Red this Own er s Mn u l thor ough ly e fore op er t ing the equip ment. Keep it with the equip ment t ll times. Re plce ments re vil le from TSE, PO Box 347, Winon, MN 55987, 800-553-2204. www.thernstge.com IMPORTANT: Plese record product informtion on pge 2. This informtion is re quired when clling the fc to ry for service. Owner s Mn ul For LS Series Lineshft Hoists
pge 2 Owner's Mnul for Thern LS Series Lineshft Hoists Two-Yer Limited Wrrnty Plese record the following: Dte Purchsed: Model No.: Seril No.: This informtion is required when clling the fctory for service. Thern, Inc. wrrnts its products ginst defects in mteril or workmnship for two yers from the dte of purchse y the originl using uyer, or if this dte cnnot e estlished, the dte the product ws sold y Thern, Inc. to the deler. To mke clim under this wrrnty, contct the fctory for n RGA numer. The product must e returned, prepid, directly to Thern, Inc., 5712 Industril Prk Rod, Winon, Minnesot 55987. The following informtion must ccompny the product: the RGA numer, the dte of purchse, the description of the climed defect, nd complete explntion of the circumstnces involved. If the product is found to e defective, it will e repired or replced free of chrge, nd Thern, Inc. will reimurse the shipping cost within the contiguous USA. This wrrnty does not cover ny dmge due to ccident, misuse, use, or negligence. Any ltertion, repir or modifiction of the product outside the Thern, Inc. fctory shll void this wrrnty. This wrrnty does not cover ny costs for removl of our product, downtime, or ny other incidentl or consequentil costs or dmges resulting from the climed defects. This wrrnty does not cover rke discs, wire rope or other wer components, s their life is suject to use conditions which vry etween pplictions. FACTORY AUTHORIZED REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY TO THE CONSUMER. THERN, INC. SHALL NOT BE LIABLE FOR ANY INCIDEN- TAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON THIS PRODUCT. EXCEPT TO THE EXTENT PROHIBITED BY APPLICABLE LAW, ANY IMPLIED WAR- RANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ON THIS PRODUCT IS LIMITED IN DURATION TO THE DURATION OF THIS WARRANTY. Some sttes do not llow the exclusion or limittion of incidentl or consequentil dmges, or llow limittions on how long n implied wrrnty lsts, so the ove limittion or exclusion my not pply to you. This wrrnty gives you specific legl rights, nd you my lso hve other rights which vry from stte to stte. Note: Thern, Inc. reserves the right to chnge the design or discontinue the production of ny product without prior notice. Aout This Mnul The Occuptionl Sfety nd Helth Act of 1970 sttes tht it is the employer s re spon si il i ty to provide workplce free of hzrd. To this end, ll equipment should e instlled, operted, nd mintined in complince with pplicle trde, industril, federl, stte, nd locl regultions. It is the equipment own er's re spon - si il i ty to o tin copies of these regultions nd to determine the suit il i ty of the equip ment to its intended use. This Owner s Mnul, nd wrning lels ttched to the equip ment, re to serve s guidelines for hzrd-free instlltion, op er tion, nd mintennce. They should not e understood to prepre you for every pos si le sitution. Informtion contined in this Owner's Mnul is pplicle only to Thern LS Series Lineshft Hoists. Do not use this mnul s source of in for m tion for ny other equip ment. The following symols re used for emphsis throughout this mn u l: Filure to follow WARNING! instructions my result in equipment dm ge, property dmge, nd/or serious personl injury. Filure to follow CAUTION! instructions my result in equipment dmge, prop er ty dmge, nd/or minor personl injury. Importnt! Filure to follow Importnt! instructions my result in poor per for mnce of the equipment.
Owner's Mnul for Thern LS Series Lineshft Hoists pge 3 Suggestions for Sfe Opertion DO the following: Red nd comply with the guidelines set forth in this Owner s Mn u l. Keep this mnul, nd ll lels ttched to the hoist, redle nd with the equip ment t ll times. Contct Thern, Inc. for replcements. Check luriction efore use. Instll the wire rope securely to the hoist drum. Keep t lest 4 wrps of wire rope wound on the drum t ll times, to serve s nchor wrps. With less thn 4 wrps on the drum the wire rope could come loose, cusing the lod to escpe. Keep hnds wy from the drum, gers, wire rope, nd other moving prts of the equip ment. Keep ll unnecessry personnel wy from hoist while in opertion. Keep out of the pth of wire rope tht might snp ck nd cuse injury if roken. Disconnect electric power efore servicing the equipment. DO NOT do the following: This product designed for lifting nd moving mteril only. Do not use this product for ny other purpose. Do not exceed the lod rting of the hoist or ny other component in the system. To do so could result in filure of the equipment. Do not use more thn one hoist to move lod unless ech hoist ws designed for use in multiple hoist system. Do not use dmged or mlfunctioning equipment. To do so could result in fil ure of the equipment. Do not modify the equipment in ny wy. To do so could cuse equip ment fil ure. Do not wrp the wire rope round the lod. This dmges the wire rope nd could cuse the lod to escpe. Use pproved rigging connectors to secure the wire rope to the lod. Do not operte the hoist with drive gurds or ger covers removed or im proper ly instlled. Do not divert your ttention from the opertion. Sty lert to the pos si il i ty of ccidents, nd try to prevent them from hppening. Do not jerk or swing the lod. Avoid shock lods y strting nd stop ping the lod smoothly. Shock lods overlod the equipment nd my cuse dmge. Do not djust the rke with the hoist holding lod. Accidentl relese of the rke could result in loss of the lod.
pge 4 Owner's Mnul for Thern LS Series Lineshft Hoists 1.1 Instlling the Hoist Importnt! Inspect the hoist immeditely following instlltion ccording to the Instructions for Periodic Inspection. This will give you record of the condition of the hoist with which to com pre future inspections. A qulified professionl should inspect or design the foundtion to insure tht it will provide dequte support. When positioning the hoist use the lifting holes provided or sling wrpped round drum nd reducer ssemly. Do not ttempt to lift or position hoist y using lifting hole on reducer. This hole is designed to lift reducer only. Do not weld the hoist frme to the foundtion or support structure. Welding the frme my void wrrnty, contct Thern, Inc. Use fsteners s instructed. Do not instll the hoist in n re defined s hzrdous y the Ntionl Electric Code, unless instlltion in such n re hs een thoroughly p proved. Do not instll the hoist ner corrosive chemicls, flmmle mterils, explo sives, or other elements tht my dmge the hoist or injure the op er tor. Ad e qute ly protect the hoist nd the opertor from such elements. Attch the hoist to rigid nd level foundtion tht will support the hoist nd its lod under ll lod conditions, including shock loding. Lineshft hoists re designed for verticl lifting only. Lift lines must e connected directly to the lod. 1.1.1 CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on instlling the equipment. 1.1.2 LOCATE THE HOIST in n re cler of trffic nd other ostcles. Mke sure the hoist is ccessile for min te nnce nd op er tion. 1.1.3 LOCATE THE HOIST in n re with dequte tempertures. Check the motor nd reducer mn u fc tur er s informtion for mient tem per ture rt ings. 1.1.4 POSITION THE HOIST to llow ccess for proper luriction. 1.1.5 INSTALL THE HOIST on horizontl surfce. The hoist is designed nd ssemled for upright or underhung instlltion, s specified t time of order. 1.1.6 MAINTAIN A FLEET ANGLE of less thn 2 degrees. The proper fleet ngle minimizes wire rope dmge y helping the wire rope wind properly into the grooves on the drum. See Figure 1. 1.1.7 FASTEN THE HOIST SECURELY to the foundtion. For Stndrd products referred to in this mnul, use corse thred fsteners, grde 5 or etter. Be sure to check the torque required for your fstener selection efore mounting hoist. Mke sure the hoist is secured to solid foundtion le to support the hoist nd the lod under ll conditions with design fctors sed on ccepted engineering prctices. Non-stndrd products tht vry from the originl design my hve different fstening requirements. Contct structurl engineer or Thern, Inc. for this informtion. CONTACT A QUALIFIED PROFESSIONAL FOR MOUNTING INSTRUCTIONS TO COMPLY WITH LOCAL CODES.
Owner's Mnul for Thern LS Series Lineshft Hoists pge 5 1.2 Instlling the Brether Plug Importnt! Sve the seled plug for use when the hoist is removed for storge or trnsport. Instll the rether plug to vent het nd pressure. Filure to do so could result in pressure uildup which could dmge the reducer. For shipment, the reducer is filled with luricnt nd seled to prevent lu ri - c tion loss. SEW Eurodrive reducers re supplied with the rether plug instlled. Before opertion the lck ruer sel locted on the rether plug MUST BE REMOVED. Refer to the reducers mnufcturer's instructions. Motovrio reducers re mintennce free nd do not require rether. Some units supplied my not hve rether plug instlled for shipment. Instll the rether plug efore opertion. 1.2.1 REMOVE THE SEALED PLUG from the rether plug hole. 1.2.2 CHECK THE LUBRICANT LEVEL in the reducer to mke sure no lu ri cnt ws lost during shipment. Refer to the reducer mnufcturer s in struc tions. 1.2.3 INSTALL THE BREATHER PLUG. The reth er plug is wired to the reducer or ttched in plstic g. Refer to the reducer mnufcturer s informtion. Figure 1 Mintining the Fleet Angle Control fleet ngle y connecting wire rope in such wy tht it is stright verticl t high trim. tten t high trim CORRECT tten t high trim INCORRECT
pge 6 Owner's Mnul for Thern LS Series Lineshft Hoists 1.3 Connecting Electric Power Importnt! Use electricl equipment with the correct rting nd Un der writ er s L o r to ry (UL) pproved. Alwys disconnect electric cur rent when the hoist is not in use. Instll proper rnch circuits, disconnect devices, protection, nd ground ing s required y rticle 430 of the Ntionl Electric Code. All electricl work must e performed y licensed electricin. Filure to do so could result in electric shock or poor hoist opertion. All control devices must e momentry contct type. Instll ll control de vic es so the hoist motor will stop when the opertor releses the device. Locte control devices so the opertor will e le to view the lod through the entire opertion. Locte control devices so the opertor will e cler of the lod, the wire rope, nd the pth of wire rope tht could snp ck nd cuse injury if roken. It is the responsiility of the owner to provide equipment for con trol ling the hoist. Elec tri cl control pckges re ville from Thern. The fol low ing guide lines re sup plied s reference for the instller. 1.3.1 CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on electricl instlltion. 1.3.2 CHECK THE COMPONENT MANUFACTURER S INSTRUCTIONS for instlling nd connecting the motor, rke, nd other equipment. 1.3.3 INSTALL A FUSE or circuit reker in the power supply circuit, s re quired y the Ntionl Electric Code. 1.3.4 INSTALL A DISCONNECT DEVICE in the power supply circuit, s required y the Ntionl Electric Code. This should e switch you cn lock in the OFF position to prevent unuthorized use of the hoist. 1.3.5 CONNECT ELECTRIC STARTER CONTROLS to the motor. Mke sure the lod rke is wired for fst rking on rkemotors tht offer this func tion. Check the com po nent mn u fc tur er s informtion. 1.3.6 CONNECT ELECTRIC POWER SUPPLY, with ground wire, to the elec tric strter control ox. Check the component mnufcturer s informtion for wiring digrm. 1.3.7 CONNECT ELECTRICAL INTERLOCK LEADS from overspeed rke to control circuit to disle the hoist when the rke hs engged. 1.3.8 CONNECT OTHER ELECTRIC EQUIPMENT to the proper terminls in the electric control ox. 1.3.9 CHECK THE CURRENT t the motor nd mke sure it grees with the current rting mrked on the hoist nmeplte. If current rting is in cor rect, hve the cir cuit inspected y licensed electricin. 1.3.10 TEST ELECTRICAL CONNECTIONS, when provided, y operting the hoist. Ensure the centrifugl rke is positioned correctly efore operting. See Figure 4. ROTATION OF THE DRUM must gree with the lels on the control device, either UP nd DOWN, or FORWARD nd REVERSE. CHECK THE LOAD BRAKE, mke sure it releses when the motor is ON, nd en gg es when the motor is OFF. Mke sure the fst rke function op er tes correctly on rkemotors tht include this feture. CONTACT THE FACTORY OR A QUALIFIED PROFESSIONAL FOR HELP.
Owner's Mnul for Thern LS Series Lineshft Hoists pge 7 1.4 Instlling the Wire Rope Importnt! Use wire rope nd other rigging equipment rted for the size of the lrgest lod you will e moving. Do not drg the wire rope through dirt or deris tht could cuse dm ge, or poor opertion. Alwys wer protective clothing when hndling wire rope. Figure 2 Instlling the Wire Rope Key Slot Anchor Instll the wire rope securely to the hoist drum. A poorly secured wire rope could come loose from its nchor nd llow the lod to escpe. Instll the wire rope so it is wound correctly s shown or the hoist nd rke will not work properly, nd could llow the lod to escpe, see Figure 2. 1.4.1 PURCHASE THE PROPER WIRE ROPE for your ppliction. Keep the following in mind when selecting wire rope. Contct reputle wire rope supplier for help. BREAKING STRENGTH of new wire rope should e t lest 8 times greter thn the lrgest lod plced on the hoist. This is minimum vlue nd will vry with the type of lod nd how you re moving it. WIRE ROPE LAY must gree with the winding direction of the drum to help insure proper winding. c WE RECOMMEND 7 x 19 glvnized ircrft cle for dimeters up to 5/16 inch. 1.4.2 ANCHOR THE WIRE ROPE to the drum using the key slot nchor. PASS THE WIRE ROPE under the drum nd position the nchor fitting in the key slot in the drum. PULL THE WIRE ROPE to firmly lodge the nchor fitting in the nrrowest prt of the key slot. Mke sure the wire rope remins securely nchored s wire rope is wound onto the drum. See Figure 2. correct 1.4.3 WIND FOUR FULL WRAPS of wire rope onto the drum y operting the hoist while holding the wire rope tught. These wrps serve s nchor wrps nd must remin on the drum t ll times. instll wire rope in proper direction s shown to securely nchor the rope in the key slot nchor
pge 8 Owner's Mnul for Thern LS Series Lineshft Hoists 1.5 Setting Trvel Limits Limit set points re dependnt on speed of opertion. Use cution with setting limits on units with vrile speed opertion. Typiclly, limits should e for the highest speed to e encountered. Correct setup my tke some trils nd djustments. Stndrd units re shipped with TER limit switches. For units equipped with other limit switches, refer to mnufcturer's instructions. Ech unit's trvel is controlled y two sets of limit switches driven from the ger ox output shft. One set controls the norml movement (norml limit) of the unit. The other set (overtrvel limit) re there to indicte n overtrvel in the event of filure to the trvel limits. Figure 3 Setting Trvel Limits djustment screws 4 3 2 1 cm switch LS1 locking screw Switch Position Trvel LS1 Up Over LS2 Up Norml LS3 Down Norml LS4 Down Over The overtrvel limits should e set first to determine the solute mximum rnge of trvel tht the unit is le to run securely. The trvel limits should e set within this rnge to limit the movement of the norml operting rnge. 1.5.1 SET LIMITS y doing the following. Overtrvel limits should e set efore trvel limits. See Figure 3. c d e f g REMOVE the limit switch cover. LOOSEN the lrge locking screw in the center of the column. Individul limits cn now e set. DETERMINE WHICH DIRECTION the limit switch cm rottes when the "UP" utton is pressed. TURN THE SCREW leled "1" so tht the microswitch is hit y the cm when the lod "opens" to the desired position. The lower limit "4" should e djusted so tht the microswitch is hit y the cm s the unit moves into position in the "DOWN" direction. REPEAT THE PROCESS with screws leled "2" nd "3" to set the norml operting trvel limits. AFTER SETTING BOTH LIMITS the locking screw cn e tightened nd the limits re-checked. REPLACE the cover.
Owner's Mnul for Thern LS Series Lineshft Hoists pge 9 2.1 Generl Theory of Opertion Importnt! Limit nonuniform winding y keeping tension on the wire rope nd y mintining the proper fleet ngle. To help insure rted per for mnce, mke sure voltge t the motor is equl to the motor s voltge rting. It is your responsiility to detect nd ccount for different fctors ffecting the condition nd per for mnce of the equipment. 2.1.1 THE FORCE REQUIRED to move the lod must not exceed the lod rting of the hoist. Consider the totl force required to move the lod, not the weight of the lod. 2.1.2 THIS EQUIPMENT CAN develop forces tht will exceed the lod rting. It is the responsiility of the equipment user to limit the size of the lod. In spect the equip ment reg u lr ly for dmge ccording to the in struc tions contined in this mnul nd in the component mnufcturer s informtion. 2.1.3 PRIMARY AND SECONDARY LOAD BRAKES provide positive lod holding. Although new worm ger hoist my pper to hold the lod in plce, this chr c ter is tic will diminish with use. Do not de pend on hoist gering to hold the lod in plce. 2.1.4 PERFORMANCE RATINGS of the equipment re determined y the design of the hoist. LINE SPEED is the speed tht the lod will trvel. The weight of the lod does not ffect line speed. LOAD RATING represents the mximum pull tht cn e plced on new equip ment. 2.1.5 DUTY RATINGS refer to the type of use the equipment is su ject to. Consid er the following when determining duty rting. c d ENVIRONMENT: hrsh environments include hot, cold, dirty, wet, corro sive, or explosive surroundings. Protect the equip ment from hrsh en vi - ron ments when possile. MAINTENANCE: poor mintennce, mening poor clening, luriction, or inspection, leds to poor opertion nd possile dmge of the equip ment. Minimize poor mintennce y crefully following the in struc tions contined in this mnul. LOADING: severe loding includes shock loding nd moving lods tht ex ceed the lod rting of the equipment. Avoid shock lods, nd do not ex ceed the lod rting of the equip ment. FREQUENCY OF OPERATION: frequent strt nd stop func tions in crese wer nd shorten the life spn of the ger trin nd lod rke com po nents. Lengthy opertions cuse luriction to ecome hot, which lso decreses the life spn of the ger trin. Increse mintennce of the equipment if used in frequent opertions. CONTACT THE FACTORY FOR MORE INFORMATION.
pge 10 Owner's Mnul for Thern LS Series Lineshft Hoists 2.2 Breking-In the Hoist 2.2.1 BREAK-IN OCCURS during the first few hours of norml op er tion. During rek-in, mting surfces ecome polished, nd clernces increse. This is desired for efficient opertion of erings nd gers. 2.2.2 INSPECT THE HOIST following rek-in ccording to the Instructions for Periodic Inspection. See section 3.4 Inspecting the Equipment. 2.3 Prepring for Opertion Importnt! When determining whether the lod will exceed the lod rting, consider the totl force required to move the lod. 2.3.1 CONSIDER THE OPERATION. Do not egin until you re sure you cn perform the entire opertion without hzrd. 2.3.2 BEFORE INITIAL OPERATION inspect the hoist nd ll components of the system ccording to Instruction for Frequent Inspection. 2.3.3 BEFORE EACH OPERATION inspect ll components of the system. OPERATORS must e in good helth, lert, thoroughly trined in op er t ing the equipment, nd properly clothed (sfety equipment s required, no loose clothing, no loose jewelry). THE LOAD must e cler of other ojects nd free to move. Mke sure the lod will not tip, ind, or in ny wy move uncontrollly. 2.3.4 KNOW YOUR LOAD nd mke sure you do not exceed the lod rting of the hoist or ny other equipment in the system. 2.4 Moving the Lod Importnt! Oey stop signl from nyone. Mintin tension on the wire rope to keep it tightly nd evenly wound on the drum. If the hoist nd lod re not visile during the entire op er tion, get help from nother person. Appoint supervisor if more thn one person is involved in the opertion. This will reduce con fu sion nd increse sfety. 2.4.1 MOVE THE LOAD slowly nd smoothly, only smll distnce t first. Mke sure the lod is lnced nd securely ttched efore continuing. 2.4.2 USE THE CONTROL DEVICE to operte the hoist. The control device should e momentry contct type, so the hoist will stop when the op er tor releses the control. 2.4.3 OBSERVE THE WIRE ROPE s it winds onto the drum. If it ecomes loose, uneven, or overlpped, stop the opertion nd rewind the wire rope efore continuing. Continued opertion with overlpped or uneven wire rope cn dmge the wire rope nd shorten its life. 2.4.4 OBSERVE THE REDUCER during opertion for signs of overheting. Frequent overheting my e sign of dmge, or my indicte the need for lrger power hoist. WATCH FOR SMOKE, the smell of urnt luricnt, nd other signs of overhet ing. Use thermocouple or other device to monitor reducer tem per ture. STOP THE OPERATION if the reducer overhets, nd llow the hoist to cool. Continued opertion my cuse dmge.
Owner's Mnul for Thern LS Series Lineshft Hoists pge 11 3.1 Clening the Hoist Importnt! Increse the frequency of min tennce procedures if the hoist is: Operted for long periods. Used to lift hevy lods. Operted in wet, dirty, hot, or cold surroundings. Clen the hoist to remove dirt nd help prevent rust nd cor ro sion. 3.1.1 CLEAN THE HOIST t lest nnully or whenever it is dirty, per ppliction or environment equipment is in. c WIPE ALL EQUIPMENT to remove dirt nd grese. LEAVE A LIGHT FILM of oil on ll surfces to protect them ginst rust nd corrosion. WIPE OFF excessive mounts of oil to void the ccumultion of dirt. 3.1.2 REMOVE ALL UNNECESSARY OBJECTS from the re round the hoist. 3.2 Adjusting the Brkes Do not djust the rke with the lod suspended. Accidentl relese of the rke could llow the lod to escpe. 3.2.1 CHECK THE BRAKES y operting the hoist with lod equl to the hoist lod rting. c RAISE THE LOAD, then lower it nd stop it out one foot off the ground. OBSERVE THE LOAD when stopped. REFER TO BRAKE mnufcturer's instructions. 3.2.2 IF EQUIPPED WITH A SECONDARY CENTRIFUGAL BRAKE, see mnufcturer's instructions for mintennce nd opertion. Brke must e oriented upright to operte properly. See Figure 4. c BRAKE WILL NOT FUNCTION if improperly instlled. BRAKE MUST BE MOUNTED so the rke se is horizontl, prllel to floor. Mximum llowle ngulr tolernce is < 2 degrees. BRAKE MUST BE MOUNTED so the rrow follows cle direction when lowering. CONTACT THE FACTORY FOR ANY INSTALLATION QUESTIONS. Figure 4 Brke Instlltion cle direction when lowering rke rrow rke se correct incorrect incorrect
pge 12 Owner's Mnul for Thern LS Series Lineshft Hoists 3.3 Luricting the Hoist Importnt! Do not leve plug holes in the reducer open. Open plug holes will llow dirt nd moisture to con tm i nte the luriction. Mke sure luricnt hs temper ture rting pproprite for the mient tempertures of the opertion. Replce the mo tor er ings if the motor is dis s sem led for ny reson. Figure 5 Luricting the Flnge Bering flnge ering, luricte with NLGI no. 2EP grese Mke sure the rether plug is clen nd open to vent het nd pres sure. Poor ventiltion my cuse overheting nd result in dmge to oil sels nd other equipment. Fill the speed reducer to the proper level without overfilling. Too much or too little luricnt will cuse overheting nd result in dmge to sels, er ings, nd gers. Motovrio reducer's re mintennce free. They do not contin rethers or require dditionl luriction. Hoists re shipped pre-filled with luricnt. Luricte the hoist prop er ly to help protect it from wer nd rust. Red the following in struc tions crefully. 3.3.1 MOTOR BEARINGS re typiclly luricted for life y the mnufcturer. Some motors require periodic luriction. Refer to the motor mn u fc tur er s in for m tion for specific in struc tions. 3.3.2 LUBRICATE THE REDUCER ccording to the mnufcturer s in struc tions. c CHECK OIL LEVEL monthly. Remove the level plug nd mke sure oil is even with the plug hole. FILL THE REDUCER ccording to the mnufcturer's instructions. Fill the re duc er until oil reches the level plug. Do not mix dif fer ent luricnts. CHANGE REDUCER LUBRICANT t lest every 12 months, or whenever it is dirty or contminted. 3.3.3 LUBRICATE FLANGE BEARING monthly. Insert NLGI #2 EP (Extreme Pressure) grese through the grese zerk. Refer to the ering mnufcturer s informtion for specific instructions. See Figure 5. 3.3.4 LUBRICATE THE WIRE ROPE y following the wire rope mn u fc tur er s rec om men d tions.
Owner's Mnul for Thern LS Series Lineshft Hoists pge 13 3.4 Inspecting the Equipment Importnt! Strt n inspection progrm s soon s you put the hoist into use. Appoint qulified person to e responsile for regulrly inspect ing the equipment. Keep written records of inspec tion. This llows comprison with com ments from previous inspec tions so you cn see chng es in con di tion or per for mnce. Perform frequent inspections: Before initil opertion. Monthly during opertion. Whenever you notice signs of dmge or poor opertion. Frequent Wire Rope Inspection: Use ASME B30.7 s guideline for rope inspection, replcement nd mintennce. Check the wire rope, end connections nd end fittings for corrosion, kinking, ending, crushing, irdcging or other signs of dmge. Check the numer, distriution nd type of visile roken wires. See prgrph 3.4.4. c nd Figure 6. Check the wire rope for reduction of rope dimeter from loss of core support, or wer of outside wires. See Figure 7. Tke extr cre when inspecting sections of rpid deteriortion such s sections in contct with sddles, sheves, repetitive pickup points, crossover points nd end connections. Do not use dmged or mlfunctioning equipment. Plce n OUT OF OR DER sign on the hoist. Do not use the hoist until the sign is re moved y qulified mintennce person who hs completely corrected the prolem. Inspect the hoist to detect signs of dmge or poor opertion efore they e come hzrdous. See Tle 1 - Inspection Checklist. 3.4.1 CONSULT APPLICABLE CODES AND REGULATIONS for specific rules on inspecting the hoist nd other equipment. 3.4.2 CHECK COMPONENT MANUFACTURER S INSTRUCTIONS for inspect ing the motor, rke, reducer, erings, wire rope, nd other equip ment. 3.4.3 In struc tions for Frequent Inspection VISUALLY INSPECT the entire hoist nd ll other equipment involved in the opertion. Check ll equipment for crcks, dents, ending, rust, wer, corrosion nd other dmge. Mke sure the wire rope is instlled correctly nd nchored securely to the drum. Check the reducer for signs of lekge. Mke sure the entire hoist is properly luricted. Mke sure the rether plug is clen, open, nd instlled correctly. Mke sure mounting fsteners re tightened securely. Mke sure the foundtion is in good condition, nd cple of supporting the hoist nd its lod under ll lod conditions. Check electricl wiring nd connections for wer, corrosion, cuts, nd other dmge. TEST HOIST PERFORMANCE y operting the hoist with lod not exceeding the lod rting. Listen for unusul noises, nd look for signs of dmge s you operte the hoist. Mke sure the wire rope winds evenly nd tightly onto the drum. If it is loose or uneven, rewind it efore continuing. Mke sure the lod moves smoothly, without hesittion or strin. Mke sure the hoist responds to the control device. It must rotte s shown on the control lels, nd it must turn off when you relese the control. Check the motor rke. Rise the lod, then lower it nd stop it few feet off the ground. If the lod continues to cost or creep, the rke needs d just ment. Refer to rke mnufcturer s instructions. Completely correct ll prolems efore continuing. Use the Trou le shoot ing Chrt to help determine the cuse of certin prolems. See Tle 2.
pge 14 Owner's Mnul for Thern LS Series Lineshft Hoists Figure 6 Broken Wires wire strnd Perform periodic inspections: Every 12 months. Whenever you return the hoist to service from storge. Whenever you notice dmge or poor opertion in frequent in spec tion. one ly Wire rope ssemly must e replced if more thn 6 wires re ro ken in one ly, or if more thn 3 wires re roken in one strnd in one ly. Whenever you hve, or think you my hve, overloded or shock loded the hoist. 3.4.4 Instructions for Periodic Inspection c VISUALLY INSPECT the hoist nd ll other equipment. Check the finish for wer, flking, or other dmge. Check ll equipment for crcks, dents, ending, rust, wer, corrosion nd other dmge. If the equipment ws overloded, or if you notice crcks or other signs of overloding nd dmge promptly remove equipment from use nd hve it repired or replced. DO NOT CONTINUE TO USE DAMAGED OR OVERLOADED EQUIPMENT OR WIRE ROPE. Check ll fsteners for stripped threds, wer, ends, nd other dm ge. Check the gerox for signs of lekge. Contct the fctory if there re ny signs of luricnt leking from the gerox. Mke sure the rether plug is clen, open nd instlled correctly, Remove gurds nd visully inspect the rotry limit switch chin for poor lignment, excessive wer, corrosion, nd other dmge. Mke sure the entire hoist is properly luricted. Mke sure ll lels nd pltes re redle, firmly ttched, free of dmge nd clen. Replcements re ville from the fctory. DRAIN A SMALL AMOUNT OF LUBRICANT from the reducer into clen continer. Mintennce free reducers do not require this. Check the luricnt for dirt, metl prticles, wter, nd other signs of contm i n tion. Completely drin the reducer if luricnt is con tm i nt ed. INSPECT THE WIRE ROPE ccording to the wire rope mnufcture's recommendtions or follow ccepted industry stndrds for wire rope inspections. Alwys wer protective clothing when hndling wire rope. Check the entire length of wire rope for ent wires, crushed res, ro ken or cut wires, corrosion, nd other dmge. Crefully inspect res tht pss over sheves or through roller guides. Note the loction nd concentrtion of roken wires. Replce wire rope if more thn 6 wires re roken in one ly, or more thn 3 wires re ro ken in one strnd in one ly. See Figure 6. Mke sure the end fittings re securely ttched to the wire rope, nd the wire rope where it is ttched is not fryed, corroded, ro ken, or otherwise dmged. Check the nchor holes in the drum nd the surrounding re for signs of wer or distortion. d e PLACE enough weight to keep the wire rope stright nd tightly drwn. Mesure the dimeter of the wire rope, especilly in res where wer is noticele. Replce the wire rope if the dimeter mesures elow the minimum dimeter t ny point. See Fig ure 7. MOVE THE DRUM with your hnds. Check for excessive movement indicting worn or loose gers or erings. Excessive movement is cused y overloding or overheting, nd is sign tht your ppliction my re quire lrger power hoist.
Owner's Mnul for Thern LS Series Lineshft Hoists pge 15 Figure 7 Rope Dimeter correct di me ter in cor rect The wire rope ssemly must e replced if the dimeter mesures less thn the minimum dimeter t ny point. wire rope dimeter up to 1/8 in up to 3/16 in up to 1/4 in up to 5/16 in up to 3/8 in minimum dimeter 7/64 in (.1094 in) 11/64 in (.1719 in) 15/64 in (.2344 in) 19/64 in (.2969 in) 11/32 in (.3438 in) f g h i Disssemle the hoist if necessry. Inspect keys, erings, sels, nd shfts for wer, distortion, nd other dmge. INSPECT THE FOUNDATION AND RIGGING Check mounting fsteners for stripped threds, wer, nd other dmge. Check the foundtion for crcks, corrosion, nd other dmge. TEST HOIST PERFORMANCE y operting the hoist with lod not exceeding the lod rting. Listen for unusul noises, nd look for signs of dmge s you operte the hoist. Mke sure the wire rope winds evenly nd tightly onto the drum. If it is loose or uneven, rewind it efore continuing. Oserve the rotting drum, look for signs of loose or misligned er ings. Mke sure the lod moves smoothly without hesittion or strin. Mke sure the hoist responds to the control device. It must rotte s shown on the control lels, nd it must turn off when you relese the control. Check the motor rke. Rise the lod, then lower it nd stop it few feet off the ground. If the lod continues to cost or creep, the rke needs d just ment. Refer to rke mnufcturer s instructions. DISCONNECT ELECTRIC POWER nd inspect electricl equipment. Check electricl wires for worn insultion, cuts, corroded connections, nd other dmge. Check voltge of electricl supply with UL pproved voltmeter. If voltge is low, hve licensed electricin inspect the circuit. Mke sure the electricl control ox is securely instlled. Look inside the control ox for signs of moisture, corrosion, urn mrks, crcks, nd other dmge. CONNECT ELECTRIC POWER. Completely correct ll prolems efore continuing. Use the trou le shoot ing chrt to help determine the cuse of certin prolems. See Tle 2.
pge 16 Owner's Mnul for Thern LS Series Lineshft Hoists Tle 1 Inspection Checklist checked oxes indicte dmge or prolem in need of repir dmges prolems generl fi nish wethered, fl king, otherwise dmged hoist jerks or hesittes during opertion prts crcked, ent, rusted, worn, otherwise dmged unusul noises, other signs of mlfunction fsteners stripped threds, ent, worn, otherwise dmged loose, not tightened to proper torque reducer gers, erings, or shfts loose, worn, otherwise dmged not properly luricted luricnt lekge luricnt contminted wire rope ent, crushed, otherwise dmged wire rope loosely or unevenly wound roken wires, see Figure 6 replce if more thn 6 wires in one ly, numer per strnd = or 3 wires in one strnd in one ly, re roken numer per ly = dimeter reduced, see Figure 7 dimeter = end connections corroded, rusted, worn, otherwise dmged not securely ttched drum nchor hole worn, distorted, otherwise dmged excessive movement or cklsh motor motor urnt out, otherwise dmged volt ge t motor low rke rke worn, roken, otherwise dmged rke does not operte properly rotry limit switch chin drive worn, corroded, otherwise dmged poor lignment or loose control device electric components corroded, urnt, otherwise dmged fils to control hoist properly electric circuit electric wires worn, cut, corroded, otherwise dmged wires unprotected, ostructing trffi c connections loose, corroded, otherwise dmged voltge t motor = lels nd pltes dirty, illegile, otherwise dmged loosely ttched or missing comments uthorized signture dte
Owner's Mnul for Thern LS Series Lineshft Hoists pge 17 Tle 2 Trouleshooting Chrt Contct the fctory for ssemly/disssemly instructions. Disssemly of the gerox efore contcting Thern, Inc. voids ll wrrnties. prolem cuse correction motor won't run circuit reker tripped or fuse lown... reset circuit reker or replce fuse electricl connections loose or dmged... inspect, repir nd tighten s necessry electric power supply filure... contct power compny motor urnt out or dmged... repir or replce s necessry limit switch struck... run hoist off limit swtich nd check djustments motor runs, drum doesn't turn loose or roken ger keys... inspect nd replce s necessry loose, stripped or roken gers... inspect nd replce s necessry motor tries to turn ut cn't unit overheted... llow to cool lod too hevy... lighten lod voltge t motor too low... inspect supply circuit nd rewire s needed electric rke not operting properly... inspect nd repir s necessry gers or erings roken or locked... inspect nd replce s necessry loss of phse... check phses centrifuge rke set... contct fctory rke does not operte properly rke relese lever in relese position... move to lock position voltge to rke incorrect... check voltge t control ox, repir s needed rke djusted incorrectly... djust rke rke discs or solenoid worn or dmged... inspect nd replce s necessry rke components seized up or dmged... inspect nd repir s necessry overspeed rke locked... inspect nd djust s necessry luricnt lekge worn erings... inspect nd replce s necessry dmged oil sels or gskets... inspect nd replce s necessry crcked or dmged reducer... inspect nd repir s necessry excessive end ply on drive shft loose or dmged keys or keywys... inspect nd replce s necessry excessively worn gers... inspect nd repir s necessry excessive worn gers or erings lod too hevy... lighten lod poor luriction of reducer or erings... inspect nd luricte s necessry overheting operted too long without rest... llow to cool lod too hevy... lighten lod poor luriction... inspect nd luricte s necessry rether plug clogged or dmged... clen or replce rether plug ering seized up... inspect nd replce s necessry unusul noises high pitched squek poor luriction... inspect nd luricte s necessry grinding noise contminted oil... drin, clen nd luricte the hoist roken gers or erings... inspect nd replce s necessry whining motor lod too hevy... lighten lod motor overheted... llow to cool motor erings urnt out... replce motor or erings rttling noise loose fsteners or setscrews... tighten ll olts nd screws worn or loose drg rke... inspect nd repir or tighten s necessry hevy thump during opertion contminnts in luricnt... drin, clen nd luricte the hoist loose setscrews or keys in gers or shfts... inspect nd repir s necessry erings defective... inspect nd replce s necessry
pge 18 Owner's Mnul for Thern LS Series Lineshft Hoists 3.5 Repiring the Hoist Importnt! It is your responsiility to deter mine when to replce prts. When considering whether to continue using prt or to re plce it, re mem er tht replcing it is the est wy to void further equip ment dmge. Replce spring pins, retining rings, nd oil sels whenever the hoist is disssemled for in spection or repir. Appoint qulified person to e responsile for ll repirs to the equipment. 3.5.1 GET FACTORY AUTHORIZATION for ll repirs. Unuthorized repirs will void the wrrnty, nd my led to dmge or filure of the hoist. 3.5.2 REPLACE DAMAGED OR POORLY OPERATING PARTS with Thern repir prts. 3.5.3 REFINISH AREAS where the pint is worn or flking. A good finish helps to protect ginst corrosion nd wether dmge. c REMOVE THE FINISH from dmged res, down to the re metl. CLEAN THE AREA thoroughly. REPAINT with high qulity primer nd finishing cot. 3.5.4 TO ORDER REPAIR PARTS, contct your locl deler. Include the fol lowing informtion when ordering: model numer seril numer (or code numer) prt numer dte purchsed, nd from whom description of wht hppened, or wht is wrong your nme nd return ddress
Owner's Mnul for Thern LS Series Lineshft Hoists pge 19 4.1 Trnsporting the Hoist Importnt! Keep record of wht you ship, nd when you send it. 4.1.1 REMOVE THE BREATHER PLUG nd instll seled plug to prevent the loss of lu ri c tion during shipment. 4.1.2 PACK THE HOIST in n upright position for trnsport, using the originl pckging mterils, if possile. c d FASTEN THE HOIST to wooden se using olts, to keep it from mov ing during trnsport. SEAL THE HOIST in plstic with desiccnt to help protect it from rust, corrosion, nd other dmge. CONSTRUCT WOODEN SIDES nd top to enclose the hoist in solid pro tec tive crte. PACK LOOSE PARTS in smll ox es or ship seprtely. 4.1.3 INSPECT THE HOIST ccording to the Instructions for Periodic In spec tion efore instlling it in new loction. 4.2 Storing the Hoist 4.2.1 FILL THE REDUCER with luricnt, nd mke sure the rether plug is clen nd properly instlled. Add rust preventtive for long term storge. Follow the reducer mnufcturer s instructions. 4.2.2 SEAL THE HOIST in plstic with desiccnt to help protect it from rust, corrosion, nd other dmge. 4.2.3 STORE THE HOIST upright, in cool clen plce wy from corrosive chem i cls nd moisture. 4.2.4 ROTATE THE DRUM PERIODICALLY to keep ering nd gers sur fc es from ecoming lcquered. Relese the rke to rotte the drum. 4.2.5 INSPECT THE HOIST ccording to the Instructions for Periodic In spec tion efore instlling it for opertion. 4.2.6 TEST INSULATION RESISTANCE in the motor to detect mois ture dmge. Refer to the motor mnufcturer s in struc tions. 4.2.7 DRAIN THE REDUCER nd fill with proper luricnt prior to opertion. See section 3.3 Luricting the Hoist.
A division of: Thern, Incorported 5712 Industril Prk Rod Winon, MN 55987 PHN 800-553-2204 FAX 507-454-5282 EMAIL: info@thernstge.com www.thernstge.com