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For internal use only General Overhaul Check List ñ PGO Page 1 Check List for Partial

For internal use only

General Overhaul

Check List ñ PGO

Page 1

Check List for Partial General Overhaul of Q Hoists

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For internal use only General Overhaul Check List ñ PGO CONTENTS: Page 2 1 General .............................................................................................................

For internal use only

General Overhaul

Check List ñ PGO

CONTENTS:

Page 2

1

General

.............................................................................................................

3

2

Preparations

.....................................................................................................

6

  • 2.1 Tools need ed

.............................................................................................

6

  • 3 Maximum allowed number of braking actions

..............................................

7

  • 3.1 Actions to be taken afte r this part ial GO:

...............................................

9

  • 4 Maximum allowed number of starts

.............................................................

10

  • 4.1 Actions to be taken afte r this part ial GO:

.............................................

10

  • 5 Maximum allowed run time

..........................................................................

11

  • 5.1 Actions to be taken afte r this part ial GO:

.............................................

14

  • 6 Maximum allowed number of control actions

............................................

15

  • 6.1 Actions to be taken afte r this part ial GO:

.............................................

15

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For internal use only General Overhaul Check List ñ PGO 1 General Page 3 As stated

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General Overhaul

Check List ñ PGO

1

General

Page 3

As stated in the standard ISO 12482-1, the user/owner of a crane must keep records of the usage of the crane.

The working conditions shall described below:

be

recorded in one

(or

more) of

the three

ways

o

Instrument recording: Hoist is equipped with a condition monitoring unit (CID).

o

Condition monitoring values can be used directly without any safety factor.

o Logbook documentation together with suitable counters: Hoist is equipped with a suitable counter (for time or distance), which allows the effective operating cycles to be calculated. The hoist shall also be equipped with a rated capacity limiter. User shall record the load spectrum.

o Condition monitoring values can be used with safety factor 1.2.

o Logbook documentation without counters: Hoist is not equipped with condition monitoring devices. The user of the hoist documents the load spectrum and the effective operating cycles.

o Condition monitoring values can be used with safety factor 1.4.

o Operating conditions are not known: Hoist is not equipped with condition monitoring devices and there is not any reliable information of the previous use of the hoist. Evaluati on has to be done according to the standard ISO 12482-1.

o Condition monitoring values can be used with safety factor 1.5.

Limits for runtime, starts, control operations and brakings for different condition monitoring methods are shown in tables below.

Starts are the number of starts to up an d down. In a case of control actions the limit value is the number of make/break ac tions to up, down or fast whichever is the highest.

When one of the condition monitoring values reaches the limit, check also the other values. Also check the remaining SWP (Safe Working Period) of the whole

hoist. If they are near the limit, it should be studied whether it

is

more

economical to carry out several partia l general overhauls or one universal

general overhaul.

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For internal use only General Overhaul Check List ñ PGO Page 4 K o n ec

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General Overhaul

Check List ñ PGO

Page 4

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For internal use only General Overhaul Check List ñ PGO Page 5 Table 1. Limits for

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General Overhaul

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Page 5

Table 1.

Limits for run time, starts, control operations and brake SWP. Condition monitoring

method: CID.

 

Class

Run time

Starts

Control

Brake SWP

 

[h]

actions

[%]

1Am (M4)

6 300

  • 1 000

134 000

640

0

2m (M5)

12 500

  • 3 000

000 000

640

0

3m (M6)

25 000

  • 7 000

500 000

640

0

Table 2. Limits for run time, starts, control operations and brake operations. Condition monitoring method: Logbook and counters, uncertainty coefficient 1.2.

Class

Run time

Run time

Starts

 

Starts

Control

Brake

 

[h]

[h]

without

with

actions

actions

without

with

counter

counter

counter

counter

 

1Am (M4)

5 250

6 300

945 000

 
  • 1 134 000

  • 533 300

300

833

2m (M5)

10 400

12 500

  • 2 000 000

500 000

 
  • 3 300

    • 533 300

833

3m (M6)

20 800

25 000

  • 6 500 000

250 000

 
  • 7 300

    • 533 300

833

Table 3. Limits for run time, starts, control operations and brake operations. Condition monitoring method: Logbook, uncertainty coefficient 1.4.

Class

Run time [h]

 

Starts

Control

Brake

 
 

actions

actions

1Am (M4)

  • 4 500

 

810

000

457

100

  • 714 200

2m (M5)

  • 8 900

2

142 800

457

100

  • 714 200

3m (M6)

17

800

5

357 100

457

100

  • 714 200

Table 4. Limits for run time, starts, control operations and brake operations. Condition monitoring method: Conditions are unknown, uncertainty coefficient 1.5.

Class

Run time [h]

 

Starts

Control

Brake

 
 

actions

actions

1Am (M4)

  • 4 200

 

756

000

426

600

  • 666 600

2m (M5)

  • 8 300

2

000 000

426

600

  • 666 600

3m (M6)

16

600

5

000 000

426

600

  • 666 600

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For internal use only General Overhaul Check List ñ PGO 2 Preparations Page 6 Test the

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General Overhaul

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2

Preparations

Page 6

Test the operation of the hoist. Drive t he hoist up and down and the trolley forth and back. Check also that the limits and emergency button operates properly. Order necessary new parts before starting the work. After changing the new parts, throw away the old parts in order to avoid their re-use.

  • 2.1 Tools needed

For internal use only General Overhaul Check List ñ PGO 2 Preparations Page 6 Test the

Wrench + sockets

8, 10, 13, 17 and 24

Nm

mm

Torque wrench

  • Plastic hammer Steel hammer

  • HEX

Socket screw

drivers 3, 5, 6 and 8

mm

  • Puller (opening > 80
    mm)

For internal use only General Overhaul Check List ñ PGO 2 Preparations Page 6 Test the

Screwdrivers of

different sizes (phillips and normal)

  • Mandrel/drift

For internal use only General Overhaul Check List ñ PGO 2 Preparations Page 6 Test the
For internal use only General Overhaul Check List ñ PGO 2 Preparations Page 6 Test the
  • Caliper

For internal use only General Overhaul Check List ñ PGO 2 Preparations Page 6 Test the

Dial indicator

  • Pliers

For internal use only General Overhaul Check List ñ PGO 2 Preparations Page 6 Test the

Marking pen

  • Circlip pliers

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For internal use only General Overhaul Check List ñ PGO Page 7 3 Maximum allowed number

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General Overhaul

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Page 7

  • 3 Maximum allowed number of braking actions

When the maximum allowed number of br aking actions has been used following operation must be done. CID warning: Warning Br SWP.

c_homo1e 4. Brake 5. Brake disc 6. Fixing screws for motor 7. Friction plate
c_homo1e
4.
Brake
5.
Brake disc
6.
Fixing screws for motor
7.
Friction plate

Change always:

Parts list number

The brake.

See Spare Part Catalogue

The hoisting coupling.

Change

the

hoisting

motor

or

Inspection method:

 

hoisting gear primary shaft if:

   

The splines of the motor shaft (either brake or coupling splines) or the

Measurement. Compare the contacting and non-contacting part

splines of the gear primary shaft are

of

the

spline. If

clear signs of wear

worn more than allowed.

exist, replace the worn component. If wear is doubted follow this instruction for measuring the spline wear. There

is dimension over teeth to be

measured. See Table 5 and Table

6

for limit values. This can be done with

the

help

of

a

normal

caliper if

performed carefully.

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For internal use only General Overhaul Check List ñ PGO Page 8 ! ORDER: Hoisting motor:

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General Overhaul

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Page 8

  • ! ORDER: Hoisting motor: See Spare Part Catalogue

  • ! ORDER: Hoisting gear primary shaft: See Spare Part Catalogue

For internal use only General Overhaul Check List ñ PGO Page 8 ! ORDER: Hoisting motor:

Table 5.

Limits for the wear of the brake splines on motor shaft.

Motor

MF10

MF11

MF13

Module [mm]

1.25

1.25

1.25

Number of teeth

18

26

26

New Wn max [mm]

 
  • 13.48 17.35

17.35

New Wn min [mm]

 
  • 13.46 17.32

17.32

Change limit in GO Wn [mm]

 
  • 13.4 17.2

17.2

 
  • 13.3 17.1

 

17.1

Final rejection limit Wn [mm] Number of teeth in measurement Wn

4

5

5

Table 6.

Limits for the wear of the coupling splines on motor and gear shaft.

Motor

MF10

MF11

MF13

MF13

Module [mm]

1.0

1.5

1.5

2.0

Number of teeth

23

18

21

18

New Wn max [mm]

 
  • 7.66 11.47

  • 6.98 15.23

 

New Wn min [mm]

 
  • 7.62 11.43

  • 6.94 15.19

 

Change limit in GO Wn [mm]

7.5

 
  • 6.7 11.2

15.0

 

7.4

 
  • 6.5 11.0

14.8

Final rejection limit Wn [mm] Number of teeth in measurement Wn

3

2

3

3

Change limit in GO Wn [mm]: shows the acceptable minimum value for the parameter Wn when the shaft has to be changed in GO. The shaft has to be changed in the GO if the value for the Wn is smaller than the change limit (it will not last to the next GO).

Final rejection limit

Wn

[mm]:

shows

the

absolute

minimum

value

for

the

parameter Wn. You do not need to use this in GO.

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For internal use only General Overhaul Check List ñ PGO Page 9 3.1 Actions to be

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Page 9

  • 3.1 Actions to be taken after this partial GO:

o

Document all performed actions.

o

CID: Reset the Brake SWP value by se tting parameter 7-24 (Br Count: Brake wear counter) to zero.

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For internal use only General Overhaul Check List ñ PGO Page 10 4 Maximum allowed number

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General Overhaul

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Page 10

  • 4 Maximum allowed number of starts

When the maximum allowed number of starts has been used following operation must be done. CID warning: Warning Starts.

  • 4.1 Actions to be taken after this partial GO:

o

CID: Change parameter 6-7 (Max ST: Maximum allowed number of starts) with parameter 1-1-2 (Starts) increased by:

 

1-1-2

6-7

(M4, 1Am):

 

+

1M134

=

 
 

(M5, 2m):

 

+

3M000

=

 
 

(M6, 3m):

 

+

7M500

=

 

Example: M4, 1Am

At the time of first GO (Warning when parameter 6-7=1M134):

o

Parameter 1-1-2=1M137

The new value of parameter 6-7=(1-1-2)+1M134 =1M137+1M134=2M271.

At the time of second GO (Warning when parameter 6-7=2M271):

o

Parameter 1-1-2=2M272

The new value of parameter 6-7=(1-1-2)+1M134 =2M 272+1M 134=3M406.

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For internal use only General Overhaul Check List ñ PGO Page 11 5 Maximum allowed run

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General Overhaul

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Page 11

  • 5 Maximum allowed run time

When the maximum allowed run time has been used following operation should be done. CID warning: Warning Run Time.

c_homo1e 1. Fan cover 2. Fan
c_homo1e
1. Fan cover
2.
Fan
  • 3. Inspection opening for brake air gap

  • 4. Brake

  • 5. Brake disc

  • 6. Fixing screws for motor

  • 7. Friction plate

Change always:

 

Parts list number

The

motor

bearings

/

the

whole

See Spare Part Catalogue

motor (See note below) Sealings (on motor flanges).

The hoisting coupling.

Note! Changing the bearings requires special competence and tools. That is the reason why bearing change is often unfeasible to perform on the site. It is highly recommended to change the whole motor.

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For internal use only General Overhaul Check List ñ PGO Page 12 Change the hoisting gear

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Page 12

Change

the

hoisting

gear

primary

Inspection method:

 

shaft if:

 

The splines of the gear primary shaft

Measurement. Compare

the

are worn more than allowed.

contacting and non-contacting part

of

the

spline. If

clear signs of wear

exist, replace the worn component. If wear is doubted follow this instruction for measuring the spline wear. There is dimension over teeth to be measured. See Table 6 for limit

values. This

can

be

done with the

help of a normal caliper if performed

carefully.

 
  • ! ORDER: Hoisting gear primary shaft: See Spare Part Catalogue

 

Change the hoisting motor if:

Inspection method:

 
 

Visual.

The winding is damaged. The coupling splines of the motor

Measurement.

Compare

 

the

shaft are worn more than allowed.

contacting and non-contacting part

of

the

spline. If

clear signs of wear

exist, replace

the

motor. If

wear is

doubted

follow

this

instruction

for

measuring the spline wear. There is

dimension

over

teeth

to

be

measured.

See

Table

6

for

limit

values.

This

can

be

done

with

the

help of a normal caliper if performed

carefully.

 
  • ! ORDER: Hoisting motor: See Spare Part Catalogue

 

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For internal use only General Overhaul Check List ñ PGO Page 13 1. Limit switch 2.

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General Overhaul

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Page 13

For internal use only General Overhaul Check List ñ PGO Page 13 1. Limit switch 2.
For internal use only General Overhaul Check List ñ PGO Page 13 1. Limit switch 2.

1. Limit switch

  • 2. Gear wheel set

  • 3. Cover

  • 4. Base

  • 5. Junction box

For internal use only General Overhaul Check List ñ PGO Page 13 1. Limit switch 2.

Figure 1. Measuring the wear of the plastic wheel

Change the limit switch if:

Inspection method:

The wear in the plastic wheel is more than allowed. Change limit in GO w>1mm. If the wear exists there has been more resistance in rotating in

Measurement. Remove the limit switch. Measure the dimension w.

switch assembly than allowed. If resistance exists, replace the limit switch unit.

Testing. Rotate the switch wheel by hand. The rotating should be easy with no significant resistance.

!

ORDER: Limit switch unit: See Spare Part Catalogue

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For internal use only General Overhaul Check List ñ PGO Page 14 5.1 Actions to be

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  • 5.1 Actions to be taken after this partial GO:

o

Document all the provided actions.

o

CID: Change parameter 6-9 (Max RT: Maximum allowed run time in hours) with parameter 1-1-3 (Run Time) increased by:

 

1-1-3

6-9

(M4, 1Am):

 

+

6 300

=

 
 

(M5, 2m):

 

+

12 500

=

 
 

(M6, 3m):

 

+

25 000

=

 

Example: M4, 1Am

At the time of first GO (Warning when parameter 6-9=6 300):

o

Parameter 1-1-3=6 370

The new value of parameter 6-9=(1-1-3)+6 300 =6 370+6 300=12 670.

At the time of second GO (Warning when parameter 6-9=12 670):

o

Parameter 1-1-3=12 700

The new value of parameter 6-9=(1-1-3)+6 300 =12 700+6 300=19 000.

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For internal use only General Overhaul Check List ñ PGO Page 15 6 Maximum allowed number

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  • 6 Maximum allowed number of control actions

When the maximum allowed number of cont rol actions (see tables 1-4) has been used following operation should be done. CID warning: Warning Control.

Change always:

 

Parts list number

The

direction

(up

and

down),

speed

change

and

See

S pare

Part

brake contactors.

 

Catalogue

  • 6.1 Actions to be taken after this partial GO:

o

Document all the provided actions.

 

o

CID: Change parameter 6-19 (Max Control: Maximum number of Control) with the maximum (value) of the parameters 2-7 (ST Up), 2-8 (ST down) or 2- 9 (ST Fast) increased by 640k0 (640 000).

Max (2-7, 2-8, 2-

 

6-19

 

9)

 

+

640k0

=

   

Example:

At the time of first GO (Warning when parameter 6-19=640k0):

o

Parameter 2-7=630k0

o

Parameter 2-8=470k0

o

Parameter 2-9=739k0

The new value of parameter 6-19=Max(2-7,2-8,2-9)+640k0

=739k0+640k0=1M379.

At the time of second GO (Warning when parameter 6-19=1M379):

o

Parameter 2-7=1M260

o

Parameter 2-8=940k0

o

Parameter 2-9=1M478

The new value of parameter 6-19=Max(2-7,2-8,2-9)+640k0 =1M478+640k0=2M118.

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