING OR MAINTAINING THE PRODUCT. Part No: TM9006-30030 300KG TM9006-36060 360KG TM9006-50030 500KG Ver: 1.0 Serial: Buyer to record serial number above This electric wire rope hoist should not be installed, operated or ! maintained by any person who has not read all the contents of these general instructions. Failure to read and comply with these instructions ! or any of the limitations noted herein can result in bodily injury and/or www.itmtools.com.au BUILDERS HOIST OPERATOR'S MANUAL 1. Warranty ........................................................................................................... 2 2. Technical Specifications ................................................................................... 3 3. Dimensions....................................................................................................... 3 4. Product Identification........................................................................................ 4 5. Safety Rules ..................................................................................................... 5 6. Application........................................................................................................ 5 7. Installation ........................................................................................................ 6 8. Operational Test Before Use ............................................................................ 7 9. Safety Inspection and Log................................................................................ 8 10. Operation.......................................................................................................... 9 11. Maintenance..................................................................................................... 10 12. Parts List .......................................................................................................... 12 13. Exploded Drawing ............................................................................................ 13 14. Inspection Log .................................................................................................. 14 1. Warranty Industrial Tool & Machinery Sales (hereinafter referred to as ITM) will, within twelve (12) months from the original date of purchase, repair or replace any goods found to be defective in materials or workmanship. This warranty is void if the item has been damaged by accident, neglect, improper service or other causes not arising out of defects in materials or workmanship. This warranty does not apply to machines and/or components which have been altered, changed, or modified in any way, or subjected to overloading or use beyond recommended capacities and specifications. Worn componentry due to normal wear and tear is not a warranty claim. Goods returned defective shall be returned prepaid freight to ITMS or agreed repair agent, which shall be the buyer's sole and exclusive remedy for defective goods. ITMS accepts no additional liability pursuant to this guarantee for the costs of travelling or transportation of the product or parts to and from ITMS or the service agent or dealer, such costs are not included in this warranty. Our goods come with guarantees which cannot be excluded under the Australian Consumer Law. You are entitled to replacement or refund for a major failure and to compensation for other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. THE MANUFACTURER RESERVES THE RIGHT TO MAKE IMPROVEMENTS AND MODIFICATIONS TO DESIGN WITHOUT PRIOR NOTICE. PRODUCTS IMPORTED AND DISTRIBUTED NATIONALLY BY: INDUSTRIAL TOOL & MACHINERY SALES 11 EASTERN SERVICE ROAD, STAPYLTON, QLD, 4207 T: 07 3287 1114 E: sales@itmtools.com.au 2 www.itmtools.com.au 2. Technical Specifications Part No. Rated Load Lifting Height Wire Rope Dia. Wire Rope Grade Motor Lifting Speed Power Supply Duty Cycle IP Rating Pendant Control Length Power Cable Length Weight TM9006-30030 300kg 30m 5mm G1900 1600 Watt 19m/min 220V 50Hz 25%: 15min/hour IP54 7m 4.5m 20.9kg BUILDERS HOIST OPERATOR'S MANUAL TM9006-36060 360kg 60m 5mm G1900 1600 Watt 13m/min 220V 50Hz 25%: 15min/hour IP54 7m 4.5m 28.4kg TM9006-50030 500kg 30m 6mm G1900 1800 Watt 13m/min 220V 50Hz 25%: 15min/hour IP54 7m 4.5m 28.4kg TM9006-30030 TM9006-36060 / TM9006-50030 www.itmtools.com.au 3 4. Product Identification Winch Body Hanger Hook BUILDERS HOIST OPERATOR'S MANUAL Carbon Brush Holder Wire Rope Maximum Cable Length Lever Load Hook Auto Stop Lever Pendant Controller 4 www.itmtools.com.au BUILDERS HOIST OPERATOR'S MANUAL 5. Safety Rules a. Before use, read and understand this manual. b. Only trained operators are allowed to use the hoist. c. Before use, complete the Daily Inspection Log as instructed in this manual. d. Before use, check for any damage or excessive wear as instructed in this manual. Do not use if damage or excessive wear is found. e. Ensure the main voltage corresponds to the voltage on the rating pate. f. The operator is required to be familiar with the hoist and hoist controls before being authorized to operate the hoist or lifting system. g. Hoist operators should be trained in proper rigging procedures for the attachment of loads to the hoist hook. Do not lift any object which is insecure or out of balance and ensure the load weight is centred. h. Before lifting a load, examine the steel cable (wire rope) to ensure that there is no twisting, kinking or turning of the bottom hook for multiple falls. i. The hoist is only used for lifting within the rated capacity. Do not lift over the rated capacity. j. Ensure to lift the load vertically. Do not lift or pull a load in any direction other than exactly vertical. k. Do not operate the hoist when it is restricted from forming a straight vertical line from hook to support in the direction of loading. l. Do not lengthen the steel cable or repair damaged steel cable. Damaged cable must be replaced by an authorized and qualified repairer. m. Ensure there are never any people standing or working underneath the hoist or load. n. Do not lift any load with the steel cable used like a sling. o. Never apply any load to the tip of hook for lifting. p. While lifting, do not operate the hoist rapidly up and down repetitively and avoid excessive inching operation. q. Do not run the hoist out of the limited position. r. Never lift a load using more than 2 hoists simultaneously. s. Do not dismantle and adjust the load limit device. t. Do not measure the weight of the load by the load limiter. u. Ensure the load you are hooking to is properly put into the hook throat with the safety latch properly closed. v. This hoist is not designed for and should not be used for lifting, supporting, or transporting personnel. w. Do not modify, upgrade, re-rate, or otherwise alter the hoist. x. Do not use the hoist in an explosive atmosphere. y. Always allow the hoist motor to stop completely before reversing. z. Ensure to leave the control pendant and cable, and the bottom hook load chain sitting vertically after completion of operation. Do not leave them in a position which will allow them to slip or swing. 6. Application This hoist is to be used only for the purpose of vertical lifting and can be used as an integrated part of an overhead gantry crane system. The equipment is to be used only for its prescribed purpose. Any other use is deemed to be a case of misuse. The user or operator and not the manufacturer will be liable for any damage or injuries of any kind caused as a result of misuse. www.itmtools.com.au 5 BUILDERS HOIST OPERATOR'S MANUAL 7. Installation UNPACKING: After removing the hoist from its box, carefully inspect the external condition of the electrical cables, steel cable, pendant controller, hooks, gearbox and motor casing for damage. INSTALLING LOAD HOOK: Before use, the load hook will need to be assembled to the hoist. 1. Pass the wire rope through the opper limiter. See Fig.1. Fig. 1 . Wire Rope pass through upper limiter 2. a) Insert the wire rope through the slot on the load hook as shown in Fig.2. b) Insert the pin into the side of the load hook. c) Ensure the pin goes through the loop in the wire rope and through the opposite side of the load hook d) Secure the pin by inserting R-Clip through the end of the pin. Fig. 2 . Thimble Load Hook Wire Rope R-Clip Pi n 6 www.itmtools.com.au BUILDERS HOIST OPERATOR'S MANUAL MOUNTING: Intended use for this Builders Hoist is to mount the hoist onto a load tested scaffold bar which will be the main support for the hoist.The suspension point should be of a correct size to hook the top hanger on to and allow it to rest properly on the scaffold bar with the safety catch locked. If the suspension bar is open ended, suitable measures should be taken to `close' it (i.e. a scaffold bracket) to ensure that the hoist will not fall off. The support bar and its supporting structure must be capable of carrying 125% of the hoist's rated capacity (Safe working load) and approved for safe operation. CONNECTING THE PENDANT CONTROLLER: Insert the pendant controller plug into the pendant controller socket and turn the fixing ring clockwise to secure the plug. Ensure the controller cable does not obstruct any load that is being lifted by the hoist or allow it to be caught location in the wire rope and drum. The length of any extension power lead is limited to 20m. Longer extension leads will cause voltage drop and will damage the motor. 8. Operational Test Before Use 1. Firmly push the Down Button to lower the lifting hook until the limit spring touches the limit switch. Power should be cut off automatically. 2. Firmly push the Up Button to raise the lifting hook until the limit spring touches the limit switch. 3. Check the emergency stop button function : While holding down either the up or down button, push the emergency stop button. Check that the hook stops when the emergency stop button is pushed. Also, check the hoist does not move in response to the push button switch. Finally, check that the emergency stop device pops out when turned to the right and that operation can be resumed thereafter. If the equipment fails to pass any of the above checks, refer to an authorised repairer to check the wiring and automatic locking function of the emergency stop device. 4. Before operating a new hoist with a load, it must be operated without load for 15 minutes to ensure it is operating without any apparent failures or problems. Refer to the Troubleshooting or discuss with the seller if any problem is identified. The same procedure should be given to the hoist if it has has been out of use for a long time. www.itmtools.com.au 7 BUILDERS HOIST OPERATOR'S MANUAL 9. Safety Inspection & Log DAILY INSPECTIONS Inspection of the below list must be carried out each day before use, and an entry reporting on the inspection must be completed in the Inspection and Service Log at the back of this user manual. Please take a copy of the blank log before first entry so you can continue the process. Logs must be archived, and will be requested if any warranty claims or injury occurs. a. Correct power supply b. With no load, test the Up, Down and Emergency Stop buttons. c. Normal motor performance including speed. d. No excessive or abnormal noise. e. Inspect the hook for damage, deformation or cracks. f. Bottom hook safety latch is functioning correctly and closes fully. g. Correct function of moving and turning parts and brake. h. No obvious worn, damaged or defected parts. i. Inspect the Steel Lifting Cable for an damage including broken wires, nicks, gouges, corrosion and distortion. Check for correct lubrication. j. Check that the cable is wound correctly on the drum as per the diagram below. k. Inspect the rating label and ensure it is displaying the specifications and ratings clearly and legible. l. Inspect the power lead and the pendant control leads for damage. m. Check that all bolts and nuts are secure and in good working order. 3 MONTH INSPECTIONS a. Check the carbon brushes for wear as per the instruction in section 9 (Maintenance) in this user manual. Clean out any carbon powder accumulation. b. Check the condition of the motor insulation. c. Check the condition of the Drum for any signs of wearing d. Lubricate the gears Repair and Maintenance Warning If damage or malfunction is identified, or the hoist can not be operated normally or as it should, consult with the supplier or a qualifed repairer. Users are not allowed to open, maintain or repair the hoist by themself. Electrical work including carbon brush checking and replacement must only be done by a qualified electrician with all required certification and tickets to complete the relevant task. 8 www.itmtools.com.au BUILDERS HOIST OPERATOR'S MANUAL 10. Operation LIFTING AND LOWERING LOADS: To lift a load, press the UP button. The drum will rotate and lift the load. To lower a load, press the DOWN button. The drum will rotate and lower the load. When the button is released, the winch will stop operating. EMERGENCY STOP BUTTON: If the emergency stop button is pressed, the hoist operation will immediately cease. Once the operator is sure that any potential problem with operations has been solved, the hoist can be put back into use. To do this, the emergency stop needs to be reset by a small turn clockwise to release the button. `UP' and `DOWN' control can then be resumed. BRAKING: The braking mechanism combines a mechanical brake and an electronic generated brake. The brake distance from the time of initial braking to stopping should be within 1.5% of the rope length wound in 1 minute. The braking distance can be determined by measuring the amount of rope that is wound in 1 minute, multiplied by 1.5%. The rope speed when the winch is not under load is 1.5 - 1.8 times faster than when under load. The braking distance will be larger when not under load but still within 1.5% of the length of the rope. OVERWIND LIMITER: The purpose of the overwind limiter is to keep the drum from being overwound when raising. The hoist will automatically stop when the load hook's flat plate comes into contact with the overwind limit lever. 70-90mm should separate the bottom of the overwind limiter from the bottom of the hoist. REVERSE WINDING LIMITER: This keeps the wire rope from being overwound and from being rewound onto the drum backwards at the bottom of the lift. Lowering will come to an automated stop when the rope moves from O to X and comes into contact with the reverse limitation bar and. In the event that this occurs, restore the wire rope by pressing the controller's "UP" button. Make sure there are always five wraps or more of wire rope on the drum to avoid this. CONTINUOUS RATING: The winch's lifespan is contingent upon the load conditions and frequency of operation. Make that the winch is operated within its continuous rating duty cycle when working for extended periods of time. Continuous rating refers to the maximum quantity of usage that is permitted in a given hour, which is 25%, (15 minutes), or 300 starts. www.itmtools.com.au 9 BUILDERS HOIST OPERATOR'S MANUAL 11. Maintenance Maintenance must only be done by a qualified and competant person. Electrical work including carbon brush replacement must only be done by a qualified electrician with all required certification and tickets to complete the relevant task. CARBON BRUSH REPLACEMENT: Periodically inspecting the carbon brushes is required. In the event that the length is less than 7.5mm, the carbon brushes must be changed. · Carefully replace carbon brushes by sliding them into carbon holders and then screwing brush caps into the holes. · Check that the carbon brush holders are positioned correctly before tightening them. · There are two pieces in a set of carbon brushes. Replace both brushes at all times. OIL LUBRICATION: The factory prelubricates the winch, eliminating the need for initial lubrication. The frequency of relubrication depends on the service provided. The recommended quantity and intervals for oil replenishment are as stated below: Grease Type -Caltex Multifak EP -Penrite Indgrease 100LX EP2 Qty 250cc Intervals 1 Year 10 www.itmtools.com.au BUILDERS HOIST OPERATOR'S MANUAL www.itmtools.com.au 11 12. Parts List BUILDERS HOIST OPERATOR'S MANUAL 12 www.itmtools.com.au 13 BUILDERS HOIST OPERATOR'S MANUAL 35 36 2 1 13 14 3 4 93-2 www.itmtools.com.au 37 48 49 50 45 46 47 51 52 53 54 55 56 57 58 59 66 67 68 69 70 71 15 6 20 106 19 16 17 18 40 41 40-1 38 39 107 109 108 94 24 5-1 7 5 12 9 42 43 89 23 8 10 34 7-1 12-1 25 62 63 65 60 61 72 73 75 74 76 79 78 77 82 81 44 83 84 90 91 92 92-1 92-2 83-4 80 11 11-1 30 85 30-1 33 32 27 28-1 31 28 29 98 26 97 96 95 99 86 102 94 88 87 103 13. Exploded Drawing 100 93 101 Date Notes BUILDERS HOIST OPERATOR'S MANUAL Auth Signature 14 www.itmtools.com.au