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Planeta PKB Series Operation And Maintenance Manual

Low headroom trolley hoist
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Operation and maintenance manual for
Low headroom trolley hoist PKB
Installation - Operation - Maintenance
IMPORTANT - READ BEFORE USE!
PLANETA-Hebetechnik GmbH • Resser Str. 17 & 23 • D-44653 Herne
Tel. +49 2325 9580-0 • Fax +49 2325 77077 • info@planeta-herne.de • www.planeta-hebetechnik.de
© Reprint, also in extracts, only with written permission of PLANETA-Hebetechnik GmbH
01-06-02-0000-0515-00-BA-EN-PLA

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  • Page 1 IMPORTANT - READ BEFORE USE! PLANETA-Hebetechnik GmbH • Resser Str. 17 & 23 • D-44653 Herne Tel. +49 2325 9580-0 • Fax +49 2325 77077 • info@planeta-herne.de • www.planeta-hebetechnik.de © Reprint, also in extracts, only with written permission of PLANETA-Hebetechnik GmbH...

  • Page 2: Introduction

    Each operator must have read the entire manual and fully understand its contents. © Copyright 2015 by PLANETA. All rights reserved. No parts of this document may be reproduced or transmitted in any form or by any means electronic or mechanical, including photocopying and recording, for any purpose without the express written permission of PLANETA.

  • Page 3: Table Of Contents

    Table of contents Introduction........................2 Definitions ........................5 Safety instructions ......................6 Symbols ......................6 Safety precautions....................7 Purpose of use ....................7 Inappropriate use ....................7 Safe operation ....................7 Proper load attachment / suspension ..............8 Installation, commissioning, maintenance and repairs..........8 Periodic inspection and tests ................
  • Page 4 11.1 Standard headroom ...................35 11.1.1 Model K hoist ....................38 11.1.2 Model N hoist ....................43 11.2 Low headroom ....................48 11.3 Ultra low headroom ...................49 Appendix I. Logbook ....................51 Appendix II. Technical specifications ................52...

  • Page 5: Definitions

    Definitions The following definitions are used in this manual: Product Wherever the term “product” is used this means the hoist trolley unit. Hoist trolley unit A hoist trolley unit means an trolley combined with an chain hoist to executed as a single unit with a standard headroom, low headroom or ultra low headroom.

  • Page 6: Safety Instructions

    Safety instructions The products of PLANETA are equipped with safety devices, such as limit switches, overload protection, brakes, etc. However, danger which arises from improper use cannot be prevented with our safety devices. Please read the safety instructions of this manual carefully to work as safe as possible.

  • Page 7: Safety Precautions

    Safety precautions The product can only be controlled by operators with the following qualifications: Complete knowledge of this manual. ‐  Reached the age of 18. ‐  Capable both physically and mentally. ‐  Have been instructed in operating and maintaining the product and have shown ‐ ...

  • Page 8: Proper Load Attachment / Suspension

    Make sure before starting with lifting, that the safe working load will not be ‐  exceeded. See chapter 3.3 “Safe Working Load”. If overload occurs always inspect the hoist trolley unit for any damage. ‐  Never put limbs between parts which might pinch or cut. ‐ ...

  • Page 9: General Information

    General information This manual describes an PLANETA hoist trolley unit for heavy duty use in an industrial environment. Technical specification If deviating specification are applicable, then the technical specifications can be found in Appendix II “Technical specifications”, and may contain one or more of the following items: Scope of supply, data &...

  • Page 10: Trolley Nameplate Designation

    Trolley nameplate designation The nameplate contains product specific information and can be found fixed to the trolley. The actual nameplate mounted can differ from the example illustration below. Safe working load / CE marking Specific information Company logo Place and country of origin In the middle of the nameplate, a small list of specific information is shown for the product.

  • Page 11: Hoist Nameplate Designation

    Hoist nameplate designation The nameplate contains product specific information and can be found fixed to the hoist. The actual nameplate can differ from the example illustration below. Safe working load Company logo CE marking Place and country of origin Specific information In the centre of the nameplate, a small list of specific information is shown for the product.

  • Page 12: Product Overview And Dimensions

    Product overview and dimensions In this chapter the main components and dimension of standard headroom, low headroom and ultra low headroom hoist trolley units are given. All illustrations show the default configuration, which might differ from reality. 3.9.1 Standard headroom Below illustration shows the main components of a standard headroom hoist trolley unit.
  • Page 13 K hoist trolley unit. For standard headroom model N hoist trolley units, dimension table 2 shall be used. If applicable, dimensions of other configurations are enclosed in Appendix II “Technical specifications” or can be obtained through your contact person at PLANETA upon request.
  • Page 14 90~143 149~203 3.000 33 kN Ø100 Ø120 42,5 Ø100 203~254 251~305 106~156 160~210 5.000 52 kN Ø125 Ø150 46,5 Ø135 210~260 255~305 7.500 84 kN >= 119 Ø160 Ø190 79,5 72,5 Ø270 10.000 104 kN >=131 Ø160 Ø190 79,2 72,5 Ø270 15.000 164 kN >=155...

  • Page 15: Low Headroom

    3.9.2 Low headroom Below illustration shows the main components of a low headroom hoist trolley unit. Component description 1. Single flange wheel 8. Safety latch load hook 2. Side plate 9. Load chain 3. Wheel shaft 10. Hand chain trolley control 4.
  • Page 16 Dimensions Below illustration and dimension table 3, shall be used for the dimensions of a low headroom model K hoist trolley unit. For low headroom model N hoist trolley units, dimension table 4 shall be used. Low headroom model K dimensions Dimensions 11 kN 55-300...

  • Page 17: Ultra Low Headroom

    3.9.3 Ultra low headroom Below illustration shows the main components of a ultra low headroom hoist trolley unit. Component description 1. Single flange wheel 9. Hand chain trolley control 2. Single flange geared wheel 10. Hand chain hoist control 3. Wheel shaft 11.
  • Page 18 Dimensions Below illustration and dimension table 5, shall be used for the dimensions of a ultra low headroom model K hoist trolley unit. For ultra low headroom model N hoist trolley units, dimension table 6 shall be used. Ultra low headroom model K dimensions Dimensions 1.000 22 kN...

  • Page 19: Transport And Storage

    Transport and Storage Transport If necessary, the hoist trolley unit can be transported to another location. To prevent damage while transporting, follow the steps below. Lift the load hook to its highest position. ‐  Put the housing down on a stable underground. ‐ ...

  • Page 20: Installation

    Installation Warning! Installation may only be carried out by competent persons! Tip! The position numbers mentioned in this chapter are according to the illustration of chapter 3.9 “Product overview”. Unpacking Before installation, the hoist trolley unit shall be unpacked from its packing. Keep any accompanying documents near the operating site of the hoist trolley ‐ ...
  • Page 21 Installation Depending on the situation, the hoist trolley unit can be installed in two ways. Option A is recommended and preferred because of the ease of installation. If the ends of the monorail aren’t accessible, due to a wall or other obstacles, follow option B instead of option A. To install the hoist trolley unit properly, the following steps shall be taken in sequence.
  • Page 22 Option B2, Disassemble and remove a section of the monorail. ‐  Lift the hoist trolley unit next to the end of the monorail with the underside of the ‐  wheels just above the bottom flange of the monorail. Attention! Watch for the orientation of the hoist trolley unit. Push the hoist trolley unit onto the monorail.

  • Page 23: Commissioning

    Commissioning After installation, it is important to make sure that the complete system is functioning properly by following the next tests and checks in the correct order. The tests and checks before commissioning must also be executed when the system has been stored or has been out of operation for a period longer than 3 months.

  • Page 24: Operation

    Operation This chapter gives a short description on how to operate hoist trolley unit. Attention! Before operating an hoist trolley unit: Read chapter 2 “Safety instructions” See section “Before use” of chapter 8.1 “Maintenance schedule”. Personal protective equipment Personal protective equipment shall be provided by the owner and shall be used where necessary. Ear and eye protection.
  • Page 25 Capacity Ultra Low Headroom Hoist model Trolley Hoist 1.000 N005 K005 2.000 N010 K010 3.000 K015 3.200 N016 29,5 5.000 K025 6.300 N032 10.000 K025 12.000 N032 Pulling force table 2 Operating an hoist trolley unit Manual push and manual geared trolleys are intended to be operated by hand. Manual push trolleys are not equipped with a drive mechanism and shall be pushed by hand.

  • Page 26: Maintenance

    Maintenance In this chapter the maintenance, lubrication and torques are given. Warning! Maintenance, inspection and damage assessment may only be executed by competent maintenance personnel. Malfunctions have to be reported immediately, to the owner, who has to initiate repair work, which is to be carried out by competent maintenance personnel. All maintenance, measurements, shortcomings, damages and repairs must be written in a logbook.

  • Page 27: Lubrication List

    When the hoist trolley unit is going to be taken out of operation for a period longer than one month, follow maintenance table 2. Taking out of service for a period longer than six months is considered as storage for which maintenance table 3 should be used. Maintenance when taking out of operation Rotate all bearing and shafts Fill all gearboxes generously with oil...

  • Page 29: Tightening Torques

    Tightening torques Tightening torques of fasteners in components such as motors gearboxes etc. should be tightened according the manufactures documentation. Other fasteners are according to below tables. Normal bolt nut connections shall be fastened according to torque table 1. All custom threads (For example support and suspension bolts, wheel shafts, guide roller shafts, etc.) shall be fastened according to torque table 2.

  • Page 30: Chain

    Chain Load chains last very long under normal usage conditions, but wear is unavoidable. Below tables shows the dimensions of a new load chain which must be used to determine the actual wear. Capacity Standard Headroom Low Headroom Model Ød Ød Ød Ød...

  • Page 31: Hook

    Wear criteria The chain must be replaced when one of the following criteria is fulfilled. Plastic deformation of a chain link as a result of tensile or bending forces. Reduction of the average wire diameter at any point on the chain link of more than 10% of the nominal thickness.
  • Page 32 Attention! If necessary, the hook pivot bearing may only be greased in the factory of PLANETA . Inspection The both hooks and hook blocks must be checked for damage and wear using the following criteria.

  • Page 33: Malfunctions

    Malfunctions Hoist trolley units last very long without malfunctions when maintenance is regularly preformed, but malfunctions are is unavoidable. Below table shows malfunctions which might occur. When a malfunction has been found it has to be reported immediately, to the owner, who has to initiate repair work, which is to be carried out by competent maintenance personnel.

  • Page 34: Taking Out Of Operation

    10 Taking out of operation To keep the hoist trolley unit in good condition when taking out of service for a period longer than one month, follow the steps below. Attention! If the hoist trolley unit is taken out of service for a period longer than six months read chapter 4 “Transport and Storage”...

  • Page 35: Spare Parts

    Request for spare parts can be issued at your contact person at PLANETA using the manufacture number of the hoist trolley unit. Warning! The use of non-original spare parts can lead to situations which are potentially dangerous to health and life.
  • Page 36 Standard headroom manual push 81000... Pos. Qty. Consisting of 6 kN 11 kN 22 kN 33 kN 52 kN 64 kN Single flange wheel Bearing Circlip Wheel shaft Hexagon lock nut Circlip Support bolt Suspension bolt Adjustment washer* Hexagon lock nut Hoist See chapter 11.1.1 “Model K hoist”...
  • Page 37 Pos. Qty. Consisting of 84 kN 104 kN 124 kN 164 kN 204 kN 254 kN Single flange push wheel Bearing Circlip Wheel shaft Hexagon lock nut Circlip Support bolt Suspension bolt Adjustment washer* Hexagon lock nut Hoist See chapter 11.1.1 “Model K hoist” or 11.1.2 “Model N hoist”. Buffer Hex head bolt Hand chain...

  • Page 38: Model K Hoist

    11.1.1 Model K hoist Below illustration and spare parts table 3 shows the spare parts of a model K hoist from 0,5 to 2,5 ton. 0,5 ton 1 ton 1,5 ton 2 ton 2,5 ton Pos. Qty. Consisting of K005 K010 K015 K020...
  • Page 39 Gear case assembly C3BA005-6103 C3BA010-6103 C3BA015-6103 C3BA020-6103 C3BA025-6103 Nameplate B C3BG005-9800 C3BG010-9800 C3BG015-9800 C3BG020-9800 C3BG025-9800 J1NA001-20080 J1NA001-20100 J1NA001-20120 Spring washer J1WS001-20080 J1WS001- J1WS011- 20100 20120 Pawl spring set A & B C3BA005-5179 Pawl C3BA005-9155 Snap ring J1SS000-00010 Friction disc C3BA005-9153 C3BA020-9153 Friction plate C3BA005-9151...
  • Page 40 20 ton / K200 Spare parts table 4 in combination with the three previous illustrations shows the spare parts of a model K hoist from 3 to 20 ton. 3 ton 5 ton 7,5 ton 10 ton 15 ton 20 ton Pos.
  • Page 41 Pawl spring set A & B C3BA005-5179 C3BA005-5179 Pawl C3BA005-9155 C3BA005-9155 Snap ring J1SS000-00010 J1SS000-00010 Friction disc C3BA005-9153 C3BA020-9153 Friction plate C3BA005-9151 C3BA020-9151 Ratchet disk C3BA005-9152 C3BA005-9152 Bushing C3BA005-9154 C3BA020-9154 Hand wheel C3BA015-9115 C3BA025-9115 Wheel stopper C1FA005-9159 C1FA015-9159 Wheel stopper pin C3BA005-9167 C3BA005-9167 J1PW01-...
  • Page 42 C2BA200-9074 Lever nut C2BA200-9074 C2BA400-9074 U nut C3BA100-90871 C3BA150-9018 Guide C3BA150-9018 Hook support C3BA150-9026 C3BA200-9026 Bottom yoke C3BA150-9030 C3BA200-9030 C3BA150-90342 Bottom plate A C3BA200-90341 Bottom plate B C3BA150-9035 C3BA200-9035 Bottom plate C C3BA20-9036 Stay-bolt C3BA150-9038 C3BA200-9038 Collar A C3BA200-9039 Collar B C3BA200-9040 Bottom shaft C3BA150-9054...

  • Page 43: Model N Hoist

    11.1.2 Model N hoist Below illustration and spare parts table 7 shows the spare parts of a model N hoist from 0,5 to 5 ton. 1 ton 0,5 ton 1,6 ton 2 ton 3,2 ton 5 ton Pos. Qty. Consisting of N005 N010 N016...
  • Page 44 10 ton / N100 16 ton / N160...
  • Page 45 20 ton / N200 25 ton / N250...
  • Page 46 32 ton / N320 Spare parts table 8 in combination with the five previous illustrations shows the spare parts of a model N hoist from 10 to 32 ton. 10 ton 16 ton 20 ton 25 ton 32 ton Pos. Consisting of N100 N160...
  • Page 47 47-3 Centre plate holder WHH50472 XHH50472 47-5 Stay bolt A for holder UHH5A0475 47-6 Stay bolt B for holder VHH50476 WHH5009B XHH5009B 47-7 Stay bolt C for holder VHH50477 47-8 Stay pipe for holder VHH50478 WHH5010 47-10 Stay pipe B for XHH5010B holder 47-12...

  • Page 48: Low Headroom

    11.2 Low headroom Below illustration shows the spare part of an manual push and geared low headroom hoist trolley unit and shall be used in combination with spare parts table 9 and 10. Tip! The shown position numbers are in accordance with chapter 3.9.2 “Low headroom”. Low headroom manual push 81300...

  • Page 49: Ultra Low Headroom

    Low headroom manual geared 81400... model N, 81410… model K Pos. Qty. Consisting of 6 kN 11 kN 22 kN 33 kN 52 kN 104 kN Single flange wheel Bearing Circlip Wheel shaft Hexagon lock nut Circlip Hoist See chapter 11.1.1 “Model K hoist” or 11.1.2 “Model N hoist”. Hand chain Hand chain wheel Hand chain guide...
  • Page 50 Ultra low headroom manual geared 81650... model N, 81660… model K Pos. Qty. Consisting of 22 kN 33 kN 52 kN 84 kN 124 kN Single flange wheel Bearing Circlip Single flange geared wheel Bearing Circlip Wheel shaft Hexagon lock nut Circlip Bottom hook block Load hook...

  • Page 51: Appendix I. Logbook

    Appendix I. Logbook The following table can be used to write down the results of installation, commissioning, maintenance, repairs, etc... Date Inspected by Results...

  • Page 52: Appendix Ii. Technical Specifications

    Appendix II. Technical specifications If applicable, the technical documentation will be included as a separate document.

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