Operation and Maintenance Manual

Portal Crane Serial Number PC-29014 04-134805 International Paper Co. - Texarkana Mill

Dangers, Warnings, Cautions, Notices

Dangers, Warnings, Cautions, and Notices are used throughout this manual to emphasize important and critical instructions. Dangers, Warnings, and Cautions always precede the paragraph or item to which they apply; Notices always follow the paragraph or item to which they apply. For the purpose of this manual Dangers, Warnings, Cautions, and Notices are dened as follows:

! DANGER
Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.

! WARNING DANGER
Warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

! CAUTION DANGER
Caution indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

NOTICE
Notice is used to notify people of installation, operation, or maintenance information which is important but not hazard-related.

COPYRIGHT
Under the copyright laws, this document may not be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine readable form, in whole or part, without the prior written consent of Morris Material Handling. Copyright 2001 Morris Material Handling, Oak Creek, Wisconsin, USA 53154 All rights reserved. Printed in the United States. Published by: Publications Department

Table of Contents
SAFE OPERATING PRACTICES STRAIGHT TRACK PORTAL CRANES v
FOREWORD v OPERATOR QUALIFICATIONS v General v Operator Tests v PHYSICAL AND MENTAL CONDITION v LOCKOUT/TAGOUT PROCEDURES vi INSPECTION AND MAINTENANCE vi General vi DAILY. vi MONTHLY vii INSPECTION AS REQUIRED. viii TROUBLESHOOTING viii SAFETY RECOMMENDATIONS viii

Transporting Wood With The Crane 2-12 Loading The Log Deck 2-13

3-1 LUBRICATION & PREVENTIVE MAINTENANCE 3-1

GENERAL 3-1 LUBRICATION 3-1 General 3-1 BOLT TORQUES 3-4 MAINTENANCE / LUBRICATION 3-4 No Lubrication Required 3-5 EACH SHIFT MAINTENANCE CHECKS 3-5 General 3-5 Inspect, Wire Rope 3-5 Lubricate Grapple 3-6 DAILY MAINTENANCE CHECKS 3-6 General 3-6 Cable Reel, General Inspection 3-6 Check Level, Grapple Reservoir 3-6 Grapple, General Inspection 3-6 Lubricate, Block Adapter/Rotate Bearing 3-6 Inspect Wheels 3-6 WEEKLY MAINTENANCE CHECKS 3-7 General 3-7 Check Level, Gantry Drive Gear Case 3-7 Check Level, Trolley Drive Gear Case 3-7 Check Level, Hoist Gear Case 3-7 Lubricate, External Lower Gantry Drive Gears 3-7 Lubricate, Sheave Bearings 3-7 Lubricate, Gantry Wheel Bearings 3-7 Lubricate, Trolley Wheel Bearings 3-7 Lubricate, Drum Pedestal Bearings (If Applicable) 3-7 Lubricate, Festoon Carrier Wheel Bearings (If Applicable) 3-7 Cable Reel, General Inspection 3-7 Grapple, General Inspection 3-8 MONTHLY MAINTENANCE CHECKS 3-8 General 3-8 Wire Rope 3-8 Lubricate, Wire Rope 3-8 Handling Wire Rope 3-9 Replace Air Filter, Grapple Reservoir 3-10 Lubricate, Drive Motors 3-10 Cable Reel, Tension Adjustment 3-10 Lubricate, Miscellaneous Pins / Linkage 3-10 GEAR INSPECTION 3-10 General 3-10 Gear Terminology 3-10 Inspection and Wear Patterns 3-12 SEMI-ANNUAL MAINTENANCE CHECKS 3-14 General 3-14

1-1 INTRODUCTION 1-1

SCOPE 1-1 INSPECTION REPORT FORM 1-1 GENERAL INFORMATION 1-1 SAFETY 1-1 WARRANTY 1-1 PURCHASED COMPONENTS 1-1 DESCRIPTION 1-1 General 1-1 TERMINOLOGY 1-2

2-1 CONTROLS AND CRANE OPERATION 2-1

GENERAL 2-1 SAFE OPERATING PRACTICES 2-1 General Crane Safety 2-1 Safe Operating Practices 2-1 On-ground Inspections And Boarding Checks 2-3 Start-up Checks 2-3 Shutdown Procedure 2-4 OPERATING CONTROLS 2-8 Operational Notes, Log Handling Cranes 2-9 CRANE OPERATION 2-10 General 2-10 Hoist Operation 2-10 Gantry Operation 2-11 Trolley Operation 2-11 Grapple Operation 2-11 MATERIAL HANDLING 2-11 General 2-11 Unloading Trucks 2-12 Reclaiming Wood From The Log Pile 2-12

Table of Contents

Cleaning, General Crane Assembly 3-14 Lubricate, Swivel Thrust Bearings 3-14 Change Oil, Gantry Drive Gear Case 3-14 Change Oil, Trolley Drive Gear Case 3-14 Change Oil, Hoist Gear Case 3-15 Change Oil, Cable Reel Gearcase 3-15 Change Oil, Grapple Reservoir 3-15 Grapple, General Inspection 3-15 ANNUAL MAINTENANCE CHECKS 3-16 General 3-16 Inspect / Clean, Drive Motors 3-16 Cable Reel, General Inspection 3-16 GENERAL DISASSEMBLY 3-16 GENERAL INSPECTION AND REPAIR 3-16 GENERAL ASSEMBLY 3-17

TROUBLESHOOTING 4-1
GENERAL 4-1

5-1 GANTRY DRIVE SYSTEM 5-1

GENERAL 5-1 DRIVE MOTOR 5-1 MOTOR BRAKE 5-1 DRIVE REDUCTION GEAR CASE 5-1 WHEEL ASSEMBLIES 5-1 General 5-1 Removal 5-1 Installation 5-2 EQUALIZER, AND TRUCK PINS AND BUSHINGS (16 WHEEL CRANES) 5-3 General 5-3 Removal - (16 Wheel Cranes Only) 5-3 Installation. 5-4 WHEEL ALIGNMENT 5-4 Equipment Required - (16 Wheel Cranes) 5-4 For 8 Wheel Cranes with Swivel Leg Ends 5-4 Analysis of Reading - (16 Wheel Cranes) 5-5 SHIMMING WHEELS 5-5 General 5-5 Wheels with capsule type housings (used until 1987) 5-5 Wheels with MCB type housings (used after 1987) 5-6 Traverse Reducer Manual (Brook Hansen) follows. 5-6

CRANE INSPECTION PROCEDURES 3-19

GENERAL 3-19 CRANE STRUCTURE 3-19 General 3-19 Welds 3-19 Bolted Connections 3-19 Pin Connections 3-19 Trolley Rails 3-19 Rail Clips 3-19 Walkways 3-19 Bumper Assemblies 3-19 Lighting Fixtures and Mountings 3-19 RUNWAY 3-19 General 3-19 Alignment 3-19 Inspection / Maintenance 3-20 REFERENCED DOCUMENTS. 3-20 Materials 3-20 Metal Track Materials 3-20 RECOMMENDED INSPECTION 3-22 Level of Inspection 3-22 Maintenance 3-22 Alignment 3-22 Track Maintenance 3-22 Rail Failures 3-23 Portal Crane Operator Shift (Daily) Check List 3-35 Crane PC-29014 3-35 Portal Crane Mechanical Shift (Daily) Check List 3-36 Crane PC-29014 3-36 Portal Crane Electrical Shift (Daily) Check List 3-37 Crane PC-29014 3-37 Routine Outage Mechanical Inspection Checklist PC-29014 3-38 Routine Outage Electrical Inspection Checklist PC-29014 3-39

6-1 TROLLEY DRIVE SYSTEM 6-1

Trolley Drive Reducer 6-1 Trolley Drive Motor 6-1 Trolley Drive Brake 6-1

7-1 HOIST SYSTEMS 7-1

GENERAL 7-1 MAIN HOIST UNIT 7-1 Description 7-1 Drive Motor 7-1 General 7-1 Description 7-1 Removal 7-1 Repair 7-2 Installation 7-2 Motor Brake 7-2 Description 7-2 Removal, Repair, And Installation 7-2 Drive Reduction Gearcase 7-3 General 7-3

4-1
ii

Description 7-3 Removal 7-3 Installation 7-3 Disassembly 7-5 Cleaning 7-6 Inspection 7-6 Repair 7-7 Assembly 7-7 Seal Replacement, Drum Shaft 7-8 Pedestal Bearing 7-8 Removal 7-8 Assembly 7-9 Upper Equalizer Sheaves 7-9 General 7-9 Removal 7-9 Cleaning And Repair 7-11 Installation 7-11 Lifting Beam Assembly 7-11 General 7-11 Removal 7-11 Cleaning And Repair 7-12 Installation 7-13 Reeving 7-13 Unreeving The Hoist Drums 7-13 Reeving The Hoist Drums 7-14 Wire Rope 7-15 General 7-15 Handling Wire Rope 7-15 Storage 7-15 Sealing of Gear Cases 7-16 Introduction 7-16 1. Surface Preparation: 7-16 2. Sealant Application Procedure: 7-16 Crane Hoist Motion Gearcases I & PH Type 7-18 Crane Traverse Motion Gearcase I & PH Type 7-18 Crane Hoist & Traverse Motion Gearcases CI Type 7-18 Crane Traverse Motion Gearcase TH Type 7-18 Crane Hoist Motion Gearcase - Bucket Trolley 7-19 MACK GRAPPLE 7-19 DEAD END ASSEMBLY INFORMATION 7-19

GANTRY BUMPERS AND RAIL SWEEPS 10-1 General 10-1 Inspection 10-1 Repair 10-1 TROLLEY BUMPERS AND RAIL SWEEPS 10-1 General 10-1 Repair 10-1

11-1 LIMIT SWITCHES AND LIMITING DEVICES 11-1

GENERAL 11-1 MAIN HOIST LIMIT SWITCHES 11-1 GEARED LIMIT SWITCH 11-1 Description 11-1 Adjustments 11-1 Maintenance 11-2 Repair 11-2 WEIGHT OPERATED LIMIT SWITCH, TYPE HB 11-4 Description 11-4 Adjustment 11-4 Maintenance 11-5 Repair 11-5 END OF DRUM LIMIT SWITCHES 11-6 General 11-6 Description 11-6 Adjustment 11-6 Repair 11-7 MISCELLANEOUS LIMIT SWITCHES 11-7 General 11-7 Maintenance 11-7 Repair 11-8 Adjustments 11-8 Hoist Overload Load Cell System (Optional) 118

12-1 COLLECTOR / CONDUCTOR / SPAN BAR SYSTEMS 12-1

GENERAL 12-1 GANTRY COLLECTOR / CONDUCTOR SYSTEM 12-1 Festoon Conductor System 12-1 POWER CABLE REPLACEMENT 12-3 General 12-3 Cable Replacement 12-3

8-1 DRIVE MOTORS 8-1

GENERAL 8-1

9-1 BRAKES 9-1 10-1 BUMPERS, SHOCK ABSORBERS AND RAIL SWEEPS 10-1
GENERAL 10-1

13-1 CAB 13-1

GENERAL 13-1 AIR CONDITIONER 13-1

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iii

14-1 CONTROL SYSTEMS 14-1

GENERAL 14-1

15-1 CABLE REELS 15-1

GENERAL 15-1 MAIN POWER CABLE REEL 15-1

16-1 MISCELLANEOUS COMPONENTS 16-1

GENERAL 16-1 WIND SPEED INDICATOR SYSTEM 16-1 LOAD CELL - (Optional) 16-1 CONTROL HOUSE AIR CONDITIONER 16-1 ADDITIONALLY, THE FOLLOWING PUBLICATIONS HAVE BEEN PROVIDED (hardcopy only): 16-1

17-1 STORM BRAKES 17-1 18-1 GRAPPLE 18-1 19-1 TV CAMERA 19-1 20-1 WIRING DIAGRAMS 20-1

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SAFE OPERATING PRACTICES STRAIGHT TRACK PORTAL CRANES

FOREWORD
It is the desire of Morris Material Handling to assure safe and economical use of the machinery it produces. This manual describes preventive maintenance, inspection and specic safety recommendations. Not all of the material presented will apply to any single Portal Crane. However, the majority of the information applies to all types of Portal Cranes, and the reader is requested to bear with those items which do not specically relate to their equipment. Safety begins with properly designed and manufactured equipment. Morris Material Handling welcomes that responsibility. However, the use of the equipment is subject to certain hazards that cannot be met by mechanical means alone, but only by the exercise of intelligence, care and common sense. Once the equipment enters service in the eld, Morris Material Handling has no direct control over its inspection, maintenance, or operation. For this reason, safety in the eld is the responsibility of the user. Most accidents involving cranes are the result of violating safety rules during operation and/or lack of inspection and maintenance procedures. Morris Material Handling recognizes that most companies who use por tal cranes have a safety program in place. If a conict exists between a rule set forth in this publication and a similar rule already set by an individual company, the more stringent of the two should be followed. 3. Crane inspectors qualied to operate a crane

Operator Tests
Every employer should require that all persons who will be authorized to operate lifting equipment must rst pass an examination which accurately measures practical knowledge of cranes and hoists and proper methods to be used in handling loads and operating the lift equipment. PHYSICAL AND MENTAL CONDITION. 1. An operator must possess good hearing, good vision (corrected or uncorrected) good depth perception especially where load spotting is critical or at some distance from the operator. 2. An operator must not have any known health condition or disability which could cause inability to react quickly. 3. An operator who is taking medication prescribed by a doctor must present written assurance from his doctor that the medication will not affect the operators ability to operate the hoist in a safe manner. 4. An operator who is known, or suspected, to be under the inuence of alcohol or drugs must not be allowed to operate a crane. 5. The operator must be safe at all times

OPERATOR QUALIFICATIONS General

Only the following personnel should be permitted to operate lifting equipment after reading this manual: 1. Appointed Qualied operators. 2. Qualied maintenance and test personnel, when required to do so in the performance of their duties.
Rev. Date 10/25/04

NOTICE
Each crane operator should be held directly responsible for the safe operation of the crane. Whenever there is any doubt as to safety, the operator should stop the crane and refuse to handle loads until safe conditions have been restored.

Revised 10/25/04

LOCKOUT/TAGOUT PROCEDURES
Lockout/Tagout is the placement of a lock/tag on the energy isolating device in accordance with an established procedure. When taking equipment out of service to perform maintenance or repair work, always follow the lockout/ tagout procedures as required by OSHA 29 CFR Part 1910.147 and outlined in ANSI Z244.1. Following these procedures will help to ensure the safety of personnel on or around the equipment by preventing accidental machine start-up. The policy shall give consideration to the following crane and hoist or lifting equipment areas: 1. Single crane runways or aisles. 2. Multiple crane runways or aisles. 3. Cranes on adjacent runway or aisle. 4. Runway or installation disconnecting means. 5. Crane or equipment disconnecting means. 6. Work to be done on equipment. 7. Work to be done other than on a crane or equipment but within the path of a crane or equipment where its movement creates a hazard.

1. Be sure that the crane is properly lubricated. 2. Inspect all brakes for proper adjustment. Check electric motor (holding) brakes by lifting a capacity or near capacity load a few inches off the ground and holding it suspended using the brake. 3. Operate each control to determine that it functions properly. Report any malfunction found to properly authorized supervisor and notify the next operator at the change of shift. 4. Visually inspect each component of the crane normally used in load handling. This inspection should include, but again not be limited to, such items as the following: A. Wire rope. Inspect for kinks or broken wire and replace damaged rope immediately. Inspect for twisted ropes, or ropes which may have come out of the drum grooving. B. All functional operating mechanisms such as sheaves, drums, and brakes, and all safety devices such as upper and lower limit switches.

! DANGER
Limit switches are safety devices, not operating controls. Never actuate them unnecessarily during normal crane operation. Unnecessary operation of limit switches will cause premature limit switch failure resulting in injury or death of personnel. C. The following general procedure should be used when checking limit switches. 1). Always move the crane to an open area, away from personnel and equipment. 2). Be sure no live load is on the hoist lines. 3). Slowly run the lifting beam up to about three (3) feet below the limit switch trip mechanism and stop the hoist motion completely. 4). (For cranes with rotary assemblies) Rotary limit should stop hoist travel before the lifting beam comes in contact with nal weight limit. 5). (For cranes with rotary assemblies) To check nal weight limit, lower hoist below where rotary limit will come in contact and manually lift nal limit weight to allow nal limit to open. Next, test up motion on hoist to see if nal limit is functioning properly. Motion should not run. Release the weight.

INSPECTION AND MAINTENANCE General

It is recommended that a per iodic inspection, lubrication, and maintenance schedule be established for each crane, and that this schedule be carefully followed. Such a procedure will prevent minor damage from becoming progressively more dangerous, as well as more costly to repair. Due to the widely varying conditions under which nearly identical cranes may operate, it is impossible for the manufacturer to state exact time intervals at which inspections and/or maintenance should be performed. All inspection, maintenance, and lubrication intervals recommended in any P&H / Morris Publication represent minimum safe inter vals for average conditions, since there is no substitute for experience or rst hand knowledge of local operating conditions. Inspections are recommended for three basic purposes and intervals. Each is discussed in the following paragraphs. DAILY. This inspection should be made at the beginning of each shift, and should include, but not necessarily be limited to, the following:

vi

STRAIGHT TRACK PORTAL CRANES

Morris Material Handling 6). Proceed to raise the beam slowly. The geared/rotary limit switch should stop the hoist prior to contact with the weight limit switch trip. 7). If the geared/rotary limit switch does not operate at the point at which it should, lower the lifting beam out of contact with the limit switch trip mechanism and notify properly authorized personnel at once. D. Visually inspect the entire crane for signs of damage which might cause unsafe operation. E. Visually inspect gear cases, motors, and brakes. Look for oil leaks, loose or missing hardware and/ or parts, and visually check the brake air gaps. Repair oil leaks, tighten bolts, replace missing or damaged hardware and/or parts, and have the maintenance department adjust the brake air gaps as necessary. F. Visually inspect the general condition of the conductor system. Report any damage to the appointed person. G.Inspect the mainline power cable reel for proper operation and alignment. During the inspection of the cable reel observe the following: 1). Observe that the cable picks up and pays out under proper tension. 2). Inspect the alignment of the cable guide rollers. 3). Listen for unusual noise during cable reel operation. Report any abnormal or unusual operation to the appointed person. Refer to Main Power Cable Reel information for more detailed instr uctions regarding the inspection of the cable reel. H.Check the runway system for debris. Move the cab in-line with each runway rail, and visually inspect for debris laying across the tracks. Remove any debris which may interfere with the operation of the crane, or obstruct its movement along the runway. Visually inspect the condition of the track itself. Look for obvious damage or misalignment. Do not operate the crane if damage or noticeable misalignment is evident. I. Check the rail cleaning bricks attached to the gantry rail sweeps. If brick surface is dirty, ip bricks to clean side or replace with new cement bricks. J. Check the hydraulic oil level in the grapple reservoir. Add oil as necessary to bring the oil level up to proper operating capacity. K. Remove wheel chocks, and/or tie downs if used. L. Release storm brakes from cab prior to use. The above visual and operational checks will take only a few minutes at the beginning of each shift, and are absolutely necessary to ensure safe operation. MONTHLY. It must be recognized that, while a Portal Crane is designed and manufactured with a factor of safety, every machine begins to wear on the day it starts working. This process will inevitably continue until, at some future date, the machine will no longer be capable of its' original workload, unless all parts subject to wear or damage are regularly inspected and repaired or replaced as needed. The following monthly inspection is intended to determine the need for repairs required to keep the machine in approximately new condition. The monthly inspection should not be limited to the items detailed below. This inspection procedure is considered minimum. Knowledge of local conditions, age and condition of a particular machine, and the severity of operation, as well as the possible effects of failure, all combine to deter mine the degree of inspection for continued safe operation. The results of the monthly inspection should be carefully recorded in a suitable log book, in full detail, and should be dated and signed by the inspector. The purpose of the monthly inspection is to nd and correct any wear or damage, which could affect the safe operation of the crane. This should include the items listed under the daily inspection as well as the following: 1. Inspect the entire crane for structural damage. 2. Inspect for cracked or worn sheaves, drums, wheels, and rails. 3. Inspect for worn, cracked, or distorted components such as pins, bushings, bearings, shafts, and gears. 4. Inspect for excessive wear of brake system parts and linings. 5. Check the condition of the re extinguisher, if furnished. 6. Inspect all motors, controls, and conductor systems, which might in any way affect the safety of the machine. 7. Visually inspect the condition of the track itself. Look for obvious damage or misalignment. Do not operate the crane if damage or noticeable misalignment is evident. Inspect the track for wear.

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Revised 10/25/04 8. Inspect the entire crane structure for damage. During inspection of the structure observe the following: A. Check that the gates and platforms are securely anchored. B. Check that the stairways and stairway landings are securely anchored to the gantry legs. C. Look for broken or cracked welds, missing or damaged hardware, and missing or damaged structural parts. Repair or replace any missing, or damaged parts or hardware. INSPECTION AS REQUIRED. T h e t h i r d t y p e o f inspection is to be done after incidents of sudden and unusual shock loads, unusual stress, or if damage is suspected due to any cause. All incidents which might affect operation of the crane should be followed by immediately taking the crane out of service and performing a thorough inspection of the crane, using all necessary nondestructive test methods. All repairs should be made before the machine is returned to service. 1. Before leaving the control station of the crane, the following precautions must be observed: A. Stop the crane at the approved location for entering or leaving the crane. (Note: crane should be parked with the grapple in the highest position. This will prevent damage to the crane if the crane is blown down track in severe weather.) B. Lower the load to the ground, and remove it from thehead block and grapple. C. Place all controls in the OFF position. D. Place the main power switch in the OFF position. E. Make a visual check for any abnormal or dangerous condition. Correct or report any which are found. F. Outdoor cranes must have the wind anchors secured so as to prevent movement caused by wind. G.Crane operators should never leave the crane during the work shift unless it is absolutely necessary. When necessary to leave, notify the proper authority and properly secure the crane.

TROUBLESHOOTING
The rst step to be taken before a troubleshooting procedure is started, is to communicate with all persons that the equipment is being removed from operation and secure any/all lockout tagout procedures. Failure to strictly follow this warning may lead to the injury or death of personnel. See Lockout/Tagout Procedures on page -vi before proceeding with Inspections. Troubleshooting a crane or a hoist is a special condition of inspection which is not always addressed in a regular inspection or preventive maintenance schedule. Troubleshooting is usually done as a result of a complaint of an unknown source of abnormal operation or noise, or any other indication of unusual performance. Special procedures for troubleshooting should be established to perform the function safely for all personnel concerned.

NOTICE
Never depend on a holding brake to suspend a load unless the operator is at the controls, alert, and in a position of readiness to handle the load. 2. An operator must not eat, read, sleep, or otherwise diver t his attention while operating a crane. Practical jokes are absolutely forbidden, and the use of alcohol or other intoxicants is not to be tolerated. An operator who is given a prescription drug by a physician should obtain written assurance that it will not prevent him from operating the crane in a safe manner, before returning to work. 3. The operator or person in charge should see that: A. All loose items such as tools or debris are removed from the crane before beginning the lift. B. The load does not contact any obstruction while lifting or traveling. C. Sudden starts and stops must be avoided. Bumping into runway and/or trolley stops is prohibited. D. The hoist line is vertical before starting the lift, slack in the line is removed slowly, and that all personnel are clear of the area before beginning the lift.

SAFETY RECOMMENDATIONS
The following safety recommendations represent the accumulated experience of Morris Material Handling regarding the most likely causes of personal injury and damage to equipment. Compliance with the following recommendations will prevent the majority of common accidents.

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STRAIGHT TRACK PORTAL CRANES

Morris Material Handling E. No load should ever pass over the heads of personnel or in any way endanger their safety. Nonoperating personnel should be warned, or told to leave the immediate area, when making lifts. F. Riding the lifting beam or grapple is prohibited. The crane is not intended to be used as a passenger elevator. G.Only the operator rides the crane while it is in operation. Visitors may ride in the cab only, with the permission of the operator. 4. ALL stop signals must be obeyed, regardless of who gives them. 5. Other than stop signals, signals are accepted from only one person at a time, unless special arrangements are made in advance for a specic lift only. 6. Standard crane signals are used and loads are not moved unless the standard signals are clearly given, seen and understood (see Figure 1). 7. The operator should test the holding brake by moving the controller to the OFF position when a load is rst lifted, and when the load is only a few inches above its starting position, to assure the ability of the brakes to hold the load. If the load is held, the brake is operating properly. If the brake does not function properly, maintain control of the load using the hoist motor and lower it slowly to rest. Report the condition to the appropriate supervisor immediately and do not make any other lifts until the condition has been corrected. 8. Never get on or off a crane when it is in motion. Never attempt to adjust, repair, or lubricate moving machinery. 9. Keep the machine clean and in good working order. Oil or grease can cause serious falls, and dirt in working parts will cause accelerated wear and consequent possible malfunction. 10. Lower the grapple to the ground before attempting any repairs or adjustments. 11. Always replace all protective guards and panels before operating the crane or hoist. 12. Keep wire ropes in good operating condition, paying particular attention to the following: A. A kinked wire rope is no longer safe. When a new wire rope has been installed, work light loads for a short period of time to allow the wire rope to adjust itself to work strains. B. Inspect all wire ropes for kinked or broken wires on a regular basis, preferably daily. 13. Never exceed the rated capacity of the crane. 14. Never use a crane for side pulling. It was not designed nor intended for such use. This practice may cause electrical as well as mechanical damage and will endanger personnel. 15. If a wire rope has been allowed to become slack, make sure that the rope is properly seated on the drum and in the sheaves before a load is lifted. 16. Never lower the lifting beam to a point where less than two full wraps remain on the drum. If all wire rope is removed from the drum, be sure it is rewound in the correct direction to prevent wire rope damage and to ensure correct operation of the hoist limit switches. 17. Never block out safety devices, such as limit switches, in order to allow operation of the crane in a manner not intended by the manufacturer. 18. If electrical power fails, place all controllers in the OFF position and keep them there until power is restored. This will prevent sudden and unexpected movement when power is restored. 19. Never remove a DO NOT OPERATE card from a control without checking to see that it is safe to do so, even if you have placed the card yourself. Someone else may be depending on that card to prevent the crane from being operated. 20. Use fuses of specied size. Blown fuses provide an indication of trouble as well as provide the main protection afforded by the electrical system. 21. Never contact another crane on the same runway if it is possible to avoid doing so. When this must be done, check rst to see that all concerned are aware that it will be done and that they are properly warned. Then, contact the crane to be pushed at the slowest possible speed and push it at very slow speed. Never move or bump a crane or hoist that has a warning ag or sign displayed. 22. While inspecting, repairing, cleaning, lubricating, or maintaining any crane, a warning ag should be placed where it is readily visible to indicate that the crane is not to be moved. The main power switch must be locked in the OFF position. When someone other than the operator is doing the work, the operator must remain at the controls, alert for possible danger to the workmen, unless specically informed to the contrary by his supervisor.

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Revised 10/25/04 23. All Portal Cranes are equipped with a warning bell or siren, which will automatically sound when the crane is moved. 24. When the crane is being serviced, repaired, lubricated, or otherwise maintained, it must be moved to a position over an area where no one will be endangered by falling material. If this is not possible, the area beneath the crane must be roped off and personnel must be warned of the reason for the precaution. 25. Repairs and adjustments should be made only by properly designated and authorized personnel. When a crane is being repaired, the maintenance person assigned is in charge of all phases of crane movement and operation, and his instructions should ordinarily be obeyed without question. Only if his instructions are contrary to safe operating practices should the operator question them. Under these circumstances, the maintenance supervisor should be contacted at once for a decision.

Standard Hand Signals

STRAIGHT TRACK PORTAL CRANES

Morris Material Handling

Standard Hand Signals

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Morris Material Handling

xii

Section 1 INTRODUCTION
SCOPE
This manual provides information for the adjustment, lubrication, operation, and maintenance necessary for the safe and efcient operation of your Morris Material Handling Straight Track Por tal Crane. If explicit information not contained in this manual is required, consult the Morris Material Handling Portal Crane Service Department, in Birmingham, AL @ (877) 943 5734 or (800) 633-1136.

SAFETY
The safe operating practices which apply to this product are printed in the Preface at the front of this manual. It is very important that operators and maintenance personnel read and be familiar with these safe operating practices in addition the operating procedures for this product. This will help to establish and preserve safe working conditions for operators, service crews, and other personnel in the area.

INSPECTION REPORT FORM

A crane inspection report form has been included at the back of Section 3 to aid in establishing a preventive maintenance program. This form should be copied and completed whenever the crane is inspected. Written, dated and signed inspection reports and records should be made on all critical items such as the grapple, wire ropes, and brakes. Reports and records should be kept where readily available to appointed personnel.

WARRANTY
The warranty that accompanies this crane clearly denes the terms under which the crane is covered. This warranty will be voided if the crane is operated under any of the following conditions: With loads in excess of the maximum rated capacity. When safe operating practices are disregarded. With accessories not designed, furnished approved by Morris Material Handling. or

GENERAL INFORMATION
The information, specications, and illustrations in this publication are based on the information for Straight Track Portal Cranes in effect when this manual was printed. Continuing improvement and advancement of product design may cause changes to the crane which may not be included in this publication. Whenever a question arises regarding this crane or this manual, please consult the Morris area representative for the latest available information. Part numbers may be occasionally shown in this manual to identify various parts and assemblies. Do not use the part numbers shown in this manual to order repair parts. When ordering repair parts, always refer to the Repair Parts Manual that has the same serial number as the crane for which the parts are being ordered.

With modications made to the crane which were not designed or approved by Morris Material Handling.

PURCHASED COMPONENTS
Components which are not manufactured by Morris Material Handling may not necessarily be covered in this manual. Refer to the literature provided by the manufacturer of the equipment in question for service and repair information.

DESCRIPTION General
The Straight Track Portal Crane consists of four basic units, the gantry, the trolley, the hoist unit, and the

Rev. Date 10/25/04

1-1

Revised 10/25/04 grapple. These units are described individually below (See Figure 1-1 on page 1-5). ADJUSTABLE VOLTAGE. A method of control by which the motor supply voltage can be adjusted or varied. A P P O I N T E D ( Pe r s o n ) . O n e a s s i g n e d s p e c i c responsibilities by the employer or the employers representative. AUTOMATIC CRANE. A crane which when activated will operated through a preset cycle or cycles. BOX SECTION. The rectangular cross section of girders, trucks, or other members which are enclosed on four sides. BRAKE. A device, other than a motor, used for retarding or stopping motion by friction or power means. BRAKE, HOLDING. A friction brake for a hoist that is automatically applied and prevents motion when power to the brake is off. BRAKE, PARKING. A brake for gantry or trolley that may be automatically or manually applied to impede horizontal movement. BRAKE, SERVICE. A brake for a gantry or trolley used by the operator, during normal operation, to apply a retarding force to the applicable drive system. BRAKING, COUNTERTORQUE (Plugging). A method of controlling speed by reversing the motor line voltage, polarity, or phase sequence to develop torque in the direction opposite the rotation of the motor. BRAKING, DYNAMIC. A method of controlling speed by using the motor as a generator, with the energy being dissipated in resistors. BRAKING, REGENERATIVE. A method of controlling speed in which the electrical energy generated by the motor is fed back into the power system. BUMPER (Buffer). A device for reducing impact when a moving crane or trolley reaches the end of its permitted travel, or when two moving cranes or trolleys come into contact. The device may be attached to the gantry, trolley, or runway. CAB. The operators compartment on a crane. CABLE BASKET. A device mounted on the lifting beam used to pay out and collect the electrical cable which feeds the grapple. CABLE REEL, MAINLINE POWER. An electrically operated device for laying down and picking up the main power cable which supplies electric power to the crane. CANTILEVER. A girder section which protrudes beyond the outboard side of the gantry legs. CAPACITY. The maximum rated load which a crane is designed to handle.

GANTRY. The gantry is the main structural member

used to span the width of the runway area. It travels the length of the runway on rails secured to the runway supporting structure. The gantry is made up of a girder, a xed leg assembly, a hinged leg assembly, and two sill beams. The sill beams serve to tie the lower ends of each leg set together.

TROLLEY. The trolley is a motor driven vehicle which

travels along a set of rails fastened to the gantry girder assembly. The trolley is used to support the hoist unit, the cab assembly, and the trolley machinery. HOIST. The hoist unit, which is mounted on the trolley assembly, is an apparatus which exerts a force for lifting or lowering loads. It is power driven through a gear reduction drive train and a hoist drum.

GRAPPLE. The grapple is suspended from the hoist

lines. The hoist lines are reeved from the hoist drum on the trolley structure, through the sheaves on the lifting beam, through upper sheaves on the trolley, and eventually are dead-ended into anchors located on the trolley frame. See Figure 1-2 on page 1-6.

NOTICE
The reeving of the lifting beams and hoist drum is covered more thoroughly is Section 7. The grapple is operated by a self-contained hydraulic system. Power for the hydraulic system is fed from the trolley deck through an electrical cable to the lifting beam and grapple assembly. The extra cable is stored in a cable basket located on the top of the lifting beam. The cable basket is designed in such a manner which allows the cable to be paid out and to be retrieved as the grapple is raised and lowered.

TERMINOLOGY
There are a number of terms commonly associated with Straight Track Portal Cranes, relating both to the construction and to the function of the crane. These terms are listed and dened as follows: ABNORMAL O P E R AT I N G CONDITIONS. Environmental conditions that are unfavorable, harmful, or detrimental to or for the operation of a crane. Examples include excessively high or low ambient temperatures, exposure to adverse weather, high winds, corrosive fumes, dust laden or moisture laden atmospheres, and hazardous locations.

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INTRODUCTION

Morris Material Handling CLEARANCE. Distance from any part of the crane to the nearest obstruction. COLLECTORS, CURRENT. Contacting devices for collecting current from runway or gantry conductors. CONDUCTORS, GANTRY. The current conductors located along the gantry structure of a crane that transmit power to the trolley. CONTACTORS, MAGNETIC. An electro-magnetic device for repeatedly establishing and interrupting an electric power circuit. CONTROLLER. A device for regulating, in a predetermined way, the power delivered to a motor or other equipment. CONTROLLER, MANUAL. A controller having all of its basic functions performed by devices that are operated by hand. CONTROLLER, SPRING RETURN. A controller that, when released, will return automatically to a neutral (OFF) position. CONTROL PANEL. An assembly of components (magnetic, static, hydraulic, pneumatic, etc.) that govern the ow of power to, or from, a motor or other equipment in response to signals from a master switch, push button station, remote control, automatic program control, or other similar device. CRANE. A machine for lifting and lowering a load and moving it horizontally, with the hoisting mechanism as an integral part of the machine. DEAD LOADS. The loads on a structure which remain in a xed position relative to the structure. On a crane, such loads include the girders, footwalks, cross shafts, drive shafts, panels, drive assemblies, etc. DEFLECTION. Displacement due to bending or twisting in a vertical or lateral plane, caused by imposed live and dead loads. DESIGNATED (Person). One selected or assigned by the employer or the employers representative as being competent to perform specic duties. DRIFT POINT. A point on a travel motion master switch or on a manual controller that maintains the brake released while the motor is not energized. This allows for coasting. DRUM. The cylindrical member around which the ropes are wound for lifting or lowering the load. ENCLOSURE. A housing to contain electr ical components, usually specied by a NEMA classication number. END APPROACH. The minimum horizontal distance. parallel to the r unway, between the outer most extremities of the crane and the centerline of the grpple. FIELD WIRING. The wiring required after erection of the crane. FIXED AXLE. An axle which is xed in the truck and on which the wheel revolves. FIXED LEG. The V shaped structure on each side of the gantry at the xed leg end. FLIP-OVER BRACKET. The main electrical feed point, generally located at the center of the crane travel, which allows the electrical feed cable to ip-over as the crane passes. FOOTWALK. A walkway with a handrail attached to the gantry or trolley for access purposes. GIRDER. The principal horizontal beams of the crane assembly which support the trolley and which is supported by the end trucks. HINGED LEG. The single leg structure on each side of the gantry at the hinged leg end. HOIST. A unit that is used for lifting or lowering a freely suspended (unguided) load. IDLER TRUCK. A non-powered truck traveling on the crane rail providing support for the crane. LIFT. The maximum safe vertical distance through which the grapple can move. LIFTING BEAM. The lower reeving assembly and cross shaped structure which supports the grapple. LIVE LOAD. A load which moves relative to the structure under consideration. LOAD. The total superimposed weight on the grapple. LOAD CARRYING PART. Any part of the crane in which the induced stress is inuenced by the load on the grapple. MAIN HOIST. The primary hoist mechanism provided for lifting and lowering the rated load. MATCH MARKING. The method of identication used on non-interchangeable parts for reference during assembly after shipment. NEUTRAL POSITION. The OFF or middle position of a master control switch lever. NORMAL OPERATING CONDITIONS (Cab Operated Cranes). Conditions during which a crane is performing functions within the scope of the original design. Under these conditions, the operator is at the operating control devices, and there is no other person on the crane.

1-3

Revised 10/25/04 PARTS OF LINE. The number of lines of rope supporting the grapple. PITCH DIAMETER, ROPE. The distance through the center of a drum or sheave from center to center of a rope passed about the periphery. PORTAL CRANE. A gantry or semi-gantry crane in which the gantry girders or trusses extend transversely beyond the crane runway on one or both ends. QUALIFIED (Person). A person who, by the possession of a recognized degree or certicate of professional standing, or who by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems related to the subject matter and work. RAIL SWEEP. A device attached to the crane and located in front of the cranes wheels to remove obstructions from the runway rail. R AT E D L OA D ( C a p a c i t y ) . T h e m a x i mu m l o a d designated by the manufacturer for which a crane or individual hoist is designed and built to lift or lower safely. REEVING. A system in which a rope travels around drums or sheaves. REGULATED SPEED. A function which tends to maintain a constant motor speed for any load for a given speed setting of the controller. ROPE. Refers to wire rope unless otherwise specied. ROTATING AXLE. An axle which rotates with the wheel. RUNWAY. An assembly of rails, beams, girders, brackets, and framework on which the crane travels. SERVICE CLASS, CMAA RATINGS. The following service class rating has been taken in whole from CMAA Specication #70, Revised 1983. It denes how the Crane Manufacturers Association of America classies service duty of this crane. Class F (Continuous Severe Service): This type of service requires a crane capable of handling loads approaching rated capacity continuously under severe service conditions throughout its life. Applications may include custom designed specialty crane essential to performing the critical work tasks affecting the total production facility. These cranes must provide the highest reliability with special attention to ease of maintenance features. SHEAVE. A grooved wheel or pulley used with a rope to change direction and point of application of pulling force. SHEAVE, NONRUNNING (Equalizer). A sheave used to equalize tension in opposite parts of the rope. Because of its slight movement, it is not termed a running sheave. SIDE PULL. The por tion of the hoist pull action horizontally when to hoist lines are not operated vertically. SPAN. The horizontal distance, center to center, between the runway rails. SPREAD. The horizontal distance, center to center, between the trolley rails. STOP. A device to limit travel of a trolley or crane gantry. The device normally is attached to a xed structure and normally does not have energy-absorbing ability. SWITCH, LIMIT. A device that is actuated by the motion of a part of a power driven machine or equipment to alter or disconnect the electric circuit associated with the machine or equipment. SWITCH, MAIN (Crane Disconnect). A switch on the crane controlling the main power supply from the cable reel/transformer. SWITCH, MASTER. A switch that dominates the operation of contactors, relays, or other remotely operated devices. TORQUE, FULL LOAD (Motor). The torque produced by a motor operating at its rated horsepower and speed. TROLLEY. The unit that travels on the gantry rails and supports the grapple. TRUCK. A unit consisting of a frame, wheels, bearings, and axles that supports the gantry girders, and end ties of the Straight Track Portal Crane. WHEEL BASE. The distance from center to center of the outermost wheels. WHEEL CHOCK. A wedge which prevents the crane from moving when unattended. WHEEL LOAD. The load without impact on and wheel with the trolley and lifted load (rated capacity) positioned to provide maximum loading.

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INTRODUCTION

Morris Material Handling

Figure 1-1 Straight Track Portal Crane

1-5

Revised 10/25/04

Figure 1-2 Straight Track Portal Crane, Trolley

1-6

INTRODUCTION

Section 2 CONTROLS AND CRANE OPERATION

GENERAL
This section provides detailed descriptions of each operating control, as well as general instructions for the recommended operation of this crane, including startup and shutdown procedures. In addition to the safe operating practices provided at the front of this manual, specic safe operating practices for this Straight Track Portal Crane are also provided in this section.

Safe Operating Practices

The following are specic safe operating practices for Straight Track Cranes, and are in addition to the Safe Operating Practices published in the Preface. 1. Always set the storm brakes and turn the power OFF at the control console by depressing the EMERGENCY STOP push button, before sliding back the operators chair. 2. Always use the seat belt.

SAFE OPERATING PRACTICES General Crane Safety

The following are recommendations which should be adhered to by all personnel in the vicinity of the crane. 1. Know how to give the EMERGENCY STOP signal. The EMERGENCY STOP signal is dened in Figure 1 under the topic Safe Operating Practices, in the preface of this manual. 2. Never divert the operators attention while he/she is operating the crane. 3. Remedy and report all hazards which are found in the operating area. 4. Be observant, and report all signs of damage or wear to the components or runway. 5. Keep protective guards and fences in place. 6. Obey tag-out regulations, and out-of-order notices. 7. Board and leave the crane at designated boarding locations. 8. Never ride on the Lifting Beam or Grapple. 9. Never work under a potential path of the load.

3. Attach the chain across the walkway ladder to the trolley platform or, if so equipped, close the swinging gate. 4. Initiate and terminate crane motions in a smooth fashion. Avoid start/stop/start/stop operations of the crane motions. 5. During crane operations, should anything unusual or unexpected happen, or for any reason the operator feel threatened or out of control, move the control levers to the OFF position, bringing the crane to a controlled stop. If the situation dictates, depress the EMERGENCY STOP push button shut all crane motions down. Assess the situation. Do not over-react. Then, carefully start over. 6. The operator should always know where all ground trafc and activity is around his crane and runway. 7. Never exceed the rated capacity of the crane. 8. Do not run the crane into the runway end stops. 9. Do not run the trolley into the girder end stops. 10. Never use limit switches to stop the gantry, trolley, or hoist. Limit switches are devices which must be tested regularly but are not to be used as normal operating controls. They are designed to stop a crane motion if the operator has miscalculated distance or speed.

Rev. Date 10/25/04

2-1

Revised 10/25/04 11. On all crane motions, the control levers can be immediately returned to the neutral position for stopping. The control is preset to provide an optimum stopping distance for each crane motion. The preset stopping distances can be extended by gradually moving the control levers back to neutral. 12. It is strongly recommended that every new operator of a gantry crane familiarize himself with the stopping distances for that crane. To check the stopping distances, operate each motion at full speed over a safe distance and return the control lever to neutral. Observe the actual distance required to come to a full stop. 13. Never raise the load any higher than necessary. 14. Do not raise a load unless the trolley is centered over the grapple. 15. Do not drag the spreader across the ground. 16. Never raise a load of logs which are butt heavy. The logs may start to slide out of the grapple, and the operator has no way of stopping them. Whenever possible, lift a level load or a butt-light load. 17. Do not move loads over personnel, trucks, equipment, or buildings. 18. When slack is apparent in the hoist lines, take up the slack at a slow hoist speed until the ropes are taut in all sheaves. 19. If the cable loop starts to fall out of the cable basket, stop the hoisting motion, and lower the grapple until the cable loop has corrected itself; then begin the hoisting motion again. 20. Do not let the grapple come into contact with the deck chains. Keep the spreader a minimum of six inches above the deck chains. 21. Do not allow excess spreader swing to develop. Swing can be minimized by allowing the spreader to swing to one extreme, and then moving the crane or trolley so as to catch up to the spreader. 22. Do not leave the crane cab in an electrical storm. 23. Do not operate the crane in high winds. If the weather becomes threatening, move the crane to the parking area. Stop crane operation, tie down the crane, and set the storm brakes. 24. If the operator looses control of the crane due to w i n d fo r c e s , t h e s t o r m b r a ke s s h o u l d b e immediately set. 25. Use care when approaching the runway end stops. It can take up to 150 feet to bring the crane to a controlled stop without wind. 26. Use the EMERGENCY STOP button in emergency cases only. This control will set all motion brakes a b r u p t l y a n d b r i n g t h e c ra n e t o a gr e a t l y accelerated stop.

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CONTROLS AND CRANE OPERATION

Morris Material Handling

On-ground Inspections And Boarding Checks

The following on-ground inspections and boarding checks should be performed on a daily basis: 1. Check for anything that will interfere with the safe and efcient operation of the crane. 2. Check runway for debris; track area must be clear before operating. Move the cab in line with runway and visually check for debris or logs across the runway. 3. Check that there are no obstructions or foreign materials laying in the pathway of the mainline conductor cable reel or the conductor cable. Make a quick visual inspection of the cable to verify that there are no abrasions or cuts in the cable. 4. Check the condition of the tracks. Report any obvious damage which is found. 5. Check for fouling in the cable reel or excessively slack cable. Check the cable tension as described in Section 12, Main Power Cable Reel. 6. Check TV Cameras (if supplied). 7. Check for worn or twisted hoist ropes. 8. Check grapple oil level. Do not use if low. 9. Check grapple oil temperature. Do not use if gauge is in RED zone. 10. Remove wheel chocks and tie-downs, before moving crane. 11. When boarding the crane, repeat the visual inspection of the work area and the crane, from the higher vantage point. 12. Check for loose objects across the girder, the cab, and the walkways. 13. On the trolley, inspect gearboxes, motors and brakes. Look for oil leaks, loose bolts and/or other parts. 14. Check the hoist rope drum, spooling and lay of the ropes on the drum. 15. Check the condition of the festoon conductor system, if supplied. (Not always used) 16. Check condition of the span bars and collectors. 17. Check the whisker limit switches located at the ends of the drum to verify that they are in good working order.

18. Walk the length of the girder and visually inspect the pin connections at the legs. Verify all pin keeper plates are in place.

Start-up Checks
CAB CHECKS. Perform the following start-up checks in the cab, before operating the crane: 1. Check the crane log entries. 2. Check the operation of the warning horn. CONTROL CHECKS (POWER OFF). Perform the following start-up checks at the control system location, before operating the crane:

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while r e p a i rs a r e b e i n g p e r fo r m e d . B e fo r e beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed. 1. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 2. Press the STOP button to verify that power is OFF. 3. Operate each Master Switch in both directions to verify smooth movement in all directions. CONTROL CHECKS (POWER ON). Perform the following start-up checks at the control system location, before operating the crane: 1. Energize the power system on the crane by placing the mainline disconnect switch in the closed (ON) position. 2. Press the START button. This function turns control power on, and will start the cable reel motors. When the cable reel starts up, check that the reel rotates slightly to take up the slack in the cable. 3. Raise storm brakes. HOIST CHECKS. Check the operation of the hoist in the following manner: 1. Move the grapple within ve feet of the upper stop limit, set by geared limit switch adjustment. 2. Run the grapple at medium speed into the upper geared limit stop position. The brake will set and hoist will quickly stop.
2-3

Revised 10/25/04 3. Note response and report any failure of brake or upper geared limit switch. 4. The lower limit switch cannot be checked routinely (unless there is a hole or low spot in the yard). It must be possible to lower the grapple, with the tines wide open, and touch the ground without tripping the lower limit. TROLLEY CHECKS. Check the operation of the trolley in the following manner: 1. Move the left hand joystick control (master switch) forward; the trolley should move forward. 2. While moving slowly, with the joystick control lever in the neutral position, momentarily depress the TROLLEY BRAKE SET push button on the left joystick, to test trolley holding brake. 3. Move the left hand joystick back, the trolley should move in reverse. 4. Return the control joystick to neutral to halt trolley movement. 5. Move the trolley along the entire length of the girder, and report any unusual vibrations or bumps. GANTRY CHECKS. Check the operation of the gantry in the following manner: 1. Move the left hand joystick control to the right; the crane should move to the right. 2. Return the control joystick to neutral to halt gantry movement. The brakes should apply, after a preset time delay, when the control lever is moved to the neutral position. The gantr y brakes will automatically release when control lever is moved to either gantry right or left position. 3. After the crane has been shut down for any length of time, it is advisable to check the cable reel when the gantry is rst moved. Move the trolley to a position where the cable reel can be readily viewed; then, accelerate the gantry to the left (away from the anchor point). Observe that the cable reel keeps up with the crane and that the cable does not get excessively slack. Then gantry right and observe that the cable is not under excessive tension. Note: This crane is equipped with a traditional grapple, the term will be used to describe the function of the device used to attach to and move loads. GRAPPLE CHECKS: Check the operation of the grapple (or whatever means is incorporated to lift loads) using the grapple manufacturers operating manual.

! WARNING DANGER
Do not depress the EMERGENCY STOP push button while either the gantry or trolley is moving. This control abruptly sets the parking brakes, which will cause at spots in the wheels due to brake lock up. Failure to observe this precaution can result in damage to the crane wheels and/or other drive components. If the crane fails to operate as described in the preceding steps, bring the crane to a full stop, depress the EMERGENCY STOP push button to shut down operation of the crane. Record malfunctions in the crane log and report them to the appointed person in charge.

Shutdown Procedure
When shutting the crane down for a shift change, perform the following: 1. Bring the crane to the designated parking area and move the trolley to the landing platform. 2. Place the grapple in the desired position for parking. (Usually in highest position) 3. Place all controls in the OFF position (and set storm brakes down if supplied). 4. Shut down the power to the crane by depressing the EMERGENCY STOP push button. 5. Unbuckle the seat belt, and slide the operators chair around. 6. Complete shift report and checklist. 7. Clean the cab area of any rubbish or trash. 8. On the way down the stairway or elevator, check for safety hazards, and maintenance problems. 9. Turn the crane over to the next operator. Inform the next operator of any maintenance or operating problems, which have not yet been resolved. When leaving the crane unattended, or shutting it down for an extended period of time, perform the following in addition to the checks outlined for a shift change: 1. Go to the various motor control panels, and turn off the following breakers: Trolley Hoist Control Power Hoist Blower

2-4

CONTROLS AND CRANE OPERATION

P&H Material Handling Grapple Gantry Cable Reel 2. Leave the light system power transformer on. 3. Descend to the ground, and connect the tie down cables to the end stop. 4. Tie the crane down by attaching the loose, open spelter socket to the equalizer truck, using the pin provided.

NOTICE
The xed end of the tie down should already be secured to the runway mounted tie-down brackets. Repeat this step for each truck as well as for each corner of the crane.

NOTICE
The grapple should be parked in the high position. Figure 2-1 Armchair Assembly

2-5

Figure 2 2 Cab Layout Revised 10/25/04

CAB PUSHBUTTON BOX ELECTRICAL BRAKING

2-6

CONTROLS AND CRANE OPERATION

Morris Material Handling Figure 2-3

TROLLEY MOVEMENT Left Joystick Actions Gantry Left Trolley Forward 1 1

Gantry Right

2 Trolley Reverse
0 -- NEUTRAL or OFF position, trolley is stopped with brakes on 1 -- Trolley moves forward at full speed 2-- Trolley moves backward at full speed NOTE: Once trolley movement is initiated after crane start-up, the trolley brakes are off until the trolley brake park pushbutton is pressed or the crane power is shutdown.

SIMULTANEOUS TROLLEY AND CRANE MOVEMENT Trolley Forward Left Joystick Actions

Portal Right Full Speed

OCMl4OA 5 -- Trolley forward at half speed and crane portal moves to the right at half speed

LIFTING BEAM AND GRAPPLE MOVEMENT Hoist Lower Right Joystick Actions 1 5 0 Hoist Raise 6

6Trolley forward at full speed and crane portal moves to the right at full speed OCMl40B 0 NEUTRAL or OFF position, lifting beam is stopped with brakes on and grapple does not rotate 1 Lifting beam lowered at full speed 2 grapple rotates clockwise at constant speed 3 Lifting beam raised at full speed 4 grapple rotates counterclockwise at constant speed 5 Lifting beam lowered at half speed and grapple rotates clock-wise at

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Revised 10/25/04

OPERATING CONTROLS
The following list describes the control push buttons, the joystick controllers, and the foot switches used to operate this crane. Refer to Figure 2-1 on page 2-5 for an illustration of the cab armchair controls. 1. JOYSTICK MASTER SWITCH, grapple SLEW/ HOIST. Use this lever to control the operation of the grapple slew (rotation) and hoist functions. Move this lever to the left to rotate the grapple to the left. Move this lever to the right to rotate the grapple to the right. Grapple rotation remains constant regardless of the amount of lever travel to the left or to the right. Pull this lever back to raise the grapple. Move this lever forward to lower the grapple.

systems. Fully depress this push button and release it to apply power to the crane allowing operation of the crane motions. 5. Grapple PUMP START PUSH BUTTON. Use this push button to apply power to the grapple pump drive motor. Fully depress this push button and release it to apply power to the grapple pump drive motor allowing operation of the grapple. Allow 5 min. for grapple to warm up prior to use. 6. Grapple PUMP STOP PUSH BUTTON. Use this push button to remove power from the grapple pump drive motor. Fully depress this push button and release it to remove power from the grapple pump drive motor, terminating operation of the grapple. 7. Grapple OPEN/CLOSE SELECTOR SWITCH. Use this two position selector switch to select between the foot pedal or thumb switch operation of the grapple open/close feature. (Optional Feature) 8. JOYSTICK MASTER SWITCH, GANTRY/ TROLLEY. Use this lever to control the operation of the gantry and trolley drive functions. Move this lever to the left to move the crane to the left. Move this lever to the right to move the crane to the right. Push this level forward to move the trolley forward. Pull this lever back to move the trolley in reverse.

NOTICE
This control lever will permit the operator to vary the hoist drive speed almost innitely between the off position and the full-on position. Drive speed varies proportionately with the amount of control lever movement. Slight movement away from the vertical (neutral) position will operate the associated drive at a slow speed, while greater movement from the vertical (neutral) position will operate the hoist drive at a higher speed. 2. TOGGLE SWITCH, grapple OPEN/CLOSE. Use this toggle switch to open and close the grapple. Move the toggle switch to the LEFT to close the grapple. Move the toggle switch to the RIGHT to open the grapple. This switch is located on the top of the right hand joystick handle.

NOTICE
This control lever will permit the operator to vary the associated drive speed almost innitely between the off position and the full-on position. Drive speed varies proportionately with the amount of control lever movement. Slight movement away from the vertical (neutral) position will operate the associated drive at a slow speed, while greater movement from the vertical (neutral) position will operate the associated drive at a higher speed. 9. HORN (SIREN) PUSH BUTTON. Depress and hold this push button to sound the warning horn (siren) used on this crane. 10. TROLLEY BRAKE SET PUSH BUTTON. Depress this push button to apply the trolley brake, for use as a parking brake. The trolley brake will then remain applied until the trolley joystick control lever is moved out of neutral in either direction. Trolley brake release then occurs automatically, allowing for movement of the trolley in either direction. 11. GANTRY POSITION RESET. (on touch screen). This resets the position control system. (Optional Feature)

! WARNING DANGER
Do not depress the EMERGENCY STOP push button while either the gantry or trolley is moving. This control abruptly sets the parking brakes, which will cause at spots in the wheels due to brake lock up. Failure to observe this precaution can result in damage to the crane wheels and/or other drive components. 3. EMERGENCY STOP PUSH BUTTON. Use this push button to disconnect power from the cranes electrical systems. Fully depress this push button and release it to disconnect power from the crane terminating operation of the crane motions. This push button when depressed will also set all motion brakes. 4. START/RESET PUSH BUTTON. Use this push button to apply power to the cranes electrical
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CONTROLS AND CRANE OPERATION

Morris Material Handling

Operational Notes, Log Handling Cranes

The following points cover general infor mation regarding the operation of the crane. TROLLEY - - The following notes apply to the trolley only. Always set the storm brakes and turn off power on the control console by depressing the EMERGENCY STOP push button, before sliding back the operators chair. Move the control lever to the full speed position quickly (when safe to do so), using a smooth and controlled action. If the wheels start to spin, move the control lever back to the neutral position, and gradually bring the trolley up to speed. To stop the trolley, allow the control lever to drop back into neutral. The trolley will stop in a preset distance, which can be extended by moving control lever to neutral gradually, but which cannot be shortened. To determine actual stopping distance for a particular trolley, start the trolley from a point which allows overrun and bring it up to full speed; then, drop the control lever into neutral and observe the stopping distance.

control lever more slowly. Reducing the acceleration rate is not normally needed, however. To stop the hoist, allow the control lever to drop into neutral. The deceleration rate is also preset, and will not vary signicantly between no load and full load, given equal positions of the control lever. To determine actual stopping distance for a particular hoist drive, lift the hoist to a safe position and bring it up to full speed in the lower direction; then, drop the control lever into neutral and observe the stopping distance. Load Float will delay the brake set after coming to a stop for up to 10 sec, allowing quick response to the next master command. Load Float feature cranes must follow the upper limit switch test procedure at every shift start to assure brake surface cleaning. (Optional Feature) Do not jog the hoist controls. Allow enough time for the hoist motion to respond to all control commands. Do not lift a swinging load. Correct load swing by allowing the load to swing to one extreme. Then, quickly operate the gantry and/or trolley motions to move the crane in line with the load so as to catch up to the load. Correct skipped grooves on the hoist drum by opening the grapple completely, and running the grapple down as far as it will go. Then raise the grapple slowly, making sure that the wire ropes feed onto the drum properly. GANTRY - - The following notes apply to the gantry only. Once the load has been secure, and it is safe to do so, operate the gantry at full speed. To stop the gantry, allow the control lever to drop back into neutral. The gantry will stop in a preset distance, which can be extended by moving control lever to neutral gradually, but which cannot be shor tened. Strong following winds can affect stopping distances and must be allowed for. To determine actual stopping distance for a particular gantry, start the gantry from a point which allows overrun and bring it up to full speed; then drop the control lever into neutral and observe the stopping distance. Generally, this distance is equal to twothirds of the out-to-out distance of the legs. Some cranes are equipped with a Plugging feature. This allows the operator to move the joystick to the opposite direction of travel and stop the motion in a shorter distance. This improves spotting capability and load control. (Optional Feature) Since the acceleration rate has been preset, the control lever can usually be moved rapidly to the full
2-9

NOTICE
The trolley is designed to oat, and in this manner will tend to line itself up with the load. On occasion, the trolley may overshoot the desired position. If this happens simply move the control lever to its slow speed position; this will correct the overshoot. Depressing the trolley brake set pushbutton in the left hand joystick control lever will hold the trolley in the desired position, such as when holding a load over the slasher deck waiting for it to clear. The trolley brake will release again when the push button is released. The TROLLEY BRAKE PARK push button located on the control touch screen is only meant for use in setting the trolley brake when the trolley is to be parked during boarding, exiting, and maintenance procedures. The brake will automatically release when the control lever is moved in either direction from neutral. HOIST - - The following notes apply to the hoist only. Once the load has been secured, and it is safe to do so, operate the hoist by moving the control lever to the full on position. The acceleration rate is preset, so the lever can be quickly moved to the full on position without causing undue stress in the hoist drive. The acceleration rate can be reduced by moving the

Revised 10/25/04 speed position without adverse affects. If, however, the wheels spin during acceleration, return the control lever to neutral and move the gantry to speed more gradually. Grapple - - The following notes apply to the grapple only. When unloading, always keep the female (longer) tines of the grapple towards the TV camera. If a camera is not used, keep the female tines facing the operator. When laying loads down, stop the opening operation to allow logs to settle out on the deck or storage pile. Then, after the load has settled out, raise the grapple from the deck or storage pile. type) limit switch. If the nal limit switch does not actuate in this type of test, adjust the geared limit switch. When testing the stop limits, never operate the hoist at high speed. Start to move the gantry at slow speed to check mainline cable reel operation. If the cable reel does not retrieve or pay out the cable properly (excessive tension or excessive slack), stop crane operation and refer the problem to the maintenance personnel.

Hoist Operation
The hoist motor is an AC Inverter Rated Squerrel cage Induction Motor and operates in conjunction with an electric shoe brake. When stopping the load by bringing the control lever to neutral, the shoe brake will apply to nal stop and hold the load. When raising the grapple, the amount of time required to slow the load to creep speed will be less, but the same operating procedures used for lowering a load should be practiced. The following are the suggested hoist operating procedures:

CRANE OPERATION General

The following paragraphs provide general instructions on the operation of the Straight Track Portal Crane. These instructions do not try to instruct a person on how to operate this specic crane, but are general operating procedures which may apply to many Straight Track Portal Cranes. Depress the START button to apply power to the cranes electrical systems. This will also start the mainline cable reel. Upon start-up of the cable reel, the reel should rotate slightly to take up the slack in the power cable. If not, have maintenance inspect, and if necessary, repair the cable reel. Depress the spreader START push button to start the hydraulic system on the grapple. Allow the grapple pump to run for at least 5 minutes before attempting operation of the grapple. Then slowly open and close the grapple several times to warm the grapple hydraulic system oil. The grapple should always be fully opened rst to synchronize both tines. During this warmup operation of the grapple, visually check for hydraulic system leaks. Rotate the grapple in both directions to verify that it rotates properly, and that there is no binding during rotation.

NOTICE
For better operator understanding, we segment the up control into ve different positions. The same is true of the down control. The rst segment is indicated by a detent. Segments 2 through 5 are actually stepless. 1. Move the control lever back to raise the grapple. When picking a load, operate in steps 1 and 2 of the control handle position until slack is out of the hoist cables, and the load appears to be properly balanced. Accelerate rapidly, but smoothly, through steps 3, 4 and 5. Decelerate from step 5 smoothly through to step 2, step 1, and then to neutral (OFF). 2. When lowering loads, move the control lever forward. Use steps 1 and 2 of the control handle position to start the load moving down. Accelerate smoothly through steps 3 through 5. During deceleration of the load, bring the control smoothly back to approximately the step 2 position. This will bring the load to a slow controlled motion. Then, move the control lever to neutral to come to a complete stop.

NOTICE
Dur ing cold weather, allow the grapple hydraulic system to warm up for a least 10 minutes before attempting grapple operation. At the start of each shift, it is important to check the hoist upper limit switch to verify that it operates properly. The upper geared limit switch should stop the hoist travel before the trip comes into contact with the nal (weight

2-10

CONTROLS AND CRANE OPERATION

Morris Material Handling

Gantry Operation
The gantry motors are the AC squirrel cage induction type used in conjunction with an AC electric disc type holding brake. Once the crane has stopped, and after a short time delay, the holding brakes are applied to hold the crane stationary. When the gantry is moving at a slow speed and the operator wishes to spot a load, move the control lever to the neutral (OFF) position. This will allow the gantry holding brakes to come on and hold the crane in position over the load. The gantry holding brakes have an adjustable timer which keeps the brakes off for a predetermined time period after the control lever is returned to the neutral (OFF) position. The brake timer bypass footswitch cuts out the timer and immediately sets the gantry brakes.

direction. The push button in the joystick control lever, on the other hand, will cause the trolley brake to remain set only so long as the push button is held depressed.

Grapple Operation
Start the grapple pump, and allow it to run for 5 minutes before attempting grapple operation. In cold weather, increase the warm-up time to 10 minutes. Open and close the grapple several times. Do not allow the cylinders to bottom out during the rst few operations. If operation is sluggish or noisy, repeat the opening and closing operations again; this will remove air from the hydraulic system. If, after opening and closing the grapple 10 times, noise or sluggishness persists, shut down the grapple operation and advise the maintenance department for further assistance.

Trolley Operation

! WARNING DANGER
The EMERGENCY STOP push button when depressed will set ALL brakes immediately. Due to the extreme shock loads which are placed on the crane when this is done, the EMERGENCY STOP push button should only be used when absolutely necessary. The trolley controls include brake set push buttons which will apply the trolley brakes when depressed. Do not depress the push buttons while the trolley is in motion. Failure to observe this precaution can result in damage to the trolley wheels and/or drive system. The trolley drive motors are of the AC squirrel cage induction type and are used in conjunction with AC disc type holding brakes. The brake circuit is designed to keep the trolley brake released (coil energized) even when the control lever is in the neutral position, unless the brake set push button has been depressed. When the operator wishes to bring the trolley to a stop, bring the control lever back to the neutral position.

NOTICE
Stop the crane operations, and depress the EMERGENCY STOP push button to shut down the crane, if the grapple fails to respond to the above preliminary tests. To accurately position the grapple over a load, it must rst be lowered close to the load to better judge the distances. When picking up a load on at ground, the grapple must be raised as it is being closed to avoid excessively slack cables, and to avoid digging into the ground. Remember to slow motions down well in advance of planned stops. No motion stops immediately. Be familiar with the equipment which you use. This will aid at the time of visual inspections because things out of the ordinary will tend to stand out. The operator should question anything which is out of the ordinary. Logs, particularly hardwood logs, are extremely slippery when wet. Handle loads which are balanced, or will wedge in the grapple.

NOTICE
If for any reason the operator does not wish the trolley to move, depressing the push button in the left hand joystick control lever will apply the trolley brakes. Note that, after depressing the trolley brake push button on the console, the trolley brake will remain set until the joystick control lever is moved out of the neutral position in either

MATERIAL HANDLING General

The following steps provide general instructions for unloading trucks, reclaiming wood from the log pile, transporting wood with the crane, and for loading the log deck. These instructions are general in nature and apply to all Log Handling Straight Track Portal Cranes.
2-11

Revised 10/25/04

Unloading Trucks
The following paragraphs describe general practices which may be used when unloading trucks: 1. Use the hoist, gantry, and trolley controls to position the grapple over the truck load. 2. Rotate the grapple to line up with the load to be lifted. Make sure that the female tines of the spreader face towards the television camera. If the crane is not equipped with a TV Camera, face the female grapple tines toward the operator. 3. Position the grapple such that the heavy end of the load will be opposite the truck cab. Always pick up the load slightly off center such that the butt ends of the logs will be higher than the small end of the logs when the load is raised off the truck. 4. Lower the grapple to the point just above the load with the tines opened to a position which places each tine approximately two feet to the outbound side of the load. 5. After the grapple has been positioned, the crane operator should wait for the truck driver or the appointed person to give hand signals.

Reclaiming Wood From The Log Pile

The following paragraphs describe general practices which may be used when reclaiming wood from a log pile: 1. To minimize log breakage in long-term storage areas, operators should try to reclaim wood from the peaks of the log piles. 2. Lower the grapple onto the log pile. Close the grapple to secure the load. 3. As the grapple envelopes the load, raise the hoist slightly. This causes the logs to rotate up into the grapple, rather than jamming in the tines. 4. When lifting a load from the pile, estimate its center of gravity. Having the load suspended slightly off level, with the butt ends of the logs higher than the smaller ends, is the safest manner in which to transport a load. 5. When the load is clear of the log pile, and it must be rotated, use the grapple slew control as required. Carefully timed intermittent jogging of the slew controller eases the load on the slew drive and prevents the logs inertia from winding-up the hoist ropes. 6. Leave single logs or isolated small groups of logs for future consolidation into a group when time permits.

NOTICE
Each site should consider how much the truck driver will be requested to assist in the off loading operations. 6. If the actions of the truck driver are unclear to the crane operator, the crane operator is to stop all operations and alert the truck driver. 7. Lower the grapple and close the tines to secure the load. The truck driver must be well away from the load at all times when the truck is being unloaded.

Transporting Wood With The Crane

The following steps describe general practices which may be observed when transporting wood with the crane: 1. Never leave a load hanging on a crane when the crane is unattended for any period of time. 2. Never lift more than the rated capacity of the crane. 3. Avoid dropping loads. This can be caused by: Failure to verify that the load is safely clamped in the grapple before lifting and then traveling. Failure to hold the grapple close during the move. Failure to verify that the wire ropes and sheaves are in good condition. Worn sheaves can cut into ropes and cause them to break. 4. Do not transport loads over the roadway, the log deck, or over trafc. 5. If, when operating the hoist, the wire ropes start jumping, the operator should stop the crane operation and inspect the drum. It is possible that

NOTICE
If the trolley will not remain spotted over the load because of high winds or other reasons, depress and hold the trolley brake set push button in the left hand joystick control lever. The trolley brake will remain set only so long as the push button is held depressed. Release the push button when the load is in the grapple and the trolley must be moved. 8. Once the load has been lifted off the truck, the crane operator should gantry back away from the truck cab. From this point on, the crane operator has full responsibility for the load and its disposition.

2-12

CONTROLS AND CRANE OPERATION

Morris Material Handling the ropes have doubled up or jumped the drum grooves. 6. Avoid careless placing of logs, which may be caused by: Failure of the operator to nest logs, resulting in high stacks which can roll away. Refer to the terminology list in Section 1 for a denition of nesting. Loads released too soon, allowing logs to roll or slip out of control. Avoid these problems by: - Selecting a good deposit area. - Releasing the load slowly. - Observing where the load is going and closing the grapple if the load is getting out of control.

Loading The Log Deck

The following paragraphs describe general practices which may be used when loading the log deck: 1. If the log deck is situated such that the loads must be transpor ted through the gantry legs, it is generally safer, easier to handle, and provides better visibility if the butt end of the load is brought through the legs rst. 2. Approach the log deck in such a manner as to reduce the possibility of unseen hangers fouling with the deck chains or str ucture. See the terminology list in Section 1 for a denition of hangers as used here. 3. When loading the log deck, keep the grapple about six inches above the deck to avoid interference with the deck chains.

2-13

Revised 10/25/04

2-14

CONTROLS AND CRANE OPERATION

Section 3 LUBRICATION & PREVENTIVE MAINTENANCE

GENERAL
This section contains recommended lubrication and preventive maintenance procedures, and intervals, for this crane. Lubrication instructions are covered rst, followed by the preventive maintenance instructions. Preventive maintenance consists of those periodic inspections, adjustments, and minor repairs which are essential to operating safety and optimum performance of your crane.

! WARNING DANGER
Inadvertent movement of the gear case shafts and attached components can result in severe personal injury. Disconnect, lock out, and tag the crane power disconnect switch before initiating lubrication procedures. 3. Disconnect, lock out, and tag the source that supplies power to the crane before lubricating equipment. 4. Check the lubricants for contamination before using them. 5. Do not allow oil or grease to come in contact with brake shoes or wheels. 6. Do not over ll gear cases. They are not intended to retain lubricants when lled beyond the maximum indicted oil levels. Use the oil level pipe to maintain the proper oil level in the gear case. 7. Before and after applying grease to the grease ttings, wipe the tting clean to prevent an accumulation of dirt which could be forced into the part being lubricated. 8. Wipe up any spilled or overowed lubricants. Table 3-1 on page 3-3 lists the recommended intervals for the lubrication and preventive maintenance of the various components of the crane as well as a few comments about each component if applicable.

LUBRICATION General
To achieve proper operation of the crane, all points requiring lubrication must be serviced with the correct lubricant, at the proper time intervals. A tabular listing of lubricant equivalents begins with the Table on page 3-3. Points such as levers, linkages, pins, and so forth should be lubricated with oil once a week. Apply a few drops of 10 W 30 motor oil to each exposed pin or lever, not equipped with grease ttings, to prevent rusting and to provide the lubrication required. The lubrication intervals recommended in this manual are based on one eight hour shift operation of the crane, ve days per week. Lubrication schedules should be adjusted accordingly, when there is more than a one shift operation. Refer to the manufacturer's manual for information concerning lubrication instructions for vendor supplied equipment. The following steps must be taken when lubricating the crane. 1. Communicate with all appropriate persons that the crane is being removed from operation. 2. Move the crane to a location where it will cause the least interference with other cranes and operations in the area, and can be accessed.

Rev. Date 10/25/04

3-1

Recommended Lubricants - Portal Cranes

Recommended Lubricants Warm Climate (+110F to +32F) Moderate Climate (+90F to +0F) All Season (+100F to -30F) Arctic Climate (+40F to -40F)

3-2
Spartan EP 220 Esso Spartan EP 220 Exxon Mobilgear 630 Mobil Geartherm Multigrade 150 Shell Meropa 220 Texaco Molub-Alloy - Gear Oil 90 Tribol Spartan EP 68 Esso Spartan EP 38 Exxon Mobilgear 626 Mobil Geartherm Mutigrade 150 Shell Meropa 68 Texaco Molub-Alloy - General Purpose Tribol Iogear EP 100 Esso Mobilgear 627 Mobil Geartherm Mutigrade 150 Shell Mutigear EP 75W-90 Texaco Tribol 773 Tribol Iogear EP 46 Esso Mobilgear 626 Mobil Geartherm Oil Arctic Shell Mutigear EP 75W-90 Texaco Tribol 713 ATF Tribol Nuto H 46 Esso Nuto H 46 Exxon Mobil DTE 25 Mobil Tellus 46 Shell Rando HD 46 Texaco Tribol 943AW-46 Tribol Nuto H 32 Esso Nuto H 32 Exxon Mobil DTE 24 Mobil Tellus 32 Shell Rando HD 46 Texaco Tribol 943AW-32 Tribol Univis N 32 Esso Univis N 32 Exxon Mobil DTE 13 Mobil Tellus 32 Shell Rando HD A2 or Supero A2 Texaco Univis N 22 or N 15 Esso Univis N 15 of J 13 Exxon Mobil DTE 13 Mobil Tellus 32 Shell Rando HD A2 or Supero A2 Texaco Molub-Alloy 533 Tribol Elbac EP 9F Esso Surett 6K Exxon Shellgear Heavy Shell Geartak 1500 Texaco Molub-Alloy - 909 Heavy Tribol Elbac EP 9F Esso Surett 6K Exxon Shellgear Medium Shell Geartak 390 Texaco Molub-Alloy - 909 Light Tribol Elbac EP 9F Esso Surett 4K Exxon Shellgear Medium Shell Geartak 46 Texaco Molub-Alloy - 909 Light Tribol Elbac EP 9F Esso Surett 4K Exxon Shellgear Arctic Shell Geartak 46 Texaco Molub-Alloy - 909 Extra Light Tribol Gear Cover Fluid 21 Esso Surett 6K Exxon Mobiltac D Mobil Shellgear Heavy Shell Texclad 2 Texaco Molub-Alloy - 936 Heavy Tribol Gear Cover Fluid 21 Esso Surett 8K Exxon Mobiltac D Mobil Shellgear Medium Shell Texclad 1 Texaco Molub-Alloy - 936 Heavy Tribol Gear Cover Fluid 6 Esso Surett 4K Exxon Mobiltac C Mobil Shellgear Medium Shell Texclad 1 Texaco Molub-Alloy - 936 Heavy Tribol Gear Cover Arctic Esso Surett 4K Exxon Mobiltac C Mobil Shellgear Arctic Shell Texclad 1 Texaco Molub-Alloy - 909 Extra Light Tribol Unirex EP 2 Esso Lidok EP 2 Exxon Mobilux EP 2 Mobil Alvania EP 2 Shell Multifax EP 2 or Summit EP M Texaco Molub-Alloy - 860/220-2 Tribol Unirex EP 1 Esso Lidok EP 1 Exxon Mobilux EP 1 Mobil Alvania EP 2 Shell Multifax EP 1 or Summit EP L Texaco Molub-Alloy - BRB 555 Tribol Unirex EP 1 or Lowtemp EP Esso Lidok EP 1 or Lowtemp EP Exxon Mobilux EP 1 Mobil Alvania EP 2 Shell Multifax EP 1 or Summit EP L Texaco Unirex EP Arctic Esso Lidok EP 0 Exxon Mobilux EP Arctic Mobil Alvania EP Leathern Shell Multifax EP 1 or Summit EP L Texaco Shell Darina EP 2 (71522) No Substitutes Shell Darina EP 2 (71522) No Substitutes Shell Darina EP 2 (71522) No Substitutes Shell Darina EP 2 (71522) No Substitutes Molub-Alloy - #771-1 Tribol Molub-Alloy - #333 EP Arctic Grease Tribol

Revised 10/25/04

Location

Lube Interval

Hoist, P&H Built Gear Reducer *

Check Oil Level Weekly Change - 6 Months * For Rexnord Trolley & Gantry Reducers, See maintenance Section

Grapple Reservoir

Check Oil Level Daily Change - 6 Months

Wire Rope *

Apply Monthly * Not Required for PFV Wire Ropes

External Gantry Gears

Apply Weekly

Grapple U-Joint and Rotate Bearing

Apply Grease Gun - Daily

Sheave Bearings, Wheel Bearings, Pedestal Bearings, Festoon Wheel Bearings, Gantry Drive Shaft

Apply Grease Gun Weekly

Drum Coupling

Lubricate - 6 Months

Electric Motors

Apply 500 - 1000 Hours

Eddy Current Load Brakes

Apply 500 - 1000 Hours (See Brakes Section)

Grapple Pins / Bushings

Apply Grease Gun - Each Shift

LUBRICATION & PREVENTIVE MAINTENANCE

Structural Pins, SlowHeavily Loaded Journals, Fixed Leg, Thrust Bearings, Swivel Joints

Apply as Specied in Maintenance Section

NOTE: This table represents a generalized summary only. The information shown here is superseded by any data provided for this manual by third party suppliers for their components.

Morris Material Handling

Table: 3-1 Portal Crane Lubrication and Maintenance Page 1 of 2 INTERVAL Do Not Lubricate Each Shift COMPONENT Gantry Motor Brakes, Trolley Motor Brakes, Main Hoist Motor Brakes Wire Rope Assemblies Grapple Cylinder Pins and Hinge Points Daily Grapple Reservoir Grapple, General Inspection Cable Reel Cable Reel, General Inspection Grapple Universal Joint and Rotate Bearing Gantry Wheel Assemblies Trolley Wheel Assemblies Weekly Gantry Drive Gear Case Trolley Drive Gear Case Main Hoist Drive Gear Case External Gantry Drive Gears Sheave Bearings Gantry Wheel Bearings Trolley Wheel Bearings Drum Pedestal Bearings Festoon Carrier Wheel Bearings Cable Reel, General Inspection Cable Reel Slewing Ring Cable Reel Slewing Gear Grapple, General Inspection Monthly Wire Rope Assemblies See Table 3-1 See Table 3-1 --------See Table 3-1 See Table 3-1 See Table 3-1 See Table 3-1 Apply Lubricant. Apply Lubricant via Grease Fittings. Lubricate via Grease Fittings. Lubricate via Grease Fittings. Lubricate via Grease Fittings. Inspect for Loose Fasteners & Debris Lubricate via Grease Fittings. Apply Lubricant Directly to Gear. Inspect for Wear or Damage. Apply Lubricant. See Table 3-1 Check Oil Level. Fill as Required. LUBRICANT --NOTES DO NOT LUBRICATE MOTOR BRAKES. Inspect for wear or damage. Lubricate pins via grease ttings. Check Oil Level. Fill as Required. Inspect for Wear or Damage. Check Oil Level. Fill as Required. Inspect for Wear or Damage. Lubricate via Grease Fittings.

--See Table 3-1 See Table 3-1 --See Table 3-1 --See Table 3-1 ---

Inspect for Damage or Wear.

If plastic coated wire rope is used, No Lubrication Is Required Grapple Reservoir Air Filter --Replace Filter.

3-3

Revised 10/25/04

INTERVAL Monthly

COMPONENT Gantry Drive Motors Trolley Drive Motors Main Hoist Drive Motors Tension, Cable Reel Miscellaneous Pins, Bushings, and Linkage

LUBRICANT See Table 3-1

NOTES Refer to Motor Section.

--10W30 ----See Table 3-1 See Table 3-1

See Cable Reel Section. Apply Lubricant using Oil Can. Inspect for gear deterioration or failure Clean the components of the crane assembly. Lubricate via Grease Fittings.

Quarterly 6 Months

Gear Inspection Crane Components and Enclosures Fixed Leg Thrust Bearings or Swivel Assemblies Gantry Drive Gear Case Trolley Drive Gear Case Main Hoist Gear Case Cable Reel Grapple Reservoir Grapple, General Inspection

Drain and Rell. See Table 3-1 See Table 3-1 ------Drain and Rell. Drain & Rell. Inspect for Wear or Damage. Clean and Inspect. Inspect for Wear or Damage.

Annually

Drive Motors Cable Reel, General Inspection

Table 3-2. Portal Crane Lubrication and Maintenance Page 2 of 2

BOLT TORQUES
All component mounting bolts, and bolts that attach structural members of the crane shall be tightened to accepted specications for the type of bolt or capscrew in question. Refer to the AISC Structural Steel handbook for bolt torque recommendations.

MAINTENANCE / LUBRICATION
It is recommended that a regular inspection schedule be set up for each crane and that this schedule be faithfully followed. It is further recommended that records be kept of all inspections and preventive maintenance which has been performed on each crane. An inspection report form should be devised for this purpose. To be effective, the inspection report form must include a simple means of conveying whatever action is required to correct discrepancies revealed through inspection. A general inspection report form is provided at the end of Section 1 of this manual. Portal Crane Check Lists are included at the end of this section. Completed inspection report forms should be retained for future reference. The expected service life, as well as more accurate intervals between inspections, can be established through a study of past inspection report forms. The need for adjustments and repairs can then be anticipated, allowing for planned crane shut downs. Replacement parts can also be ordered in advance of actual need, thereby reducing crane down time. It should be noted that any recommended inspection and maintenance intervals are based on this crane being used in CMAA Class F service. Where crane use exceeds this average, the intervals must be proportionately shortened. Where crane use is considerably less than average, the intervals may be lengthened. Factors such as duty cycle,

3-4

LUBRICATION & PREVENTIVE MAINTENANCE

Morris Material Handling percent of capacity lifts, ambient temperatures, and atmospheric contamination must also be considered when establishing inspection intervals.

Inspect, Wire Rope

All wire rope will eventually deteriorate to a point where it is no longer serviceable. There are three basic causes of wire rope deterioration. They are: 1. Abrasion or wear.

No Lubrication Required

! DANGER
Do not lubricate the Morris manufactured motor brakes used on this crane. Lubricants which come into contact with the brake linings will cause brake slippage. This may lead to uncontrolled operation of the associated crane motion, resulting in injury or death of personnel. The motor brakes manufactured by Morris Material Handling do not require lubrication, and should not be lubricated. All pivot points on these brakes are provided with permanently lubricated roller bearings. The use of lubricants on the brake assemblies can only introduce oil or grease onto the brake linings. If the brake linings become oil soaked, or grease coated, brake operation will be inhibited, and may lead to uncontrolled operation of the crane. I f t h e b ra ke l i n i n g s d o b e c o m e o i l o r gr e a s e contaminated, replace the linings or discs as outlined in the brake section of this manual. In addition to the replacement of the linings or discs, thoroughly clean the entire brake assembly being sure to remove all traces of oil or grease.

2. Corrosion. 3. Fatigue, caused by pulling, bending, crushing or kinking forces applied to the rope during normal service. None of the above causes of deterioration can be entirely eliminated. However, they may be minimized though proper inspecting, cleaning & lubricating of the rope. Wire rope should be observed for wear and damage during operation and be inspected once each week for the following: 1. Internal wear caused by grit penetrating between the strands and wires. 2. Kinking 3. Lubrication 4. Corrosion 5. Number of broken wires per rope lay. NOTE: A rope lay is dened as the axial distance along the rope in which one strand makes one complete turn around the rope.

6. End attachment. 7. The condition of the sheaves over which the rope must pass, including sheave alignment. 8. The amount of wear on the outer wires. Replace the rope for the following reasons: 1. The core showing through more than one pair of strands. 2. Kinking damage. 3. Wire damage due to contact with an electrical circuit or that has been subject to overheating. 4. Reduction in rope diameter. 5. Evidence of bird-caging. This increase in wire rope diameter is usually caused by the sudden releasing of a heavy load while the rope is twisted. 6. Broken wires at end ttings. It is recommended that a crane used more than 16 hours a day have its hoist ropes replaced at least once every year. For replacement of the wire rope, and the

EACH SHIFT MAINTENANCE CHECKS General

The following lubrication and maintenance procedures should be performed on a per shift basis.

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while performing inspection and lubrication. Before beginning inspection and lubrication, try the control to verify that power has been removed from the equipment being worked on.

3-5

Revised 10/25/04 suggested methods to be used, see the topic Wire Rope Replacement in Section 7 of this manual.

Grapple, General Inspection

Inspect the grapple for proper operation, wear, or damage. Inspection should included, but not be limited to the following items: 1. Check that the oil temperature is within the normal operating range. If not determine the cause, and correct. 2. Check the pressure gauge readings to verify that they are within specied limits. Refer to Section 7, H o i s t S y s t e m s , G r a p p l e , fo r p r e s s u r e specications. 3. Check for abnormal noise or vibration during cable pick-up, and during cable payout. 4. Inspect all hydraulic connections for leaks, and/or damage. 5. Check the return line lter gauge. Change the lter when the gauge indicates a clogged or restricted lter. 6. Check for air in the hydraulic oil. This condition indicates that a leak has developed in the hydraulic system. Find and correct the condition. 7. Check the condition of the hoses. Replace damaged or worn hoses. 8. Check the condition of the cylinder connection pins. Replace worn or damaged pins. 9. Visually inspect the air breather lter. Replace dirty or clogged lter elements. 10. Inspect the condition of the accumulator. Recharge the accumulator is necessary.

Lubricate Grapple
Lubricate the grapple cylinder head pins, and rod end pins using the type of lubricant specied in Table on page 3-3. Fully open the grapple, and lower it to the ground or onto a maintenance stand. Apply lubricant to the pin connections using a grease gun via the grease ttings provided. Lubricate the grapple hinge points using the type of lubricant specied in Table on page 3-3. Apply the lubricant directly to the hinged joint using a grease gun.

DAILY MAINTENANCE CHECKS General

Before proceeding with the Daily maintenance checks, verify that all Each Shift maintenance checks have been performed. The following lubrication and maintenance procedures should be performed on a Daily basis.

Cable Reel, General Inspection

Inspect the cable reel for proper operation, wear, or apparent damage. Cable reel inspection should include, but not be limited to the following items: 1. Check for proper cable payout as described under the Main Power Cable Reel section. 2. Check for proper cable pick-up as described under the Main Power Cable Reel section. 3. Check for abnormal noise or vibration during cable pick-up, and during cable payout. 4. Inspect the cable reel guide rollers for wear, damage, or misalignment. Correct misalignment as necessary, and replace damaged or worn rollers.

Lubricate, Block Adapter/Rotate Bearing

Lubricate the block adapter and the rotate bearing using the type of lubricant specied in Table on page 3-3. Apply the lubricant either directly to the point of lubrication or via the grease tting, if so provided.

Check Level, Grapple Reservoir

Operate the grapple open and close functions to warm the grapple hydraulic system oil. Open the grapple tines completely, and lower the grapple to the ground. Shut down all crane operations. Remove the oil level dipstick, and check the reservoir oil level. The oil should come up to the full mark on the dipstick. If the oil does not reach up to the full mark on the dipstick, add oil of the type specied in Table on page 3-3 until the oil reaches up to the full mark on the dipstick.

Inspect Wheels
Inspect the wheel assemblies for damage or wear. Inspection should included, but not be limited to the following items: 1. Inspect the wheel for cracks or chips in the wheel tread, or the wheel itself. 2. Inspect the wheel for at spots or unusual wear patterns. 3. Check the mounting hardware to verify that it is tight and secure.

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LUBRICATION & PREVENTIVE MAINTENANCE

Morris Material Handling If any of the above conditions exist the crane should be scheduled for repairs as soon as possible. brush. Replace the gear drive cover. Repeat for all remaining wheel assemblies. Refer to gantry drive upper gear case instructions for oil bath enclosed lower gears.

WEEKLY MAINTENANCE CHECKS General

Before proceeding with the Weekly maintenance checks, verify that all of the Each Shift and Daily maintenance checks have been performed. The following lubrication and maintenance procedures should be performed on a Weekly basis.

Lubricate, Sheave Bearings

Lubricate all sheave bearings using the lubricant specied in Table on page 3-3. Apply lubricant to each sheave bearing via the grease ttings provided. Wipe excess lubricant from the grease tting after the bearing has been lubricated.

Check Level, Gantry Drive Gear Case

Remove the gear case dipstick, and check the gear case oil level. The oil level should be between the HIGH and the LOW marks on the dipstick. If the oil level is at or below the LOW mark on the dipstick, remove the ller cap, and add oil of the type specied in Table on page 3-3, through the ller cap opening, until the oil level is brought up to the HIGH mark on the dipstick. Clean and reinstall the gear case inspection cover, and the dipstick.

Lubricate, Gantry Wheel Bearings

Lubricate all gantry wheel bearings using the lubricant specied in Table on page 3-3. Apply lubricant to each wheel bearing via the grease ttings provided. Wipe excess lubricant from the grease tting after the bearing has been lubricated.

Lubricate, Trolley Wheel Bearings

Lubricate all trolley wheel bearings using the lubricant specied in Table on page 3-3. Apply lubricant to each wheel bearing via the grease ttings provided. Wipe excess lubricant from the grease tting after the bearing has been lubricated.

Check Level, Trolley Drive Gear Case

Remove the gear case dipstick, and check the gear case oil level. The oil level should be between the HIGH and the LOW marks on the dipstick. If the oil level is at or below the LOW mark on the dipstick, remove the ller cap, and add oil of the type specied in Table on page 3-3, through the ller cap opening, until the oil level is brought up to the HIGH mark on the dipstick. Clean and reinstall the gear case inspection cover, and the dipstick.

Lubricate, Drum Pedestal Bearings (If Applicable)

Lubricate all drum pedestal bearings using the lubricant specied in Table on page 3-3. Apply lubricant to each drum pedestal bearing via the grease ttings provided. Wipe excess lubricant from the grease tting after the bearing has been lubricated.

Check Level, Hoist Gear Case

Remove the gear case dipstick, and check the gear case oil level. The oil level should be between the HIGH and the LOW marks on the dipstick. If the oil level is at or below the LOW mark on the dipstick, remove the ller cap, and add oil of the type specied in Table on page 3-3, through the ller cap opening, until the oil level is brought up to the HIGH mark on the dipstick. Clean and reinstall the gear case inspection cover, and the dipstick.

Lubricate, Festoon Carrier Wheel Bearings (If Applicable)

Lubricate all festoon cable carrier wheel bearings using the lubricant specied in Table on page 3-3. Apply lubricant to each wheel bearing via the grease ttings provided. Wipe excess lubricant from the grease tting after the bearing has been lubricated.

Cable Reel, General Inspection

Inspect the cable reel for proper operation, wear, or apparent damage. Cable reel inspection should include, but not be limited to the following items: 1. Loose fasteners. Tighten all fasteners as described under the topic, Bolt Torques.

Lubricate, External Lower Gantry Drive Gears

Lubricate the gantry external drive gears. Remove the gear drive cover, and apply lubricant of the type specied in Table on page 3-3, directly to the teeth of the drive gear, and the drive pinion using a stiff bristle

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Revised 10/25/04

Grapple, General Inspection

Inspect the grapple for proper operation, wear, or apparent damage. Grapple inspection should include, but not be limited to the following items: 1. Check the cylinders for blow-by in both the open and the closed positions. If blow-by is found to be present, repair or replace the cylinders. 2. Inspect the condition of the accumulator. Recharge the accumulator if necessary. 3. Inspect the structure of the grapple frame, and the grapple tines for cracks, damage, wear, etc. Inspect all welds for cracks. Repair damage as necessary.

2. It should have sufcient adhesive strength to stay on the rope. 3. It should be able to penetrate between the wires and strands. 4. It should be insoluble under the conditions of application. 5. It should have high lm strength. 6. It should resist oxidation. Before applying lubrication, accumulations of dirt or other abrasive material must be removed from the rope. Cleaning can be done with a wire brush dipped in solvent, compressed air, or live steam. Apply lubricant immediately after the rope is cleaned. The lubricant should be thin enough to penetrate the strands to the core but not so thin that it will run off the rope. It must not be so thick that it merely coats the outside of the rope. The best lubricant is a fairly thick, semi-plastic type, which is applied hot in a thinned condition. This type of lubricant will penetrate while hot and cool off to form a plastic ller and coating which will then resist the penetration of water. Three methods of applying lubricant to wire rope are illustrated in Figure 3-1 on page 3-9. Each has its advantages, and no single method is recommended in preference to the other. The most convenient method should be used.

MONTHLY MAINTENANCE CHECKS General

Before proceeding with the Monthly maintenance checks, verify that all of the Each Shift, Daily, and Weekly maintenance checks have been performed. The following lubrication and maintenance procedures should be performed on a Monthly basis.

Wire Rope
Information on lubricating and handling the wire rope used on this crane follows.

Lubricate, Wire Rope NOTICE

A plastic coated wire rope (PFV) is available for use on this crane. If this product is utilized, DO NOT LUBRICATE THE WIRE ROPE. When a rope bends over a sheave or straightens from a slack position, wires move or slide against each other. Lubrication is a necessity to minimize wear as a result of movement and to minimize corrosion of wires and deterioration of the bre core. No set rule can be given concerning the frequency of lubrication. The severity of the duty and the amount of corrosive elements to which the rope is exposed will serve as a guide in determining the frequency of lubrication. An open gear and wire rope lubricant (GL) conforming to Morris Specication 464 is recommended for use as wire rope lubricant. A wire rope lubricant must have the following characteristics. 1. It should contain no acids or alkalies.

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LUBRICATION & PREVENTIVE MAINTENANCE

Morris Material Handling

Figure 3-1 Lubricating Wire Rope

Handling Wire Rope

The following paragraphs explain the proper methods for handling wire rope. Unreel or uncoil wire rope as follows:

must not be allowed to revolve so rapidly that rope is thrown off. 3. If a loop is inadvertently formed in the rope as it is being unreeled, the loop must be removed immediately before it leads to kinking. Figure 3-2 illustrates how a loop progresses to a permanent kink. If the loop is allowed to close up to the point shown in part 2 of the gure, the kink shown in part 3 has been formed. A kinked wire rope has been severely weakened and must not be used. 4. Use care during all phases of wire rope handling to avoid dragging a rope through dirt or around objects which could scratch, nick, crush, or induce sharp bends in the rope.

! DANGER
Wear leather gloves when handling wire rope. This is to prevent cutting the hands on the wire rope. Failure to observe this precaution will result in personal injury. 1. Wire rope must be unreeled or uncoiled correctly to prevent twisting or kinking (See Figure 3-3 ). 2. A reel can also be mounted horizontally on a shaft for unreeling rope. If this method is used, the reel

3-9

Revised 10/25/04

Replace Air Filter, Grapple Reservoir

Replace the reservoir air lter. If subject to extremely dirty area where a lot of dust is generated, replace this lter every two weeks.

Lubricate, Drive Motors

The drive motors should be lubricated on a regular basis as described in the Motor Section. Refer to the Motor section whenever servicing the drive motors. A thorough inspection should be made of motor bearings at each motor maintenance interval. A periodic check should also be made for a build-up of dust or other foreign matter in the motor interior. (DC and Wound Rotor Motors Only)

Cable Reel, Tension Adjustment

Figure 3-2 Kinking of Wire Rope Perform the cable tension adjustment procedure as described in the Cable Reel Section.

Lubricate, Miscellaneous Pins / Linkage

Points such as levers, linkages, pins, and so forth should be lubricated with oil once a month. Apply a few drops of 10W30 motor oil to each exposed pin or lever, not equipped with grease ttings, to prevent rusting and to provide the lubrication required. Wipe any excess lubricant form the levers, linkages, or pins.

GEAR INSPECTION General

The following topics describe some of the basic terms associated with gears as well as what to look for when inspecting gear teeth. All gearing should be inspected on a Quarterly basis.

Gear Terminology
The following terms dene some of the basic terms which are associated with gears, and gearing in general (refer to Figure 3-4 on page 3-12): ADDENDUM: Addendum is the height by which a tooth projects beyond the pitch circle or pitch line; the radial distance between the pitch circle and the addendum circle. Figure 3-3 Handling Wire Rope BACKLASH: Backlash is the difference between the thickness of a tooth and the width of space in which it meshes. When backlash exists between two gears, one gear can be turned through a very small angle while the mating gear is held stationary. Backlash is n e c e s s a r y t o c o m p e n s a t e fo r e r r o r s a n d
LUBRICATION & PREVENTIVE MAINTENANCE

3-10

Morris Material Handling inaccuracies in the spacing and in the form of the gear teeth, to provide a space between the teeth for lubricant, and to allow for the expansion of the teeth with a temperature rise. BOTTOM LAND: Bottom land is the surface at the bottom of the tooth space. CIRCULAR PITCH: Circular pitch is the distance along the pitch circle or pitch line between the corresponding proles of adjacent teeth. CIRCULAR THICKNESS OF TOOTH: Circular thickness of tooth is the length of the arc between the two sides of a gear tooth, as measured along the pitch circle unless otherwise specied. CLEARANCE: Clearance is the radial distance between the working-depth circle and the root circle. DEDENDUM: Dedendum is the depth of a tooth space below the pitch circle or pitch line; the radical distance between the pitch circle and the root circle. FACE WIDTH: Face Width is the length of the teeth in an axial plane (the place which is parallel to the shaft centerline). FILLET CURVE: Fillet curve is the concave portion of the tooth prole where it joins the bottom of the tooth space. PITCH CIRCLE: Pitch circle is the curve of intersection of a pitch surface of revolution and a plane of rotation. It is the imaginary circle that rolls without slipping with a pitch circle of a mating gear. ROOT CIRCLE: Root Circle is tangent to the bottom of the tooth space when viewed in a cross section. TOOTH PROFILE: Tooth prole is one side of a gear tooth in a cross section between the outside circle and the root circle. WORKING DEPTH: The depth of engagement of two gears, that is, the sum of their operating addendums. TOP LAND: Top Land is the surface at the top of the gear tooth. WHOLE DEPTH: Whole Depth is the distance measured from the top land to the bottom land.

3-11

Revised 10/25/04 Figure 3-4 General Gear Information

Inspection and Wear Patterns

Inspect all gearing on a Quarterly basis, looking for the following signs of gear deterioration or failure. If any of the following problems are found, the problem should be corrected, and the gear, or gear set should be replaced as soon as possible. Figure 3-5 on page 3-13 shows the various types of gear wear which are described in the following paragraphs. WEAR 1. ABRASIVE WEAR: Abrasive wear is typied by a lapped appearance; radial scratch markings or grooving of the tooth contact surfaces, and is generally caused by foreign material in the lubricating oil. 2. CORROSIVE WEAR: Corrosive wear is a deterioration of the tooth surface from chemical action. It is often caused by active ingredients in the lubricating oil, such as acid, moisture, and/or extreme pressure additives. Lubricants also can become contaminated from various chemicals from the atmosphere, or from foreign material such as salt water or liquid chemicals. 3. SCORING: Scoring is wear resulting from a failure of the lubricant lm due to localized overheating of the mesh, permitting metal to metal contact. This contact produces alternate welding and tearing, which removes metal from the tooth surfaces. Frosting is a form of scoring typied by micropitting under thin lm conditions. SURFACE FATIGUE 1. PITTING: Pitting is a surface fatigue occurring when the endurance limit of the tooth material is exceeded. Excessive shock or over loading promotes pitting.

3-12

LUBRICATION & PREVENTIVE MAINTENANCE

Morris Material Handling

Figure 3-5 Gear Wear Patterns

3-13

Revised 10/25/04 2. SPALLING: Spalling is similar to destructive pitting except that the pits are usually larger, very irregular in shape, and quite shallow. Spalling is usually caused by excessively high contact stress levels. The edges of the initial pits break away rapidly, and large irregular voids are formed. These voids often join together to form larger voids. 3. CASE CRUSHING: Case crushing is a sub-surface fatigue failure which occurs when the endurance limit of the tooth material is dramatically exceeded. Severe shock loading promotes case crushing. PLASTIC FLOW 1. COLD FLOW: Cold ow is the cold-working deformation of the tooth surfaces caused by high contact stresses and the rolling and sliding action of the gear mesh. The dents and battered appearance of the surfaces are a result of a dynamic loading due to operation, while the prole is in the process of deteriorating from a combination of cold-working and wear. 2. RIPPLING: Rippling is generally caused by high contact stresses under cyclic operation which have a tendency to roll and knead the contact surface resulting in the rippling of immediate surface. equipped with these bearings, disregard the following topic. Lubricate the bearing located in the swivel points using the type of lubricant specied in Table on page 3-3. Raise the crane off the runway and set on jack stands. Apply lubricant to the bearings via the grease ttings provided. Wipe excess lubricant from the grease tting and surrounding areas. Raise the crane off the jack stands, remove the stands and lower the crane onto the runway. (Jacking storm brakes can also be used on 16 wheel cranes).

Change Oil, Gantry Drive Gear Case

1. Drain and rell the gantry drive gear cases. See additional information in the Motor Section of this manual. 2. VERIFY that the breather is clean and functioning or replace.

Change Oil, Trolley Drive Gear Case

Drain and rell the trolley drive gear cases using the following procedure: 1. Operate the associated drive system for several minutes to warm the gear oil.

SEMI-ANNUAL MAINTENANCE CHECKS General

Before proceeding with the Semi-Annual maintenance checks, verify that all of the Each Shift, Daily, Weekly, a n d M o n t h l y m a i n t e n a n c e c h e ck s h ave b e e n performed. The following lubrication and maintenance procedures should be performed on a Semi-Annual basis.

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while r e p a i rs a r e b e i n g p e r fo r m e d . B e fo r e beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed. 2. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 3. Remove the gear case drain plug located at the base of the gear case, and drain the oil into a suitable container. 4. Clean and reinstall the drain plug.

Cleaning, General Crane Assembly

Dust and other foreign matter will accumulate on the components of the crane. These accumulations must be removed periodically, especially from the drive motors, Magnetorque brakes (where applicable), control panel interiors and motor brakes. Use a vacuum cleaner or clean cloth to remove dust from the components of the crane.

Lubricate, Swivel Thrust Bearings NOTICE

Swivel Gantry Truck thrust bearings are not applied to all portal cranes. If your crane is not

5. Remove the gear case inspection cover. 6. Add gear lubricant of the type specied inTable on page 3-3, through the gear case inspection cover opening until the oil has reached up to the HIGH mark on the gear case dipstick.

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LUBRICATION & PREVENTIVE MAINTENANCE

Morris Material Handling 7. Clean and reinstall the gear case inspection cover, and the dipstick. 8. VERIFY that the breather is clean and functioning or replace.

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while r e p a i rs a r e b e i n g p e r fo r m e d . B e fo r e beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed. 3. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 4. Remove the oil drain plug, and drain the oil into a suitable container. 5. Flush the reservoir using clean oil. 6. Install the drain plug, and ll the reservoir with the type of lubricant specied in Table on page 3-3, until the oil reaches up to the HIGH mark on the dipstick.

Change Oil, Hoist Gear Case

Drain and rell the hoist drive gear case using the following procedure: 1. Operate the associated drive system for several minutes to warm the gear oil.

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while r e p a i rs a r e b e i n g p e r fo r m e d . B e fo r e beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed. 2. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 3. Remove the gear case drain plug located at the base of the gear case, and drain the oil into a suitable container. 4. Clean and reinstall the drain plug. 5. Remove the gear case inspection cover. 6. Add gear lubricant of the type specied in Table on page 3-3, through the gear case inspection cover opening until the oil has reached up to the HIGH mark on the gear case dipstick. 7. Clean and reinstall the gear case inspection cover, and the dipstick. 8. VERIFY that the breather is clean and functioning or replace.

Change Oil, Grapple Reservoir

Drain and rell the grapple reservoir as follows: 1. Operate the grapple open and close functions to warm the grapple hydraulic system oil. 2. Fully open the grapple tines, and lower the grapple to the ground. 3. Remove the oil drain plug, and drain the hydraulic oil into a suitable container. 4. Flush the reservoir using clean hydraulic oil. Replace or clean the oil lter. 5. Install the drain plug, and ll the hydraulic reservoir with the type of lubricant specied in Table on page 3-3, until the oil reaches up to the HIGH mark on the dipstick. 6. VERIFY that the breather is clean and functioning or replace.

Change Oil, Cable Reel Gearcase

Drain and rell the cable reel Gearcase using the following procedure: 1. Operate the crane the length of the runway to warm the cable reel oil. 2. Move the crane into the maintenance area, and shut down all crane operations.

Grapple, General Inspection

Inspect the grapple for proper operation, wear, or apparent damage. Grapple inspection should include, but not be limited to the following items: 1. Grease the electric motor. 2. Inspect block adapter for cracks or elongations, etc.

3-15

Revised 10/25/04 3. Inspect pins, bushings, upper frame, tines and electrical connections. may be enough to cause the drum to rotate should the brake be released and/or removed. 4. Care should be taken to see that the parts that have been removed are not nicked or damaged. 5. Tag electrical wires when disconnecting them to aid in proper reconnection. Also, refer to the wiring diagrams fur nished with the crane when troubleshooting or rewiring the electrical systems. 6. Before any adjustments or repairs are started, all controls must be in the OFF position. Main and emergency switches should be opened and locked in the open (OFF) position. Warning signs should be placed on these switches and later removed, only by the person who placed them there. 7. Before unfastening any component, be sure to secure the component to prevent it from shifting or dropping. 8. Appropriate safety equipment must be supplied and used for each operation. This includes safety harnesses for high level work.

ANNUAL MAINTENANCE CHECKS General

Before proceeding with the Annual maintenance checks, verify that all of the Each Shift, Daily, Weekly, Monthly, and Semi-Annual maintenance checks have been perfor med. The following lubr ication and maintenance procedures should be performed on a Annual basis.

Inspect / Clean, Drive Motors

The drive motors should be cleaned and inspected at least once each year. Cleaning, and inspection of the drive motors is in the Motor Section. Refer to the Motor Section whenever servicing the drive motors. A thorough inspection should be made of the motor bearings at each motor maintenance interval. A periodic check should also be made for a build-up of dust or other foreign matter in the motor interior on AC Wound Rotor and DC Motors.

GENERAL INSPECTION AND REPAIR

The following are general recommendations which may be utilized during routine cleaning, inspection, and repair of most crane components: 1. Clean all parts thoroughly, using kerosene, diesel oil or a suitable commercial cleaning solvent. Never use a hot alkaline solution on nished parts or bearings. 2. Inspect all gears for worn, cracked, or broken teeth. 3. Inspect all bushings for wear, scoring or galling. 4. Replace all oil seals and O-rings. 5. Replace all gaskets, making sure the replacement gaskets are of the same thickness as the old gaskets. Use gasket mater ial of the same composition. 6. Inspect all anti-friction bearings for excessive play, distorted races, and roller wear or damage. Prepack all anti-friction bearings with a good grade of bearing grease before reassembly. 7. Smooth out ridges on shafts. Be particularly careful to inspect all surfaces on which seal lips seat. These surfaces must be very smooth to prevent wearing away the seal lip, which will cause oil or grease leaks. 8. Inspect all threaded items and replace items that have damaged threads.

Cable Reel, General Inspection

Inspect the cable reel for proper operation, wear, or apparent damage. Cable reel inspection should include, but not be limited to the following items: 1. Inspect the cable reel brake assembly. Repair, rebuild, or replace the Mag Coupler Drives as necessary. 2. Tighten all fasteners as described under the topic, Bolt Torques. 3. Inspect slip rings and clean out housing

GENERAL DISASSEMBLY
The following points should be kept in mind during disassembly of any component: 1. Disassembly should be limited to that required for specic repairs. Never disassemble an assembly beyond the point necessary to x the trouble. 2. Never use more force than necessary while dismantling an assembly, In most cases a great deal of force is not required. 3. Before performing any work on the hoisting system, lower the grapple to its lowest travel point, and place suitable blocking under it. Tie off the hoist wire ropes. The weight of the ropes

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LUBRICATION & PREVENTIVE MAINTENANCE

Morris Material Handling 9. Inspect all other parts for any evidence of damage. Replace or repair any part which is in questionable condition. The cost of the part is often minor in comparison with the cost of repeating the job if the part should fail.

GENERAL ASSEMBLY
The following points should be kept in mind when reassembling any component of the crane: 1. When torque values are specied, be sure to use a torque wrench and tighten as directed. Refer to topic, Bolt Torques, for instructions regarding bolt torque procedures and values. 2. Always prepack anti-friction bearings with suitable bearing grease before nal assembly. 3. If a bearing is to be heated for assembly purposes, the entire bearing should be immersed in an oil bath for sufcient time to heat it throughout, refer to Figure 3-6 on page 3-18. 4. Never force a bearing on a shaft if the t appears to be so tight that the inner race will be distorted. Either cool the shaft, or heat the bearing, or do both. 5. Inspect all grease passages to be sure they are open and clean. 6. Smooth out all nicks, burrs, or galled spots on shafts, bores, pins or bushings. 7. Check the t of keys in keyways. File or grind the key, if necessary, to make sure it ts without interference. 8. Roller bearing spacers are ground to t individual bearings and they must be reassembled to the bearing from which they were removed.

3-17

Revised 10/25/04

F444

Figure 3-6 Heating of Bearings

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LUBRICATION & PREVENTIVE MAINTENANCE

Morris Material Handling

CRANE INSPECTION PROCEDURES

GENERAL
This section covers structural inspection of the overall crane. It also provides a general inspection of the runway and lists the allowable out-of-alignment tolerances permitted for normal crane operation.

Rail Clips
Periodically inspect the rail bed for standing water, subsurface seepage, erosion or other factors which could cause settling of the runway rails resulting in loose rail clips. Replace or reset loose or damaged rail clips.

Walkways
Inspect the walkways for cracks, or damage. Inspection of the walkways should include, but not be limited to the following items: Rust. Missing Hand Railings. Loose or missing bolts, and/or attaching hardware. Cracked, stressed, or broken welds.

CRANE STRUCTURE General

The following procedure should be used as a guideline when inspecting the overall crane structure. Record and report any damage which is found.

Welds
Inspect all welds on a regular basis. Weld inspection should include, but not be limited to the following areas: Hairline cracks. Paint chipping (indication of stress at that area). Corrosion.

Bumper Assemblies
Inspect the bumper assemblies as described in Section 10.

Lighting Fixtures and Mountings

Clean the light xtures on a regular basis. A nonabrasive soap solution containing no chlorinated or aromatic hydrocarbons should be used to wash the light reectors and enclosures. A soft cloth or brush may be used to aid in cleaning the xtures. Rinse in clean, cold water, and dry with a soft towel.

Bolted Connections
All bolts are to be torqued to specications as described under the topic, Bolt Torques. Loose bolts are an indication that the bolt may have stretched, and therefore they must be replaced. Do not re-tighten. Loose bolts can be detected by tapping the bolts head with a hammer. There is a denite difference in the sound made by a loose bolt, and one that is properly tightened. A properly tightened bolt will make a sound very similar to the sound made by tapping directly on the structure or bolted frame.

NOTICE
Aromatic Hydrocarbons: A compound that contains elements that will harm the lighting xture rubber mounting pads. It may be acidic and corrosive.

RUNWAY General
Inspect the runway system and its alignment as follows: Check for loose base plates. Check rail clips and bolts. Retighten loose clips. Replace clips which are broken or damaged.

Pin Connections
Pin connections are unlikely to loosen; however, inspect keeper plates regularly to verify that they are tight. Replace any damaged or missing hardware and/or keeper plates.

Trolley Rails
Inspect the trolley rails regularly for cracks. Cracks in the trolley rails should be ground out, and rewelded.

Alignment
Crane rails out of alignment can place severe structural and mechanical stress on the crane. Overall alignment must not differ by more than 1/4 inch from the true center of the rail.

3-19

Revised 10/25/04 Crane Rail Level allowable undulation (change in elevation) must not exceed 1/8 over any six foot section of rail. For additional tolerances of the runway system see Figure 3-7 on page 3-21. WOOD PRESERVATIVE. AREA Manual, Chapter 17, Part 2 (Creosote-Coal Tar Solution or Creosote).

Metal Track Materials

RAIL. Crane Rail Section 171-CR (171 lb. rail). New rail shall be controlled cooled. TRACK SPIKES. New 11/16 x 6 cone neck spikes, in accordance with AREA Manual, Chapter 5, Part M. JOINTS. All rail joints shall be thermite welded and ground smooth. TIE PLATES. Tie plates shall be at type. Plates may be manufactured or fabricated. Metallurgy and tolerances of manufactured plates shall conform to AREA Manual, Chapter 5, Part 1. Fabricated plates shall be solid steel (fy = 36,000 psi). Holes shall be accurately punched to match the rail size. ANTI-SPLITTING DEVICES. These shall be antisplitting strip irons conforming to AREA Manual, Chapter 3, Part 1.9. GEOGRIDS BETWEEN LAYERS. Geogrids shall be provided between layers. Tensar geogrids (SS1 & SS3 Sizes) which are recommended are available through Contech, Inc.

Inspection / Maintenance
GENERAL. This topic includes a typical procedure which covers the inspection and maintenance of the runway rails, ties plates, ties and ballast required for portal cranes to maintain operational tolerances of vertical and horizontal alignment set forth by Morris Material Handling. REFERENCED DOCUMENTS. M O R R I S P O RTA L CRANES. Track Layout for Flexible Portal drive CranesDiagrammatic, Figure 3-7 on page 3-21. O C C U PAT I O N SAFETY AND H E A LT H ADMINISTRATION (OSHA). General Industry OSHA Safety and Health Standards (1910), latest revision. AMERICAN RAILWAY ENGINEERING ASSOCIATION (AREA). Manual for Railway Engineering (Fixed Properties), Volume 1, Chapters 1 through 5, including all supplements. AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM). Standards. EQUIVALENCE. The owner shall be the sole judge of equivalence. Where a given manufacturers product is specied herein, it is given as a measure of quality and products of equivalent quality must be furnished.

Materials
GENERAL. All materials for maintenance of crane rails shall be new and as specied herein. Each item shall be of the size to t the rail section. BALLAST. Ballast shall conform to AREA Manual, Volume 1, Chapter 1, Part 2 (Ballast), and shall be crushed stone, size number 4 or 5. The percentage of wear of prepared ballast tested in accordance with ASTM test method C131 shall not be greater than 40 percent. CROSS TIES. AREA Manual, Volume 1. Chapter 3, Part 1 (Cross Ties) states that ties shall be 9 x 7 x 6 - 0 minimum, of new, treated mixed hardwood suitable for the par ticular use, with static bending stress at proportional limit of 8000 psi. Cross ties shall be spaced 18 inches on center. (Concrete Ties - 24 centers) TIE PLUGS. AREA Manual, Chapter 3, Par t 1 (Specications for Tie Plugs.)

3-20

CRANE INSPECTION PROCEDURES

Morris Material Handling

Figure 3-7 Runway Tolerances

3-21

Revised 10/25/04

RECOMMENDED INSPECTION Level of Inspection

CURSORY INSPECTION. A Cursory inspection of the track shall be made on a daily basis. The inspector shall be thoroughly familiar with the crane tolerance diagram (Morris Portal Cranes, Track Layout for Flexible Portal Cranes-Diagrammatic). The inspector shall observe both rails during the operation of the loaded crane in addition to operation of the unloaded crane. The inspector shall note the following for immediate maintenance: Voids in the ballast beneath the ties. Suspended ties not in contact with the ballast when the rail is not loaded. Split ties. Loose spikes which are not in rm contact with the rail. Horizontal movements exceeding those given in the tolerance diagram. Operational track subsidence exceeding those given in the tolerance diagram. Movement of the rail with respect to the tie plate. Movement of the tie plate with respect to the tie. Worn or cracked tie plates. Loose or damaged bolts in rail joints. Rail failures, See AREA Manual, Chapter 4, Part 3, Description of Rail Failures for illustrations of typical rail failures. Rail failure descriptions have been reproduced under the topic, Rail Failures, later in this section. The cursory inspection shall respond immediately to suspended ties and voids in the ballast to prevent rail failure and resultant replacement of rail sections. TOOL INSPECTION. A tool inspection of the track shall be made on a bi-monthly basis. The inspector shall be equipped with a six (6) foot straight edge and machinists scale. The inspector shall verify the tolerances by measuring the offset as illustrated on the tolerance diagram. Immediate maintenance is required where tolerances exceed the limits given. INSTRUMENT INSPECTION. Inspection of the track shall be made on a quarterly basis. The inspector shall be equipped with surveying instruments, a theodolite and a precise level. The inspector shall verify the alignment tolerance shown on the tolerance diagram.

Any deviation shall be gradual or sweeping, not abrupt or sort.

Maintenance
GENERAL. In general, the track shall be maintained in accordance with applicable sections of the AREA Manual. Trackbed - - - Chapter 1, Part 1.4 Ballast - - - Chapter 1, Part 2.3 Ballast - - - Chapter 5, Part 5, Tamping Ties - - - Chapter 3, Parts 5.1 Ties - - - Chapter 5, Part 7.2 Rail - - - Chapter 5, Part 5

Alignment
VERTICAL ALIGNMENT. Misalignment vertically shall be corrected by reballasting the track. The procedure shall be identical to the procedure of Ballasting and Surfacing for the nal lift. HORIZONTAL ALIGNMENT. Misalignment horizontally shall be corrected by jacking the track. To prevent horizontal movement due to misalignment or crane operation, the ballast shall be tightly tamped around the tie. Tamping shall begin one foot from the rail and progress toward the rail. Tamping shall be carried out on both sides of the rail and the tie simultaneously. When the tie has been tightly ballasted in the center, tamping shall progress toward and around the ends of the tie. The ballast shall be trimmed to the level of the top of the tie and extended to a full six (6) inches beyond the end of the tie. Slope of the ballast on each side of the track shall not be less than two horizontal to one vertical (2:1). RELATIVE MOVEMENT. Relative movement between the rail or the tie shall be corrected by tightening or replacing the spikes. REPLACEMENT. Split tie which cannot be corrected with anti-splitting devices shall be replaced. Tie plates indicating wear in excess of 1/8 inch shall be replaced. Rails which show evidence of any failure as illustrated on the AREA Manual, Description of Rail Failures, shall be replaced. All broken or cracked metal pieces shall be replaced.

Track Maintenance
MAINTENANCE SUPERVISION. All track maintenance shall be performed under the direction of qualied and competent supervisory personnel, including foremen and gang leaders, experienced in railroad construction.

3-22

CRANE INSPECTION PROCEDURES

Morris Material Handling LAYOUT. Track shall be maintained to the lines and grades indicated on the crane general arrangement drawing. UNLOADING THE MATERIALS. The use of picks when handling ties in not permitted. Rails shall be unloaded from the cars by cranes or shall be slid down a skidway of two rails, guided by means of rope at each end of the tie. TIES. Cross ties shall be spaced on proper centers. All ties shall be laid normal to the centerline of the track with the wide hardwood face down. Moving and placing ties with picks or shovels is not permitted. The top surface of the ties shall provide full bearing for the tie plates. If adzing of a tie is required to give the tie plate a full bearing surface when the rail is placed at proper gage, this tie shall be treated with preservatives after adzing, even if it had been treated before. RAIL. The base of the rail and the surface of the tie and tie plate shall be cleaned prior to laying. The rail shall be laid without bumping or striking, to proper gauge and tolerances as specied by the appropriate drawing. SPIKING TIES AND TIE PLATES. Spiking shall be in accordance with AREA Manual, Chapter 5, Part 4, Paragraph 12 through 16, and Appendix 1 thereof. TIE PLUGS. It spikes are withdrawn, the holes shall be swabbed with preservatives and plugged with treated tie plugs of proper size to t the hole. RAIL JOINTS (If Not Thremit Welded). The joint bar and gearing surface of the rail shall be secured rmly. Joints should be re-tightened one to three months after application and one (1) year intervals thereafter. Graphite grease is benecial in providing lubrication and preventing corrosion. BALLASTING AND SURFACING. Ballast Distribution. Distribution of the ballast shall be to the depth indicated in the crane specications. Care shall be taken when distributing ballast from automotive equipment to prevent forming of ruts that would impair proper roadway drainage. TAMPING. The ballast shall be power tamped under both sides of the cross ties for the full length of the tie. Ballast at both ends of the cross ties shall be tamped simultaneously and ballast on each side of the rail and tie shall also be tamped simultaneously. POSITION OF TRACK. When the track is within one or two inches of the nal grade and the ballast under the track has been compacted, a nishing lift shall be u n d e r t a ke n , w i t h d u e a l l owa n c e fo r ex p e c t e d settlement. The track shall be brought to a true and nished surface and the ballast shall be trimmed as specied. RE-SETTING OF TIES AFTER JACKING TRACK. After tamping has been completed and the jacks removed, all ties which have been pulled loose shall be respiked. BALLAST COMPACTION CONTROL. Testing of ballast shall be in accordance with the AREA Manual, Chapter 1, Part 2. TEMPORARY WORK. Drainage shall be maintained and the accumulation of water that might affect the stability of the base of ballast shall not be permitted.

Rail Failures
TRAVERSE FISSURE. A progressive crosswise fracture starting from a crystalline center or nucleus inside the rail head from which it spreads outward as a s m o o t h b r i g h t o r d a r k , r o u n d o r ova l s u r fa c e substantially at a right angle to the length of the rail. The distinguishing features of a traverse ssure from other types of fractures or defects are the crystalline center or nucleus and the near ly smooth surface of the development which surrounds it. COMPOUND FISSURES. A progressive fracture originating in a horizontal split rail head which turns up or down in the head of the rail as a smooth, bright or dark surface progressing until substantially at a right angle to the length of the rail. Compound ssures required examination of both faces of the fracture to locate the horizontal split head from which they originate. DETAIL FRACTURE. A progressive fracture originating at or near the surface of the rail head. These fractures should not be confused with traverse ssures, compound ssures, or other defects which have internal origins. Detail fractures may arise from shelly spots, head checks or aking. SHELLY SPOTS. Where a thin (usually 3/8 inch in depth or less) shell-like piece of surface metal becomes separated from the parent metal in the rail head, generally at the gage corner. It may be enhanced by: 1. A black spot appearing on the rail head over the zone of separation. 2. A piece of metal breaking out completely, leaving a shallow cavity in the rail head. In the case of a small shell there may be no surface evidence, the existence of the shell being apparent only after the rail is broken or sectioned. HEAD CHECKS. Hair line cracks which appear in the gage corner of the rail head, at any angle with the length of the rail. When not readily visible the presence of the checks may often be detected by the rampy feeling of their sharp edges.

3-23

Revised 10/25/04 FLAKING. Where small shallow akes of the surface metal generally not more than 1/4 inch in length or width break out of the gage corner of the rail head. ENGINE BURN FRACTURE. A progressive fracture originating in spots where driving wheels have slipped on top of the rail head. In developing downward they frequently resemble the compound or even traverse ssures with which they should not be confused or classied. HORIZONTAL SPLIT HEAD. A horizontal progressive defect originating inside of the rail head usually 1/4 inch or more below the running surface and progressing horizontally in all directions, and generally accompanied by a at spot on the running surface. The defect appears as a crack lengthwise of the rail when it reaches the side of the rail head (see Diagrams 1, 2 3 in Figure 3-8 on page 3-25). VERTICAL SPLIT HEAD. A vertical split through or near the middle of the rail head, and extending into or through the head. A crack or rust streak may show under the head close to the web or pieces may be split off the side of the rail head (see Diagrams 4, 5, 6, 7 in Figure 3-8 on page 3-25). CRUSHED HEAD. Flattening or crushing down of the rail head (see Diagrams 8, 9 in Figure 3-8 on page 325). PIPED RAIL. A rail showing a vertical split, usually in the web, due to failure of the sides of the shrinkage cavity in the ingot to unite in rolling (see Diagram 10 in Figure 38 on page 3-25). SPLIT WEB. A lengthwise crack along the side of the web and extending into or through the web (see Diagram 11, 12 in Figure 3-8 on page 3-25). BROKEN BASE. Any break in the base of the rail (see Diagrams 13, 14 in Figure 3-8 on page 3-25). ORDINARY BREAK. Any partial or complete break in which there is no sign of ssure, and in which none of the defects listed above can be seen (see Diagrams 15, 16 in Figure 3-8 on page 3-25). DAMAGED RAIL. Any rail broken or damaged by wrecks, broken, at, or unbalanced wheels, slipping or similar conditions.

3-24

CRANE INSPECTION PROCEDURES

Morris Material Handling

Figure 3-8 Rail Failures, Diagrams 1 through 16

3-25

Revised 10/25/04

Preventive Maintenance
Client
Report No.: Our Ref: Your Ref: Attention:

Crane Serial No. Description

1. Visual Inspection 2. Mechanical Inspection 3. Electrical Inspection 4. Operational Check 5. Limit Switch Functions 6. Spare Parts 7. Recommendations

Capacity:

Performed By: Customer Verification: Date:

Check Lists Attach F562A

3-26 CRANE INSPECTION PROCEDURES

Morris Material Handling

3-27

Revised 10/25/04

Line No.

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

END TRUCKS - Gantry Truck Wheels Axle Bearings Gearcase Coupling Truck Gearcase and Gears

Motor Pinion Motor Gear

Crane Alignment End Trucks Guards Bumpers and Rail Sweeps Platforms Railings and Guards Cab Cab Windows Ladders and Stairways Rail Clamps and/or Tiedown Cables or Wheel Chocks Runway Tails and End Stops TROLLEY Wheels Axle Bearings

Gear Case Bearings and Oil Seals Gearcase

MAIN HOIST Bottom Lifting Beam - Sheaves - Bearings Upper Sheaves

3-28

CRANE INSPECTION PROCEDURES

See Additional Notes

Requires Replacement

Requires Adjustment

Requires Lubrication

O.K.

Morris Material Handling

See Additional Notes Requires Replacement

Line No.

Description

36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53

Wire Rope Rope Drum Drum Shaft Drum Gear Drum Pinion Intermediate Gear Intermediate Pinion Motor Gear Motor Pinion Gear Case Bearings and Oil Seals Couplings Cable Dead End Fittings MAINTENANCE HOIST Bottom Block Upper Sheaves Wire Rope Rope Drum Drum Shaft Drum Gear Drum Pinion Intermediate Gear Intermediate Pinion Motor Gear Motor Pinion Gear Case Bearings and Oil Seals END STOPS PULL-A-HOIST (TRACTOR UNIT) CABLE REEL Bearings and Oil Seals Mag Coupler Spyder Couplings Mag Coupler Motor and Back Stop Bearings Brushes and Brush Holders Collector Rings Conductor Cable and Termination Point Cable Guide and Rollers

OPTIONAL

54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70

Requires Adjustment

Requires Lubrication

O.K.

3-29

Revised 10/25/04
See Additional Notes Requires Replacement

Line No.

Description

71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105

GRAPPLE Motor Couplings Cable Basket and Electric Cables Gears and Pinions Collector Rings Brushes and Brush Holders Sleeves and Pins Bearings Grapple Arm Hydraulic Readings and Fluid Res. Level and Filters END TRUCK MOTORS

Rotor Stator

Bearings and Oil Seals

MAIN HOIST MOTORS

Blower Stator and Rotor

Bearings and Oil Seals

MAINTENANCE HOIST MOTOR

Rotor Stator

Bearings and Oil Seals

TROLLEY MOTORS

3-30

CRANE INSPECTION PROCEDURES

Requires Adjustment

Requires Lubrication

O.K.

Morris Material Handling

See Additional Notes Requires Replacement

Line No.

Description

106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140

Rotor Stator

Bearings and Oil Seals

BRAKES Gantry Brake Linings Gantry Brake Wheel or Discs Gantry Brake Coil and Linkages Main Hoist Brake Linings Main Hoist Brake Wheel Main Hoist Brake Coil and Linkages Maintenance Hoist Brake Linings Maintenance Hoist Brake Wheel or Discs Maintenance Hoist Brake Coil and Linkages Trolley Brake Linings Trolley Brake Wheel or Discs Trolley Break Coil and linkages

MISCELLANEOUS Main Hoist Limit Switch(2) (GLS and Upper Weight) Maintenance Hoist Limit Switch Overload Limit Switch Track Switches (Optional)

Hoist Rope Whisker Limit Switches

Gantry Brake Time Delay Master Controllers: Gantry / Trolley Joystick

Requires Adjustment

Requires Lubrication

O.K.

3-31

Revised 10/25/04
See Additional Notes Requires Replacement

Line No.

Description

141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164

Main Hoist with Gantry Slew Switch

Maintenance Hoist Pushbuttons Cab Seat AssemblySlider Mechanism MOTOR CONTROLS Gantry Main Hoist Trolley Maintenance Hoist Contactors and Auxiliary Contacts

Brake Panels FESTOON SYSTEM (Optional) Trolleys Cable Trolley Conductors Trolley Collectors ElevatorSeparate Check List If Applicable Control HouseDoors, Lighting, Air Cond. Units, Fire Extinguisher Emergency Lighting Systems Incinerator Toilet Unit (Optional) Walkway Lights Cab Air Conditioner/Heater Fire Estinguisher(s)Cab Fire Estinguisher(s)Other Locations Gantry Motion Lights and Horns TV Monitor(s)Camera(s) TV Monitor(s)Lights(s) TV Monitor(s)Monitor(s)

3-32

CRANE INSPECTION PROCEDURES

Requires Adjustment

Requires Lubrication

O.K.

Morris Material Handling

See Additional Notes Requires Replacement

Line No.

Description

TV Monitor(s)Wireless Link Wind Speed Indicator (Anemometer) Gai-Tronics Communication System (Optional) Capacity PlatesTrolley Capacity PlatesGrapple Warning Horn(Cab Operated)

MAINTENANCE
Line Referenc e

Notes

Requires Adjustment

Requires Lubrication

O.K.

3-33

Revised 10/25/04

Recommendations

3-34

CRANE INSPECTION PROCEDURES

Morris Material Handling

Portal Crane Operator Shift (Daily) Check List Crane PC-29014

NOTE: Do this portion of the checklist before you operate this equipment: General Appearance Track Condition - Clear [ ] Dry [ ] Wet [ ] Tie Downs and Chocks - Removed [ ] Wheel Condition (8) Oil Level in Gantry Box FL2/1____ HL2/1_____ Grapple Condition a) Oil level in hydraulic unit b) Pin Condition c) Hydraulic Leaks NOTE: Do this portion of the checklist after you enter the cab: General condition - cab clean, etc. Fasten seat belt - start crane & Grapple (allow to warm up) Release storm brakes Limit switch test - upper hoist - (Must Do Each Shift) FL1/2 ____ HL1/2_____ Run trolley both directions Hoist Wire Ropes - OK [ ] Observe rails - verify clear Run gantry both directions Cable reel take up __________ Payout ___________ Open grapple fully/set timing

d) Did Operations grease all points? yes [ ] no [ ] T.V. monitor okay? e) Condition of power cable & guards (8) Sheaves & (4) guards (Lifting Beam) Hoist cable condition Mexican hat cable basket and cable condition Condition of cable drum Oil level in hoist gear box Trolley wheels & rails Oil level in trolley gear boxes Trolley mounted sheaves (4) Lights / Trolley / Walkways / Gantry Access stairs/walks/gates/Control House Doors Shut/Air Conditioners - Operating Any existing damage noted ______________ Wires on Legs / Gantry Motor Wires Weather Conditions:____________________________ Remarks: ____________________________________ Was equipment damage reported to foreman? yes [ ] no [ ] List any downtime/reason: _______________________ Warning horn and light on during gantry motion? yes [ ] no [ ] Did equipment damage occur on this shift? yes [ ] no [ ] What happened? What time?

Reported By ____________________________ Date: __________________________________ Time:__________________________________

Shift:__________________ Approved By:___________

3-35

Revised 10/25/04

Portal Crane Mechanical Shift (Daily) Check List Crane PC-29014

General Appearance Visual inspection of brake wheels / shoes / discs Track condition - Clear [ ] Dry [ ] Wet [ ] Wheel condition Oil level in gantry box FL1_____ HL1_____ FL2 _____ HL2 _____ Grapple Condition a) Oil level in hydraulic unit b) Pin Condition & keeper plates c) Hydraulic Leaks d) Did maintenance grease all points? yes [ ] no [ ] e) Condition of power cable & guards (8) Sheaves & (4) guards lifting beam Hoist cable condition Mexican hat cable basket and cable condition Condition of cable drum Oil level in hoist gear box Trolley wheels & rails Oil level in trolley gear boxes Trolley mounted sheaves (4) Access stairs / walks / gates/control house doors shut Any damage noted Remarks: List any downtime / reason:______________________ (where accessible) _____________________________

Reported By ____________________________ Date: __________________________________ Time:__________________________________

Shift:__________________ Approved By:___________

3-36

CRANE INSPECTION PROCEDURES

Morris Material Handling

Portal Crane Electrical Shift (Daily) Check List Crane PC-29014

List any downtime / reason: General Appearance________________________ Grapple Condition________________________ (Wires Intact) Condition of Power cables: a) Trolley to Mexican Hat b) Mexican Hat junction box to Grapple Junction box Lights / Trolley / Walkway / Gantry Remarks:

Any damage noted

Wires on legs / Drive Motor JB and Wires

Visual inspection of all contactors Controls

Weather Conditions

Reported By ____________________________ Date: __________________________________ Time:__________________________________

Shift:__________________ Approved By:___________

3-37

Revised 10/25/04

Routine Outage Mechanical Inspection Checklist

DATE: OK X General Structure Structural Pins & Keepers Gantry Brakes (4) Trolley Brakes (2) Hoisting Brake (1) Hoist Wire Ropes (4) (4) Sheaves and Dead Ends Uppers Lifting Beam / Sheaves (8) / Grapple and Attachment Pin Gantry Wheels / Tracks / Bumpers Trolley Wheels / Tracks / Bumpers / Cab Idler Wheels Grapple (Lube Each Shift) Gear Reducers - Trolley/Hoist/ Gantry Stairs/Ladders/Gates/Walkways Welds and Bolts Hoist Encoder Coupling Cable Reel (I.E. Inspections) Cable Reel Guide Gantry Swivel Joints * X * * * * * * X X X X X X *

PC-29014
Six Months

Quarterly

Monthly

Weekly

Inspected By

X X X X X

X X

Remarks:

The original of this report should be mailed to the Safety Supervisor and a copy to the Maintenance Supervisor / Planner. * = Lubricate as required ________________________________________ Mechanical

3-38

CRANE INSPECTION PROCEDURES

Morris Material Handling

Routine Outage Electrical Inspection Checklist

DATE: OK X Grease all motor bearings on main hoist/trolley/gantry. Check hoist/trolley/gantry motors and hoist blower motor. Span Bars and Collectors All covers/guards in place, panel enclosure doors closed. Open all cabinets and junction boxes, check all connections and cables for signs of arcing or heat. Initially monthly - then 6 months after - 6 months Check all cable on legs and end trucks for log damage. Check operation of brakes. Check limit switches: upper weight/upper & lower geared/drum ends Inspect/repair light xtures or order replacements if necessary. Inspect cab/seat/master switches/wipers/air-conditioned/heater. Inspect T.V. monitor and camera. Inspect wind speed indicator. Inspect grapple slip rings Inspect gantry take-up reel slip rings. Inspect cable reel cable and guide rollers. Check sirens/strobe lights, repair or replace as necessary. Check/set gantry brake set-timer to 2 to 4 seconds.(Minimum) Controls (General) (All connections checked) Safety devices (bells, lights, limit switches, seat belt, guards). Motors and couplings. Hoist (1) + Gantry (4) + Trolley (2) Transformer and main switch. Note: Be sure to follow appropriate lock-out procedures during inspections. Remarks: Check fault list on diagnostic panel & drives. The original of this report should be mailed to the Safety Supervisor and a copy to the Maintenance Supervisor / Planner. X X X X X X X X X X X X X X 6 Mo. X

PC-29014
Six Months X X X X X

Quarterly

Monthly

Weekly

Inspected By

Electrical

3-39

Revised 10/25/04

3-40

CRANE INSPECTION PROCEDURES

Section 4 TROUBLESHOOTING
GENERAL
This section provides general information necessary for the general troubleshooting of this crane. Table 4-1 provides a general outline of problems which could be experienced with normal use of this crane. It lists the trouble, the possible cause, and the possible solution for the trouble being experienced.

Table: 4-1 Portal Crane Troubleshooting TROUBLE Grapple does not raise or lower. POSSIBLE CAUSE No power supplied to the hoist drive motor. Hoist contactor not operating. POSSIBLE REMEDY Check limit switches, breakers, fuses, and power line connections for an open circuit, grounded, or faulty connections. Check the control panel connections. Check the contactor coils and control cables for open or short circuits. Reset the overload relay if one is used. Check the limit switch contacts. Replace if necessary. Check the adjustment of the geared limit switch. Check the brake adjustment. Check for loose or broken connections. Check the brake contacts, the rectier, the brake circuit transformer and the brake solenoid or coil. Make sure that load weights are within the rated capacity of the crane. Adjust, repair, or replace the limit switches as necessary. Interchange any two of the three power lead connections at the power source (check for single phasing). Rewind the wire rope in the proper direction. Check the wire rope for damage. If necessary, replace it. Check the operation of the lower limit switch.

Limit Switch is tripped or open.

Motor brake does not release.

Excessive loading. Grapple does not stop at upper or lower travel limits. Grapple moves in the wrong direction. Limit switches are not opening the hoist control circuit. Improper phasing (phase reversal).

The hoist wire rope is wound on the drum in the wrong direction.

Rev. Date 10/25/04

4-1

Revised 10/25/04 Table: 4-1 Portal Crane Troubleshooting TROUBLE Grapple does not stop quickly. POSSIBLE CAUSE Motor brake is slipping. POSSIBLE REMEDY Brake linings are worn, dirty, or glazed. Check the condition of the brake linings and all other remaining brake components for wear or damage. Clean or replace parts as necessary. Adjust the brake as described in the brake section of this manual. Check the operation of the brake rectier. Check the operation of the Magnetorque. Check the motor brake for misadjustment, or binding. Check the brake rectier for a possible malfunction. Check the Magnetorque current. Check the motor connections. If necessary, reconnect the motor per the applicable wiring diagram. Adjust or repair, the upper limit switch as required. Repair or replace the raise contactor. Repair or replace the damaged interlock assembly. Adjust or repair, the lower limit switch as required. Repair or replace the damaged interlock assembly. Replace the lower contactor. Replace the affected controller. Replace or repair the motor. Shut the system down and locate the short. Repair or replace affected components. Lubricate rope. See Section 3 of this manual. Replace sheaves. If necessary, replace wire rope. Grapple must be centered over the load such that the wire rope is vertical before a lift begins. Also, make sure that the wire rope wraps smoothly onto the hoist drum.

Inoperative brake rectier. (DC Brakes) Inoperative Magnetorque. (Static Stepless) Poor acceleration with a load on the grapple. Motor brake is binding or dragging.

Excessive Magnetorque current. (Static Stepless) Incorrect connections at the motor.

Hoist will not raise, but will lower normally.

Upper limit switch tripped due to misadjustment or malfunction. Faulty raise contactor. Faulty electrical or mechanical interlocks on the lower contactor.

Hoist will not lower, but will raise normally.

Lower limit switch tripped due to misadjustment or malfunction. Faulty electrical or mechanical interlocks on the raise contactor. Faulty lower contactor.

Hoist runs only at one speed.

Damaged directional controller. Shorted motor. (Static Stepless) Short in motor secondary circuit. (Static Stepless)

Hoist wire rope is worn.

Lack of wire rope lubrication. Worn sheaves. Grapple is being used for side pulling.

4-2

TROUBLESHOOTING

Morris Material Handling Table: 4-1 Portal Crane Troubleshooting TROUBLE Grapple moves in one direction or intermittently. POSSIBLE CAUSE Open limit switch or switches. Loose electrical connections. Worn or dirty controller contacts. Contactors and/or relays do not function properly. Faulty motor operation. POSSIBLE REMEDY Adjust, repair, or replace the geared and/or weight limit switches as necessary. Ensure all electrical connections are secure. Clean, repair, or replace the associated controller, or pushbutton. Repair or replace the contactor or relay. Check the motor for continuity with the motor circuit. Check to make sure all connections are proper and that they are secure. Check the collectors for free movement of the spring loaded arm, a weak spring, or poor connections. Repair or replace the weight operated upper limit switch as necessary. Check the power source for proper continued voltage. Ensure the electrical connections are correct, and secure. Check limit switches, breakers, fuse, and power line connections for an open circuit, grounded or faulty connections. Check the control panel connections. Check the contactor coils and control cables for open or short circuits. Reset the overload relay if one is used. Check the brake adjustment. Check for loose or broken connections. Check the brake contacts, the rectier, the brake circuit transformer and the brake solenoid or coil. Check the weight of the loads being handled. Make sure that loads are within the rated capacity of the crane. Interchange any two of the three power lead connections at the power source (check for single phasing).

Collectors make poor contact with the conductor bar. Normally closed contacts of the upper weight operated limit switch are arcing. Hoist is unable to lift a rated load. Improper electrical power. Improper electrical connections. Trolley will not move in either direction. No power supplied to the trolley drive motor. Trolley contactor not operating.

Motor brake does not release.

Excessive loading.

Trolley moves in the wrong direction.

Improper phasing (phase reversal).

4-3

Revised 10/25/04 Table: 4-1 Portal Crane Troubleshooting TROUBLE Trolley does not stop quickly. POSSIBLE CAUSE Motor brake is slipping. POSSIBLE REMEDY Brake linings are worn, dirty, or glazed. Check the condition of the brake linings as well as all other remaining brake components for wear or damage. Clean or replace parts as necessary. Adjust the brake as described in the brake section of this manual. Check the operation of the brake rectier. Check the motor brake for mis-adjustment, or binding. Check the brake rectier for a possible malfunction. Check the motor connections. If necessary, reconnect the motor per the applicable wiring diagram. Replace the damaged or faulty contactor. Repair or replace the damaged interlock assembly. Replace the affected controller. Replace or repair the motor. Shut the system down and locate the short. Repair or replace affected components. Ensure all electrical connections are secure. Clean, repair, or replace the associated controller, or pushbutton. Repair or replace the contactor or relay. Check the motor for continuity with the motor circuit. Check to make sure all connections are proper and secure. Check the power source for proper continued voltage. Ensure the electrical connections are correct, and secure.

Inoperative brake rectier. (DC Brakes) Poor acceleration of trolley with a load on the grapple. Motor brake is binding or dragging.

Incorrect connections at the motor.

Trolley will not move in one direction, but operates normally in the opposite direction. Trolley operates only at one speed.

Faulty or damaged directional contactor. Faulty electrical or mechanical interlocks on the contactor. Damaged directional controller. Shorted motor. Short in motor secondary circuit.

Trolley operated intermittently.

Loose electrical connections. Worn or dirty controller contacts. Contactors and/or relays do not function properly. Faulty motor operation.

Trolley is unable to move a rated load.

Improper electrical power. Improper electrical connections.

4-4

TROUBLESHOOTING

Morris Material Handling Table: 4-1 Portal Crane Troubleshooting TROUBLE Gantry will not move in either direction. POSSIBLE CAUSE No power supplied to the gantry drive motor. Gantry contactor not operating. POSSIBLE REMEDY Check limit switches, breakers, fuse, and power line connections for an open circuit, grounded or faulty connections. Check the control panel connections. Check the contactor coils and control cables for open or short circuits. Reset the overload relay if one is used. Check the brake adjustment. Check for loose or broken connections. Check the brake contacts, the rectier, the brake circuit transformer and the brake solenoid or coil. Check the weight of the loads being handled. Make sure that loads are within the rated capacity of the crane. Check cable reel oil level. Check the input to no-volt relay. Replace oil pressure switch and/or oil level switch if oil pressure and level correct. Open the motor circuit breaker, have the operator operate the gantry controller, and check that contractors are pulling in. If not, repair circuit as necessary. Disassemble drive gear case to determine the cause of binding. Dirty track. Clean track as necessary. If track is ice covered, apply sand to increase traction.

Motor brake does not release.

Excessive loading.

Drive motors are locked out due to cable reel low oil pressure, or low oil.

Open circuit on gantry controller in cab, or in festoon.

Drive wheels not turning. Drive wheels spinning on track.

4-5

Revised 10/25/04 Table: 4-1 Portal Crane Troubleshooting TROUBLE Excessive wear on gantry wheel anges. POSSIBLE CAUSE Gantry drive motor failure. Incorrect operation of skew switches. (Static Stepless ONLY) Incorrect operation of electric load brakes. (Static Stepless ONLY) POSSIBLE REMEDY Run crane and check motor currents per phase, these should be within 10%. Check the operation of skew switches as described in Section 11. For excessive ange wear, the per phase current would have to be low, indicating lack of torque, or high, indicating rotor connected incorrectly (swapped with stator) or reverse rotation. The rotor currents should also be checked on rst point stall. Check gear train and wheel bearings as in procedure above. Check alignment of equalizers to drive/idler trucks, as described in Section 3. Note: Before carrying out this procedure, it should be determined if the bushings and pins are worn. Interchange any two of the three power lead connections at the power source (check for single phasing). Brake linings are worn, dirty, or glazed. Check the condition of the brake linings as well as all other remaining brake components for wear or damage. Clean or replace parts as necessary. Adjust the brake as described in the brake section of this manual. Check the operation of the brake rectier. Check the motor brake for misadjustment, or binding. Check the brake rectier for a possible malfunction. Check the motor connections, and if necessary, reconnect the motor per the applicable wiring diagram. Replace the damaged or faulty contactor. Repair or replace the damaged interlock assembly. Replace the affected controller. Replace or repair the motor. Shut the system down and locate the short. Repair or replace affected components.

Gantry wheel bearing failure. Misalignment equalizer and drive/idler trucks.

Gantry moves in the wrong direction. Gantry does not stop quickly.

Improper phasing (phase reversal).

Motor brake is slipping.

Inoperative brake rectier. Poor gantry acceleration with a load on the grapple. Motor brake is binding or dragging.

Incorrect connections at the motor.

Gantry will not move in one direction, but operates normally in the opposite direction. Gantry operates only at one speed.

Faulty or damaged directional contactor. Faulty electrical or mechanical interlocks on the contactor. Damaged directional controller. Shorted motor. Short in motor secondary circuit.

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TROUBLESHOOTING

Morris Material Handling Table: 4-1 Portal Crane Troubleshooting TROUBLE Gantry operates intermittently. POSSIBLE CAUSE Loose electrical connections Worn or dirty controller contacts. Contactors and/or relays do not function properly. Faulty motor operation. POSSIBLE REMEDY Ensure all electrical connections are secure. Replace, clean, or repair the controller contacts. Repair or replace the contactor or relay. Check the motor for continuity with the motor circuit. Check to make sure all connections are proper and secure. Check the power source for proper continued voltage. Ensure the electrical connections are correct and secure. Check the system voltage and coil voltage, and watch for voltage variations during start-up time. Check wiring and coil nomenclature, etc. Check with an ohmmeter. If necessary, replace the coil. Disconnect power. Check for free movement of magnet and contact assembly. Clean with a non-volatile solvent or degreasing uid. Free up or replace the mechanical interlock. Clean or replace the worn parts. Replace worn or damaged magnet parts. Improve contact continuity. Locate and correct the cause of the low voltage. Secure of replace the hardware. Handle and store contactors carefully. Replace damaged parts.

Gantry is unable to move a rated load.

Improper electrical power. Improper electrical connections.

Contactor fails to pick up and seal.

Low voltage.

Incorrect magnet coil or improper connections. Contactor fails to pick up and seal. Coil open or shorted. Mechanical obstruction. Contactor fails to drop out. Gummy substance on pole faces or magnet sides. Mechanical interlock binding. Worn or rusted parts causing binding. Residual magnetism due to lack or air gap in magnet path. Contact chatter. Poor contact continuity in control circuit. Low coil voltage. Contact supports discoloring. Open coil circuit. Loose connections. Mechanical damage due to careless handling.

4-7

Revised 10/25/04 Table: 4-1 Portal Crane Troubleshooting TROUBLE Oil leaking from gear case. (Also See Seal Failure) POSSIBLE CAUSE Oil seals are worn or damaged. Breather lter clogged Gear case gaskets are damaged. Welding of contacts. Abnormal motor inrush current. Rapid jogging. POSSIBLE REMEDY Replace all worn or damaged gear case seals. Replace breather Replace any damaged gear case gaskets. Check for grounds, shorts, or excessive motor load current. Install larger device rated for jogging service or caution the operator not to excessively jog the control. Replace contact springs, and check the contact carrier for damage. Replace parts as necessary. Correct voltage condition. Clean the contacts with non-volatile solvent. Remove short fault and check to be sure that the fuse size is correct (if applicable). Do not le silver contacts. Replace the contacts if they have been led or dressed. Check for grounds, shorts, or excessive motor currents. Install larger device rated for jogging or warn operator not to jog hoist excessively. Replace contact springs, check contact carrier for damage. Replace parts as necessary. Clean the contacts with non-volatile solvent. Clean and tighten. Check for excessive motor load current. Restore normal voltage level.

Insufcient tip pressure.

Low voltage preventing magnet from sealing. Foreign matter preventing the contacts from closing. Short circuit. Short contact life or overheating. Contacts have been lled or dressed. Interrupting excessively high currents. Short contact life or overheating. Excessive jogging. Weak contact pressure.

Dirt or foreign matter on contact surface. Loose connection. Sustained overload. Excessive wear due to high coil voltage.

4-8

TROUBLESHOOTING

Morris Material Handling Table: 4-1 Portal Crane Troubleshooting TROUBLE Burned coil (overheating). POSSIBLE CAUSE Overvoltage or high ambient temperatures. Incorrect coil. Shorted turns caused by mechanical damage or corrosion. Undervoltage, causing failure of the magnet to seal in. Dirt or rust on pole faces, increasing the air gap. Low torque in one direction, normal torque in the opposite direction. Motor overheats. One reversing contactor pole is not making contact. Excessive duty cycle. POSSIBLE REMEDY Check application and circuit. Coils will operate satisfactorily over a range of 85 110% of rated voltage. Check rating, and if incorrect, replace with the proper unit. Replace the coil. Correct system voltage. Clean pole faces. Shut the control system down. Clean, repair, or replace the affected contactor. Check the weight of the loads being handled and the number of motor starts per hour. Do not exceed the hoist duty cycle or rated load. Check the data stamped on the motor nameplate for the correct power supply which is to be used. Voltage should be within 10% of that which is stamped on the motor nameplate. Check the motor windings for open or short circuits. Check the supply lines for balanced currents. Check the application and replace the motor, if necessary. Remove the motor and inspect the bearing and motor support. Repair or replace the motor. Remove the motor and determine the cause for the jam. Correct as necessary. Check the adjustment of the motor brake. Check the brake rectier or brake control circuit, and brake solenoid. Check the operation of the brake rectier as described under the brake rectier TROUBLES.

Incorrect voltage/frequency.

The three-phase power supply has had a phase loss and/or unbalanced current. Motor problems. Insufcient horsepower. Motor bearing damaged. Motor problems. Damaged motor parts. Jammed or binding speed reducer. Motor brake overheats. Brake is not releasing or is partially releasing. Inoperative brake rectier. (DC Brakes ONLY)

4-9

Revised 10/25/04 Table: 4-1 Portal Crane Troubleshooting TROUBLE Brake does not release or partially releases. POSSIBLE CAUSE Solenoid coil is open or shorted. Open brake circuit. Damaged brake rectier, or transformer. POSSIBLE REMEDY Check all brake electrical connections. Check the brake solenoid coil for open or short circuits. Check the brake rectier and the brake rectier transformer as described in the following steps. 1. Measure the output voltage and current of the bridge rectier circuit. Compare these values with the voltage and current for the bridge rectier circuit (refer to the brake rectier panel for the applicable voltage and current). 2. If the bridge circuit outputs are low, measure the transformer secondary voltage. Compare the measured voltages with the secondary voltage shown on the assemblys nameplate. 3. If the measured transformer voltages agree with the nameplate voltages, replace the bridge rectier circuit. 4. If the transformer output is low, measure the voltage across the transformer primary. 5. If the voltage measured across the primary agrees with the voltage shown in the secondarys nameplate, replace the transformer. 6.If the transformer output is correct, measure the same voltage between the yellow terminals on the bridge circuit. 7. If no voltage input to the bridge circuit is evident, replace the brake relay. 8. If there is no measurable voltage across the transformer primary, check the toggle switch for an open condition. Check for blown fuses. Replace the blown fuses, and/or replace the open toggle switch as applicable. Correct or replace parts as necessary. Correct or replace parts as necessary. Correct as necessary. Replace the key, the shaft or the output sleeve as necessary. Identify and correct.

Speed reducer is unstable on its mounting. Speed reducer is unstable on its mounting.

Hollow output sleeve not parallel to the input shaft. Mounting shaft bent, damaged or too small for the output sleeve. Missing or worn or damaged keyway or key seat. Misapplied, loose or misaligned mounting components.

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TROUBLESHOOTING

Morris Material Handling Table: 4-1 Portal Crane Troubleshooting TROUBLE Speed Reducer, Gear Case malfunctions. POSSIBLE CAUSE Damaged or worn bearings. Damaged or worn gearing. Wrong or insufcient lubricant. POSSIBLE REMEDY Inspect and replace worn parts. Inspect and replace worn parts. Drain and replace the lubricant as specied in the lubrication section or in the manufactures instructions. Properly seat the motor assembly, and tighten all mounting bolts to the correct torques. Check for proper assembly of the speed reducer components, and inspect, adjust or replace parts as necessary. Drain and replace the lubricant as specied in the lubrication section or in the manufacturers instructions. Remove from the heat source, or replace seals with seals rated for the ambient temperatures in which the drive is operating. Add lubricant as specied in Section 3. Check that the vent plug is in place and clean. Remove burrs using ne sandpaper. Replace seal, or seals, as necessary. Replace the casting. Repair damaged threads and/or tighten the drain plug. Replace the gasket. Relocate the vent plug above the oil level.

Motor and support are not seated properly. Improper assembly or maintenance of speed reducer components. Seal Failure. Abrasive contaminants or sludge in the oil. Excessive operating temperature causing brittle seals. Insufcient lubrication. High pressure in the gear case. Burrs on the shafts. Oil Leakage. Input or output shaft oil seal failure. Cracked or porous gear case castings. Damaged or loose drain plug. Damaged plug or gear case threads. Damaged or broken gasket. Improper vent plug location.

4-11

Revised 10/25/04

4-12

TROUBLESHOOTING

Section 5 GANTRY DRIVE SYSTEM

GENERAL
This section describes the components of the gantry drive system, and includes removal, disassembly, cleaning and inspection repair, assembly, and installation instructions of the major components. Lubrication and preventive maintenance of these components are covered in Section 3. Gantry is a term used to describe the structural assembly of the legs and main girder, as well as the motion of the crane along its runway. The gantry is supported at the end of each leg by means of a drive truck with tone idler wheel and on drive wheel resting on the track. The trucks are pin/swivel connected to the leg end and can be considered to bear the weight of the leg and associated structure equally between them. The gantry drive system used on this Portal Crane consists of a helical bevel right angle gear reduction driving 2 gantry wheels through a spur gear reduction system on the gantry truck side. Generally, each corner of the gantry is driven, making a total of four driving motors. The driving torque to move the crane along the track is supplied by the gantry drive motors. To slow the crane down, braking torque is provided by control circuitry. When the crane has come to rest, the holding brakes will be applied automatically under the control of a timer. The holding brakes serve only to hold the crane in position.

MOTOR BRAKE
The motor brake used on the gantry is a self-adjusting DC brake. Information on this brake is located in Section 9.

DRIVE REDUCTION GEAR CASE

Informational the gantry gear case is located at the end of this section.

WHEEL ASSEMBLIES General

Jack up the truck assembly until the wheel has cleared the rail head. Jacking of the truck assembly is facilitated by the use of the jacking plate located vertically in line with the truck pin. It is suggested that a large size steel plate bed be laid out across at least three rail ties to provide a suitable foundation for the jacks. If the outer wheel assembly has to be removed, support should be provided under the motor bed plate to compensate for the off center loading caused by the motor and brake assemblies. The motor bed plate is designed so that the wheel assembly can be rolled out from underneath, once the sweep plate and bumper assembly have been removed. It is strongly suggested that if any work is done on the shaft and wheel assemblies, that new bearings be installed at this time. (Storm Brakes can also be used to jack)

Removal
Use the following procedure to remove a wheel assembly from the truck assembly.

DRIVE MOTOR
The motor used on this drive system is a conventional AC squirrel cage motor. Lubrication, preventive maintenance, and repair of the drive motor is covered in Section 8. Refer to that section whenever servicing the motor itself.

! WARNING DANGER
Inadvertent movement of the crane can result in severe personal injury. Disconnect, lock out, and tag the crane power

Rev. Date 10/25/04

5-1

Revised 10/25/04 disconnect switch before initiating removal procedures. 1. Disconnect, lock out, and tag the source that supplies power to the crane before removing equipment. 2. If necessary, remove the drive gearmotor assembly. 3. Loosen hex nuts (11) which secure the wheel assembly to the truck assembly. 4. Jack up truck assembly until the tread of the wheel to be removed is at least 1/4 above the rail head. 5. Remove bolts (9), hex nuts (11), and lockwashers (10) which secure the wheel assembly to the truck assembly. 6. Roll the wheel assembly clear of the truck. It is suggested at this stage that the whole assembly be moved to a suitable indoor working area for further dismantling. 7. Remove bearing retainers (3 and 14) from the bearings. Each bearing retainer is a clip t onto the bearing, and the use of force should not be necessary. 8. Remove bearings (2) from shaft (1, 12, or 16)) as necessary. 9. Mount the wheel and shaft assembly in a press such that the shoulder on the shaft is on the underside of the wheel assembly, thus permitting the shaft to be pressed out of the wheel bore. The press used for this operation should be at least, 50 - 100 ton capacity. 10. Clean up shaft and/or wheel bore as necessary, removing nicks, burrs, gall marks, etc. 11. If a number of wheels and shafts are to be replaced, it is recommended that the shaft diameters and wheel bores be measured and recorded so that a interference t of between 0.002 - 0.004 inch can be maintained. 12. If grease tting (8) is damaged, remove it from the bearing retainer. Install a new grease tting.

Installation
Use the following procedure to install the wheel assembly to the truck assembly.

! WARNING DANGER
Inadvertent movement of the crane can result in severe personal injury. Disconnect, lock out, and tag the crane power disconnect switch before initiating installation procedures. 1. Disconnect, lock out, and tag the source that supplies power to the crane before installing equipment. 2. Apply graphite grease to the axle and the wheel bore prior to assembly. 3. Position the wheel on a press. Install the axle into the wheel such that the shoulder on the axle shaft will seat up against the top side of the wheel when the shaft has been installed. It is recommended to cold (nitrogen) shrink the axle for assembly to the wheel. Heat applied to the wheel can damage the heat treat process for wheel tread hardness. 4. Heat the bearings prior to installation, as described in Section 3 of this manual. 5. Pack the bearing with grease before replacing bearing housings. Refer to Section 3, for the proper type of lubricant to be used in the bearings. 6. Assemble bearings (2) to axles (1, 12, or 13). Fully seat the inner race of the bearings against the shoulder on the axle shaft. 7. Heat bearing retainers (3 and 14) to a maximum of 350F. While still hot, install the bearing retainers onto the axle and bearing assembly. Fully seat the bearing retainers onto the outer race of each bearing. 8. Roll the wheel assembly into place under the truck assembly. 9. Install new bolts (9), lockwashers (10), and hex nuts (11). Securely tighten the bolts as described under the topic, Bolt Torques, in Section 3 of this manual. 10. Jack the crane off the blocking, remove the blocking, and lower the crane onto the runway head

5-2

GANTRY DRIVE SYSTEM

Morris Material Handling

Figure 5-1 Wheel Assembly - Idler C-0982 and Driver B-3648

EQUALIZER, AND TRUCK PINS AND BUSHINGS (16 WHEEL CRANES) General
Usually, if the truck bushings and pins are worn, then the equalizer bushings and pins will be in a similar condition. Therefore, it is strongly recommended that the equalizer and trucks be removed as a complete assembly and taken to a suitable working area. (16 Wheel Cranes) In order that the crane may be properly supported, Morris Material Handling jack stands should be used. These not only provide proper support for the crane, but when used with the proper jacks (two 150 ton) will simplify the removal of the truck assembly. Prior to performing the following procedure, remove the gantry gearmotor and motor support. Move the trolley to the end of the girder opposite that which is being repaired.

Removal - (16 Wheel Cranes Only)

Use the following procedure to remove the equalizer and trucks assembly from the crane leg:

! WARNING DANGER
Inadvertent movement of the crane can result in severe personal injury. Disconnect, lock out, and tag the crane power disconnect switch before initiating removal procedures. 1. Disconnect, lock out, and tag the source that supplies power to the crane before removing equipment. 2. Place jack stands and jacks in position under crane leg. 3. Remove keeper plates at equalizer pin.
5-3

Revised 10/25/04 4. Jack up crane, to take load off equalizer pin. Using feeler gauge, determine if clearance is present, and drive out pin. Secure the keeper plates using the capscrews and lockwashers provided. 3. Move the assembled equalizer and truck assembly into position beneath the crane leg. 4. Install the equalizer to the crane leg. Install the keeper plate and secure it using the capscrews and lockwashers provided. 5. Jack the crane off the jack stands, remove the jack stands, and lower the crane onto the runway rail.

! WARNING DANGER
The equalizer assembly must be stabilized before the following procedure is carried out. Temporary outriggers may be welded onto the equalizer to aid in stabilizing it while it is removed from the crane leg. Failure to stabilize the equalizer will result in the assembly falling to one side when it is separated from the crane leg. A falling assembly can result in severe personal injury or death. 5. Move equalizer out from under leg, this should be free enough to be pushed by hand, however the unit is top heavy and great care must be taken to ensure that it does not tip over. If required, outriggers can be temporarily welded on, to provide support. 6. Remove truck pins, examine pins and bushings for wear, particularly if the pin has worn through the bushing and into the weldment. Oversize bushings should be ordered so that if this condition arises, the weldment can be line bored for a concentric t on the bushing. 7. In general the bore in the leg ends for the equalizer pins do not see any wear, but they should be checked for concentricity and size before replacing and pinning equalizer assembly. If they appear worn, Morris Material Handling should be contacted for the appropriate repair procedures.

WHEEL ALIGNMENT
Align the gantry wheels as described below. Use this procedure after the wheels, the end trucks, or the equalizer have been repaired or replace. This procedure should also be used to check the alignment of the gantry wheels on a periodic basis.

Equipment Required - (16 Wheel Cranes)

The following are tools which are required to perform the alignment of the gantry wheel. This list does not try to list every tool which will be required, rather only those which may not normally be kept on hand in a mechanics tool chest. Theodolite (3) Targets (see Figure 5-2 on page 5-5) (1) Plumb Bob (1) 100 feet monolament line (1) magnetic base (push button dial indicator type) (1) 13-1/2 inch set up rod with groove (see Figure 52 on page 5-5) (1) 13-14 inch inside micrometer Various wrenches for bearing housing bolts

Installation.
Use the following procedure to install the equalizer and trucks onto the crane leg:

For 8 Wheel Cranes with Swivel Leg Ends

! WARNING DANGER
Inadvertent movement of the crane can result in severe personal injury. Disconnect, lock out, and tag the crane power disconnect switch before initiating installation procedures. 1. Disconnect, lock out, and tag the source that supplies power to the crane before installing equipment. 2. Assemble the truck assemblies to the equalizer assembly. Install the truck pins and keeper plates.

Assure with a straight edge that the wheels in each end truck are aligned/parallel with each other. Corner to corner measurements are not required.

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GANTRY DRIVE SYSTEM

Morris Material Handling

Analysis of Reading - (16 Wheel Cranes)

U s e t h e fo l l ow i n g p a ra gra p h s t o a n a l y ze t h e measurements taken in the preceding procedure. Review the readings taken across all four wheels at each cor ner. Deter mine if there is a patter n of misalignment (are all wheels out of alignment approximately the same amount and directions)? If they are, the problem could be in the leg end pin or bore. If so, refer this condition to Morris Material Handling Service Department. Wheel Review the readings of each individual wheel. If any individual wheel is misaligned in excess of 0.035, recheck the wheel to verify the readings. Should your second readings indicate similar misalignment, refer to the topic, Shimming Wheels, following.

SHIMMING WHEELS General

Wheels can be shimmed into alignment to correct tracking problems, however, there are two types of wheeling housings and each must be addressed separately as outline in the following topics.

Indicate Directions Indicate Which Trucks Are Drive Trucks Line of Sight

NOTICE
Consult Morris Material Handling Service Department before shimming drive wheels.

Wheels with capsule type housings (used until 1987)

Use the following procedure to shim wheel assemblies which utilize the capsule type bearing housings (see Figure 5-3). 1. Calculate the shim thickness required using the following formula: (Misalignment x 11.75) 24 Rounded up to the nearest 0.010 inch = Shim Thickness 2. Jack up the crane leg until the wheel in question clears the rail. 3. Unbolt the wheel bearing housing and roll the wheel forward to expose the bored bearing seat. 4. Add the calculated thickness shim to appropriate location as shown in Figure 5-3.
OCM145-F

the

5. Replace the wheel assembly, bolt the bearing housings, recheck the wheel alignment.

Figure 5-2 Measurement Record Form

5-5

Revised 10/25/04 MAXIMUM ALLOWABLE SHIM THICKNESS. Idler wheels may be shimmed as described above. Consult the Morr is Mater ial Handling Ser vice Department before shimming drive wheels.

Figure 5-3 Shimming Locations, Capsule Bearing Housing

Wheels with MCB type housings (used after 1987)

Use the following procedure to shim wheel assemblies which utilize the MCB type bearing housings (see Figure 5-4). 1. Calculate the shim thickness required using the following formula: (Misalignment x 12.25) 24 Rounded up to the nearest 0.010 inch = Shim Thickness 2. Jack up the crane leg until the wheel in question clears the rail. 3. Unbolt the wheel bearing housing and roll the wheel forward to expose the bored bearing seat. 4. Add the calculated thickness shim to appropriate location as shown in Figure 5-4. the

Figure 5-4 Shimming Locations, MCB Bearing Housing

Traverse Reducer Manual (Brook Hansen) follows.

5. Replace the wheel assembly, bolt the bearing housings, recheck the wheel alignment.

5-6

GANTRY DRIVE SYSTEM

Section 6 TROLLEY DRIVE SYSTEM

Trolley Drive Reducer. See Section 5 (Brook Hansen) Trolley Drive Motor. See Section 8, Bulletin ED-11-4. Trolley Drive Brake. See Section 9, Bulletin ED-12-12.

Rev. Date 10/25/04

6-1

Revised 10/25/04

6-2

TROLLEY DRIVE SYSTEM

Section 7 HOIST SYSTEMS

GENERAL
This section describes the components of the hoist systems, and includes removal, disassembly, cleaning and inspection, repair, assembly, and installation instructions of the major hoist components. Lubrication, and preventive maintenance of these components is covered in Section 3. First well cover the main hoist unit, followed by the maintenance hoist unit. At the end of this section is information on the grapple system. vendor supplied information for a more detailed description of this motor. Removal. Use the following procedure as a guideline when removing the drive motor from its mounting:

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while r e p a i rs a r e b e i n g p e r fo r m e d . B e fo r e beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed.

MAIN HOIST UNIT Description

The main hoist drive system uses a gear case, an electric motor, a motor brake, and a drum assembly. For cranes of higher capacity and/or higher speeds, the hoist system may be provided with two gear cases, two drive motors, and two brakes driving a single drum. The torque developed by the motor is transmitted to the drum assembly through the speed reduction gear case. The gear case reduces the motor speed while increasing the motor torque. This reduced speed, and increased torque is then transmitted to the drum assembly, thus causing the drum to rotate.

! DANGER
A safety harness must be worn at all times while working on trolley machinery. Injury or death of personnel will result if this precaution is not observed. 1. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 2. If necessary, remove the motor brake as described in ED Bulletin 12 (Section 9). 3. Disconnect the motor electrical leads at the motor junction box. Tag the leads to aid in proper connection during motor installation. 4. Disconnect the drive coupling, or couplings, which connect the motor shaft extensions to the associated gear case, or shafting. Remove motor blower assembly - if Required. 5. Remove any electrical conduit, and/or junction boxes which may interfere with the removal of the

Drive Motor
General. The following paragraphs describe how to remove, and install the drive motor. Lubrication, preventive maintenance, and repair of the drive motor is covered in Bulletin ED-11-4 for AC Squirrel Cage motors (found in Section 8- MOTORS). Refer to this section whenever servicing the motor itself. Description. The motor used on this drive system is a AC Squirrel Cage motor. Refer to Bulletin ED-11-4 and

Rev. Date 10/25/04

7-1

Revised 10/25/04 drive motor. Disconnect encoder coupling (If applicable). 6. Support the drive motor using a crane or maintenance hoist, and remove the drive motor mounting hardware. 7. Remove the drive motor from its mounting, and move it to a suitable work area before performing any further motor maintenance. Repair. The lubrication, preventive maintenance, and repair of the drive motor is covered in ED Bulletin 11-4 (Section 8). Refer to Section 8 whenever servicing the motor. Installation. Use the following procedure to install a new or repaired drive motor: 5. If necessary, install couplings which secure the motor shaft extensions to adjacent driven shafts. Install and securely tighten the coupling attaching hardware. 6. Install all electrical conduits and/or junction boxes which had been removed to permit motor removal. 7. Connect the motor to the motor control system using the tags installed during the removal procedure. 8. Connect any other wires, brackets, conduits, etc. which had been removed to permit removal of the drive motor. 9. Apply power to the crane and test the operation of the drive motor as follows: A. Operate the drive motor controller, and determine if the motor is rotating in the proper direction. B. If the motor is not rotating in the proper direction, disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. Interchange any two of the motor line leads at the motor terminal box. C. Apply power to the crane. Test the operation of the drive motor again to verify that the direction of rotation is correct. D. Secure all electrical connections in accordance with local, state, and federal safety laws. E. Install all covers and guards which had been removed to perform the motor rotation test. 10. Make a nal check to verify that connections are tight, and that all mounting hardware is secure.

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while r e p a i rs a r e b e i n g p e r fo r m e d . B e fo r e beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed.

! DANGER
A safety harness must be worn at all times while working on trolley machinery. Injury or death of personnel will result if this precaution is not observed. 1. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 2. Set the drive motor into its mounting using a crane or hoist. 3. Align the motor shaft with the adjacent gear case shaft, or line shaft, such that the shafts are parallel to each other, and such that the shaft ends are square. Whenever a motor is removed from its mounting, grind off the shear bars located along the motor mounting feet, and install new shear bars only after the motor is aligned as stated above. 4. Secure the motor to its mounting using the hardware provided. Securely tighten the mounting hardware.

Motor Brake
Description. The motor brake used in conjunction with the drive motor on this drive system is a spring-set, magnetically-releases electric shoe type brake. No modulation of the braking force is possible - - the brake is either fully applied, or it is fully released. Refer to Bulletin ED-12-12 (in Section 9) for a more complete description of this brake. Removal, Repair, And Installation . T h e r e m o va l , repair, adjustment, and installation of this brake is also covered in Bulletin ED-12-12 (in Section 9).

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HOIST SYSTEMS

Morris Material Handling

Drive Reduction Gearcase

General. The following paragraphs describe the disassembly, cleaning, inspection, repair and assembly of the hoist drive gear case. Complete removal and installation of the gear case is not necessary during normal overhaul procedures. However, procedures for the removal and installation of the gear case (as a unit) are provided for those who wish to remove and install a complete gear case. Description. This drive gear case is a three center-two reduction gear box designed for use on hoist drive systems. Helical gearing is provided on the rst reductions, with spur gearing being provided on the nal reduction. Spherical roller bearings are provided throughout the gear case eliminating the need to shim bearings. Each bearing is suspended in a bearing retainer which is held in the gear case by three or six capscrews. A single piece oil seal is provided at the drum shaft location when the gear case is shipped from the factory. If the drum shaft oil seal must be replaced, the split oil seal must be installed as described under the topic, Seal Replacement, Drum Shaft. Removal. The following procedure is provided for informational purposes only, under normal overhaul conditions the gear case need not be removed as a complete assembly. Refer to the disassembly procedure if a general gear case overhaul is in order. Use the following procedure to remove the gear case as a complete unit: 1. Unreeve the grapple, and remove the wire rope from the drum assembly as described under the topic, REEVING.

death of personnel will result if this precaution is not observed. 2. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 3. If necessary, remove the geared limit switch assembly as discussed in the limit switch repair section of this manual. 4. Remove the capscrews which secure the drum pedestal bearing to the pedestal base. 5. Remove the brake wheel, and brake assembly as described in Section 9, ED-Bulletin 67. 6. Remove the hex nuts, lockwashers, and bolts which secure the motor drive coupling halves together, and separate the coupling halves. 7. Remove the gear case drain plug, and drain the gear oil into a suitable container. 8. Remove the hex nuts, lockwashers, and bolts which secure the gear case cover, and remove the gear case cover. It may be necessary to rap the gear case seam with a lead mallet to break the seal between the gear case cover and the gear case base. 9. Raise the drum an amount sufcient enough to permit the bearings to be removed from the ends of the drum shaft. 10. Remove the drum pedestal bearing, and bearing retainer. 11. Remove the bearing, and the bearing retainer from the drum gear end of the drum shaft. 12. Remove the drum from its mounting by lifting straight up. Lower the drum to the ground and support it on blocking. 13. Remove the capscrews which secure the gear case to its base, or grind off welds. 14. Lift the gear case from its base, and lower it to the oor. 15. Proceed with the disassembly of the gear case as described under the topic, Disassembly. Installation. Use the following procedure to install a new or rebuilt gear case:

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while r e p a i rs a r e b e i n g p e r fo r m e d . B e fo r e beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed.

! DANGER
A safety harness must be worn at all times while working on trolley machinery. Injury or

NOTICE
The gear case cover must be removed from the gear case to allow for installation of the drum assembly.

7-3

Revised 10/25/04 Figure 7-1 Hoist Drive Gear Case, Exploded View (Typical Only)

7-4

HOIST SYSTEMS

Morris Material Handling 13. If necessary, install the geared limit switch as described in the limit switch repair section of this manual. 14. Apply power to the crane, and test the operation of the hoist unit. Make adjustments or corrections as necessary. Disassembly. U s e t h e fo l l o w i n g p r o c e d u r e t o disassemble the gear case (see Figure 7-1 on page 74): If the gear case has been removed from the trolley, disregard the rst few steps which apply to the draining of the oil and the removal of the gear case cover. 1. Unreeve the grapple, and remove the wire rope from the drum assembly as described under the REEVING topic in this section. 2. Release the motor brake as described in Section 9.

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while r e p a i rs a r e b e i n g p e r fo r m e d . B e fo r e beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed.

! DANGER
A safety harness must be worn at all times while working on trolley machinery. Injury or death of personnel will result if this precaution is not observed. 1. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 2. Raise the assembled gear case into position on the trolley frame. 3. Secure the gear case to its mounting base using the c a p s c r ew s p r ov i d e d . S e c u r e l y t i g h t e n t h e capscrews. 4. Lower the drum assembly into position over the gear case and drum bearing pedestal. 5. Assemble the drum pedestal retainer, and bearing to the pedestal end of the drum shaft. 6. Assemble the bearing and bearing retainer to the drum gear end of the drum shaft (see Figure 7-1 on page 7-4). 7. Lower the drum assembly onto the drum bearing pedestal, and onto the gear case base. 8. Position the drum pedestal bearing on its mounting base. Install the mounting bolts, lockwashers, and hex nuts to secure the bearing to the bearing pedestal. 9. Seal and tighten bolts in accordance with Morris/ P&H Technical Advisory. 10. Install the brake as described in Section 9. 11. Align the motor pinion shaft with the motor shaft, and install the motor coupling. Install the coupling bolts, hex nuts, and lockwashers. Securely and evenly tighten the hex nuts. 12. Install the drain plug. Fill the gear case to the proper oil level as described in Section 3.

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while r e p a i rs a r e b e i n g p e r fo r m e d . B e fo r e beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed.

! DANGER
A safety harness must be worn at all times while working on trolley machinery. Injury or death of personnel will result if this precaution is not observed. 3. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 4. If necessary, disconnect and remove the geared limit switch from the drum pedestal bearing. 5. Remove drain plug (33), and drain the gear oil into a suitable container. 6. Remove hex nuts (04), lockwashers (03), and bolts (02) which secure gear case cover (01). Lift the gear case cover from the gear case. It may be necessary to rap the gear case seam with a lead mallet to break the seal between the gear case cover and the gear case base.

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Revised 10/25/04 7. Remove the coupling bolts which secure the halves of the motor drive coupling together, and separate the halves of the motor drive coupling. 8. Remove capscrew (22) and lockwashers (23) which secure bearing retainers (25). 9. Lift the motor pinion shaft (28) from gear case base (01) as a complete assembly. Disassemble the motor pinion shaft as follows: The drum shaft oil seal may be replaced as described under the topic, Seal Replacement, Drum Shaft. 12. Remove capscrews (37), and lockwashers (38) which secure bearing retainer (39) to gear case base (01). 13. Jack up the drum slightly (3/8 to 1/2 inch) to relieve the pressure on the bearing retainer. Block the drum in this position. 14. Remove bearing retainer (39), and bearing (40) from the end of the drum shaft. 15. Remove O-rings (41) from the groove in bearing retainer (39). 16. Remove oil seal (36) from the bore in bearing retainer (39). Cleaning. Clean all gear case parts in solvent. The use of a stiff bristle brush will facilitate the removal of accumulated dirt and sediments on the gear case components.

NOTICE
The motor pinion, and motor pinion shaft used on this gear case are integral parts and can not be separated. If the shaft or the pinion is damaged beyond repair, the pinion and shaft must be replaced as a unit. A. Remove bearing retainers (25) from the pinion shaft (28). B. Remove bearings (27), and oil seals (24) from bearing retainers (25). C. Remove O-rings (26) from the groove in bearing retainers (25). 10. Remove capscrews (14) and lockwashers (15) which secure bearing retainers (16). 11. Lift the intermediate pinion shaft (19) from gear c a s e b a s e ( 0 1 ) a s a c o m p l e t e a s s e m bl y. Disassemble the intermediate shaft using the following procedure: A. Remove bearing retainers (16), and bearings (18) from intermediate pinion shaft (19). B. Remove O-rings (17) from the grooves in bearing retainers (16). C. If motor gear (21) is damaged beyond further use, remove it from intermediate pinion shaft (19) using a press. Suppor t the motor gear on blocking and apply pressure to the end of the intermediate pinion shaft. Do not lose key (20) when the motor gear clears the shoulder of the pinion shaft.

! DANGER
Wear eye protections (goggles or safety glasses) when using compressed air. Personnel injury will result if this precaution is not observed. Dry parts using low pressure ltered compressed air (15 psi maximum). Inspection. A l l d i s a s s e m b l e d p a r t s s h o u l d b e inspected to determine their tness for continued use. Pay particular attention to the following: 1. Inspect all gears for wear, cracked, or broken teeth. Gear inspection information located in Section 3. 2. Inspect all bushings for wear, scoring or galling.

! CAUTION DANGER
A bearing that appears loose or rotates roughly must be replaced. Failure to observe this precaution will result in bearing and/or gear case component damage. 3. Inspect all bearings for play, distorted races, and roller or ball wear or damage. Inspect bearings for freedom of rotation. 4. Inspect for ridges caused by wear on shafts. If ridges caused by wear are apparent on shafts, replace the shaft. Inspect all surfaces on which oil

NOTICE
If the drum gear, or drum is damaged, the drum and drum gear assembly must be returned to the Morris Material Handling for repairs. The drum gear is pressed onto the drum shaft, and any attempt to remove the drum gear in the eld may cause serious damage to the drum gear and/or the drum shaft. The bearing and bearing retainer on the drum gear end of the shaft may be removed as described in the following step.
7-6

HOIST SYSTEMS

Morris Material Handling seal lips seat. These surfaces must be very smooth to prevent wearing away the seal lip. Repair. Actual repairs are limited to the removal of small burrs and other minor surface imperfections from gears and shafts. Use a ne stone or emery cloth for this work. Do not use steel wool. 1. Worn or damaged parts must be replaced. Refer to your Parts Manual for information. 2. Inspect all remaining parts for evidence of damage. Replace any part which is in questionable condition. The cost of the part is often minor in comparison with the cost of redoing the job. 3. Smooth out all nicks, burrs, or galled spots on shafts, bores, pins, or bushings. 4. Examine all gear teeth carefully, and remove nicks or burrs. 5. Polish the edges of all shaft shoulders to remove small nicks which may have been caused during handling. 6. Replace all gaskets, oil seals, and O-rings any time the hoist is disassembled for inspection or repair. Assembly. Use the following procedure to assemble the hoist gear case (see Figure 7-1 on page 7-4): 1. Before assembling the gear case, lubricate all bearings, O-rings, and oil seals with gear oil, so that the bearings, O-rings and oil seals have adequate lubrication upon gear case start-up. 2. Assemble new O-rings (41) to bearing retainer (39). 3. Assemble bearing retainer (39) to the end of the drum shaft, and install bearing (40) into bearing retainer (39). 4. Install a new oil seal (36) into bearing retainer (39). 5. Raise the drum off its blocking, and remove the blocking. Lower the drum assembly onto the gear case base. 6. Align the holes in the bearing retainer with the holes in the gear case base. 7. Secure the bearing retainer using capscrews (37), and lockwashers (38). Securely and evenly tighten the capscrews. 8. Install a new drum shaft split oil seal as described under the topic, Seal Replacement, Drum Shaft. 9. Assemble the intermediate pinion shaft using the following procedure: A. Assemble new O-rings (17) to bearing retainers (16). B. Press motor gear (21) onto intermediate pinion shaft (19) until the gear has seated against the shoulder on the intermediate pinion shaft. C. Assemble bearings (18) to intermediate pinion shaft (19). the ends of

D. Assemble bearing retainers (16) with new Orings (17) to the ends of the intermediate pinion shaft. 10. Install the assembled intermediate pinion shaft into the gear case base. Make sure that the drum gear, and the intermediate pinion properly mesh. 11. Secure bearing retainers (16) to gear case base (01) using capscrews (14), and lockwashers (15). Securely tighten the capscrews. 12. Use the following procedure to assemble the motor pinion shaft: A. Assemble new O-rings (26) to bearing retainers (25). B. Press new oil seals (24) into the end bores of bearing retainers (25). C. Assemble bearings (27) to the ends of motor pinion shaft (28). D. Assemble bearing retainers (25) with the new oil seals and new O-rings, onto motor pinion shaft (28). 13. Lower the assembled motor pinion shaft into the gear case base. Make sure that the motor gear and the motor pinion properly mesh. 14. Secure bearing retainers (25) to gear case base (01) using capscrews (22), and lockwashers (23). Securely and evenly tighten the capscrews. 15. Check each shaft assembly to verify that it is properly seated in the gear case, and that no binding occurs. 16. Seal and tighten bolts in accordance with Morris/ P&H Technical Advisory. 17. Attach the motor drive coupling to the motor pinion shaft. Secure the coupling halves using the bolts, lockwashers, and nuts provided. 18. Apply power to the cranes control system. 19. Return the brake to normal operation. 20. Reeve the hoist drum and grapple as described under the topic, REEVING.

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Revised 10/25/04

Seal Replacement, Drum Shaft

Use the following procedure to replace the drum shaft oil seal:

1. Pry the oil seal from its groove in the gear case. 2. Work a new split seal into the oil seal groove. Make sure that the split on the oil seal is facing up.

Figure 7-2 Drum Pedestal Bearing, Exploded View

Pedestal Bearing NOTICE

This pedestal bearing is used in conjunction with single gear case drives only, if your crane utilizes a dual gear case drive, disregard the following topic, Pedestal Bearing.

Removal. Use the following procedure to replace the drum shaft pedestal bearing. Refer to Figure 7-2 on page 7-8, and disassemble the drum pedestal bearing: 1. Remove the geared limit switch from its mounting as described under the topic, Geared Limit Switch, in Section 11. Remove the geared limit switch drive from the end of the drum shaft. 2. Remove hex nuts (08), lockwashers (09), and bolts (07) which secure bearing housing (01) to the bearing pedestal.

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HOIST SYSTEMS

Morris Material Handling 3. Attach a lifting device to the drum assembly, and raise the drum an amount sufcient enough to permit the removal of the pedestal bearing from the pedestal. 4. Pull the pedestal bearing assembly from the drum shaft. 5. Remove retaining rings (05) which secure bearing retainers (02 and 03), and remove the bearing retainers. 6. Pull bearing (04) from bearing housing (01). 7. If grease tting (06) is damaged, remove it from bearing housing (01) and install a new grease tting. Assembly. Refer to Figure 7-2 on page 7-8, and assemble the drum pedestal bearing as follows: 1. Install bearing (04) into bearing housing (01). 2. Install bearing retainers (02 and 03) against bearing (04). Secure the bearing retainer with retaining rings (05). 3. Slide the bearing assembly onto the drum shaft. Make sure that the large bearing retainer goes onto the drum shaft rst. 4. Align the bearing housing with the holes in the bearing pedestal, and lower the drum assembly onto the bearing pedestal. 5. Install bolts (07), hex nuts (08), and lockwashers (09) to secure the bearing housing to the bearing pedestal. 6. Install the geared limit switch drive shaft into the end of the drum shaft. 7. Install the geared limit switch as described under the topic, Geared Limit Switch, Section 11. removed in order to replace or repair a damaged upper equalizer sheave. 1. Move the trolley to the loading platform, and set the trolley parking brake. 2. Fully open the grapple and lower it to the ground. Operate the hoist control lever in the lower direction to introduce slack into the wire ropes.

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while r e p a i rs a r e b e i n g p e r fo r m e d . B e fo r e beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed.

! DANGER
A safety harness must be worn at all times while working on trolley machinery. Injury or death of personnel will result if this precaution is not observed. 3. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 4. Support the hoist wire rope which passes around the sheave to be repaired, by anchoring it to the trolley leg or another xed structure. Apply tension to the wire rope anchor such as to relieve the tension applied on the equalizer sheave. 5. Remove capscrews (03), and lockwashers (04) which secure keeper plate (15), and remove the keeper plate.

Upper Equalizer Sheaves

! DANGER
General. The following procedures describe the removal and installation of the upper equalizer sheave assemblies. General repair information is also included. Removal. Use the following procedure to remove an upper equalizer sheave from its mounting in the upper trolley leg (see Figure 7-3 on page 7-10): Suppor t the sheave before removing the sheave pin. Failure to support the sheave before removing the sheave pin will result in the sheave falling, possibly causing the injury or death of personnel.

NOTICE
The following procedure is written on the basis that the hoist wire ropes do not have to be

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Revised 10/25/04 Figure 7-3 Upper Equalizer Sheave

6. Support sheave (01), and carefully withdraw sheave pin (02), from saddle (05). Lower the sheave from the saddle and remove the wire rope from the sheave.

! DANGER
Support the saddle before removing the saddle pin. Failure to support the saddle before removing the saddle pin will result in the saddle falling, causing the injury or death of personnel. 9. Support saddle (05), and carefully withdraw saddle pin (06), releasing saddle (05) from the trolley leg. Lower the saddle from the trolley leg. 10. As the saddle pin is removed from the trolley leg mounting, catch each wear plate (10) as it drops off the saddle pin. If bushings (11) are damaged, remove them from saddle (05).

NOTICE
When removing the sheave from the saddle, make sure that the spacers and the bearing do not fall free of the sheave. 7. Remove spacers (13), and bearings (14) from sheave (01). 8. Remove hex nuts (16), capscrews (07), and lockwashers (08) which secure keeper plate (09), and remove the keeper plate.

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HOIST SYSTEMS

Morris Material Handling 11. If lube ttings (12) are damaged, remove them, and install new lube ttings. Cleaning And Repair. Thoroughly clean each part of the equalizer assembly using solvent. Tighten the capscrews as recommended under the topic, Bolt Torques, in Section 3. 12. Release the support which is securing the wire rope to the trolley frame.

! DANGER
Wear eye protections (goggles or safety glasses) when using compressed air. Personnel injury will result if this precaution is not observed. Dry parts using low pressure ltered compressed air (15 psi maximum). Inspect each piece for wear, cracks, or other damage. Replace those parts which are worn or damaged beyond further use. Installation. Use the following procedure to install the equalizer sheave assembly (see Figure 7-3 on page 710): 1. If necessary, press new bushings (11) into saddle (05). Make sure that the bushings are fully seated into the saddle bores. 2. Raise the saddle into position on the trolley leg. 3. Insert saddle pin (06) into the trolley leg just enough to install a wear plate (10). Install a wear plate between the trolley leg frame and the saddle. 4. Push the saddle pin through the wear plate, and through the saddle just until the point where the remaining wear plate can be installed. 5. Install the wear plate between the saddle and the trolley leg frame, and push the saddle pin through the trolley leg frame. 6. Center the saddle pin in its mounting, and install keeper plates (09). Secure the keeper plates using capscrews (07), lockwashers (08), and hex nuts (16). Tighten the hex nuts as recommended under the topic, Bolt Torques, in Section 3. 7. Pack bearings (14) with bearing lubricant of the type specied in Section 3, and install the bearings into sheave (01). 8. Install seals (13) against the faces of bearings (14). 9. Raise the sheave and bearing assembly into position. Loop the wire rope assembly around the sheave. Install the sheave into saddle (05) 10. Install sheave pin (02) securing sheave (01) to saddle (05). 11. Install keeper plate (15), and secure it to saddle (05) using capscrews (03), and lockwashers (04).

Lifting Beam Assembly

General. The following procedures describe the removal and installation of the lifting beam assembly. General repair information is also included. Removal. Use the following procedure to remove the lifting beam assembly from the crane (see Figure 7-4 on page 7-12):

NOTICE
The following procedure is written on the basis that the lifting beam is going to be completely removed from the crane hoist system. If complete removal of the lifting beam is not required, refer to the applicable portions of this procedure to accomplish the needed repairs. 1. Lower the grapple to the ground with the tines in the fully open position, or place the grapple in the maintenance stand. 2. Disconnect the grapple power cables which are attached between the grapple and the lifting beam.

! DANGER
Adequately support the grapple such that the grapple will remain standing when the lifting beam and grapple are separated. Failure to observe this precaution will lead to the injury or death of personnel. 3. Adequately support the grapple such that the grapple will remain standing when the lifting beam is separated from the grapple. 4. Remove capscrews, lockwashers, and keeper plate, which secures grapple pin. Remove the grapple pin, and separate the lifting beam and the grapple. 5. Lower the lifting beam onto a suitable support or maintenance stand. 6. Operate the hoist lower function until the strain has been removed from the hoist wire ropes. 7. Unreeve the hoist wire ropes as described under the topic, Unreeving.

7-11

Morris Material Handling 8. Use the following procedure to disassemble the lifting beam sheave assemblies: Figure 7-4 Lifting Beam Assembly

A. Remove capscrews, and lockwashers which secure rope guard. Lift the rope guard from the lifting beam sheave frame. B. Remove capscrews, lockwashers, and keeper plate which secures sheave pin. C. Support sheave, and withdraw sheave pin. Remove the sheave assembly from the lifting beam sheave frame.

seals and spacers are not lost. the spacer/seals will fall free when the sheave is removed from the lifting beam sheave frame. There are two spacer/seals for each sheave. D. Remove bearing from sheave using a press. E. If lube tting is damaged, remove it from sheave pin, and install a new lube tting. Cleaning And Repair. Thoroughly clean each part of the lifting beam assembly using solvent.

NOTICE
When the sheave is removed from the lifting beam sheave frame, make sure that the spacer/

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Morris Material Handling 6. Connect the grapple power cable, and any other cables which were disconnected to permit the separation of the grapple from the lifting beam.

! DANGER
Wear eye protections (goggles or safety glasses) when using compressed air. Personnel injury will result if this precaution is not observed. Dry parts using low pressure ltered compressed air (15 psi maximum). Inspect each piece for wear, cracks, or other damage. Replace those parts which are worn or damaged beyond further use. Installation. Use the following procedure to install the lifting beam assembly on the crane (see Figure 7-4 on page 7-12): 1. Use the following procedure to assemble the lifting beam sheave assembly. A. Pack bearings with the type of lubricant specied in Section 3, until the bearing is approximately 2/ 3 full. B. Install each bearing into sheave. C. Coat spacers/seals with a heavy grease, and afx them to the sides of each sheave and bearing assembly. D. Install the sheave, bearing, and spacer/seal into the lifting beam sheave frame.Install spacers along each side of the sheave. E. Install sheave pin to secure the sheave and bearing assembly in the lifting beam sheave frame. Repeat this procedure for each remaining sheave. F. Completely seat each sheave pin until keeper plate can be installed. G.Secure the keeper plate using capscrews, and lockwashers. Securely tighten the capscrews. H.Lubricate each set of sheaves as described in Section 3, of this manual. 2. Reeve the hoist wire ropes into the lifting beam assembly as described under the topic, Reeving, following in this section. 3. Raise the lifting beam assembly off its stand, and position it over the grapple. 4. Lower the lifting beam over the grapple, and install grapple pin. 5. Secure the grapple pin using keeper plate, capscrews, and lockwashers. Securely tighten the keeper plate capscrews.

Reeving

! DANGER
Wear leather gloves when handling wire rope. This is to prevent cutting the hands on the wire rope. Failure to observe this precaution will result in personal injury. Unreeving The Hoist Drums. U s e procedure to unreeve the hoist unit: the fo l l o w i n g

1. Lower the grapple onto the ground or suitable grapple stand. 2. Temporarily de-activate the lower limit switch, if one is used. This will allow all of the wire rope to be payed off the drum. 3. Operate the down control lever, or push button until all but one wrap of wire rope has been fed off the hoist drum. 4. Shut down the cranes control system. Make sure that the hoist brake is set.

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while r e p a i rs a r e b e i n g p e r fo r m e d . B e fo r e beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed. 5. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made.

! WARNING DANGER
Do not disconnect the wire rope dead end from the hoist drum without rst attaching a g u i d e ro p e . Fa i l u r e t o o b s e r v e t h i s precaution lead to the injury or death of personnel should the wire rope fall to the ground. 6. Attach a guide rope to the wire rope which is suspended from the drum. Make sure that this

7-13

Revised 10/25/04 guide rope is of sufcient length to reach to the ground. 7. Wrap the loose end of the guide rope around a xed object on the trolley such that the descent of the guide rope can be controlled. controlled rate, thus lowering the wire rope to the ground at a safe speed. 8. Have someone maintain tension on the loose end of the guide rope while another person disconnects the dead end of the wire rope from the hoist drum. Disconnect only one dead end at a time. 9. Gradually lower the end of the wire rope to the ground. Disconnect the guide rope from the wire rope. 10. Unreeve the grapple as necessary. 11. Repeat the above procedure for the remaining dead end assembly.

NOTICE
Wrapping the loose end of the guide rope around a support or hand rail will permit a person to maintain tension on the loose end of the rope with a minimum of effort. This allows the person to pay out the guide rope at a

Figure 7-5 Reeving Diagram

Reeving The Hoist Drums. U s e procedure to reeve this crane:

the

fo l l o w i n g

1. Reeve the grapple as necessary using Reeving Diagram 105E925 (Figure 7-5 on page 7-14) as a guide to proper wire rope locations.

2. Attach the wire rope to its dead end points using Drawing 907E139 as a guide. Refer to Dead End information at the end of this section. 3. Wrap the wire rope around the drum such that two full wraps of wire rope are held secure by the rope clamp (see Figure 7-6 on page 7-15).

7-14

HOIST SYSTEMS

Morris Material Handling 4. Install the wire rope clamp(s), and securely tighten their capscrews. 5. Re-activate the lower limit switch. 6. Check to verify that the wire rope is properly seated in the grooves of the bottom block sheaves. Figure 7-6 Attaching Rope Clamps

Wire Rope
General. The following topics cover general practices which should be observed when handling or storing wire rope. Lubrication of wire rope is covered in Section 3. Handling Wire Rope. T h e fo l l o w i n g p a r a g r a p h s explain the proper methods for handling wire rope. Unreel or uncoil wire rope as follows:

! DANGER
Wear leather gloves when handling wire rope. This is to prevent cutting the hands on the wire rope. Failure to observe this precaution will result in personal injury. 1. Wire rope must be unreeled or uncoiled correctly to prevent twisting or kinking (See Figure 7-7 on page 7-15). 2. A reel can also be mounted horizontally on a shaft for unreeling rope. If this method is used, the reel must not be allowed to revolve so rapidly that rope is thrown off. 3. If a loop is inadvertently formed in the rope as it is being unreeled, the loop must be removed immediately before it leads to kinking. Figure 7-8 on page 7-16 illustrates how a loop progresses to a permanent kink. If the loop is allowed to close up to the point shown in part 2 of the gure, the kink shown in part 3 has been formed. A kinked wire rope has been severely weakened and must not be used. 4. Use care during all phases of wire rope handling to avoid dragging a rope through dirt or around objects which could scratch, nick, crush, or induce sharp bends in the rope.

Figure 7-7 Handling Wire Rope

Storage
Spare wire rope must be stored in a coil, or on a reel, and protected against weather, possible damage, and corrosive elements in the air.

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Revised 10/25/04 Figure 7-8 Kinking of Wire Rope Any cured sealant in the areas of the parting faces must be removed prior to the installation of the cover. Apply a lm of oil to the inside diameter of the shaft seals before sliding the seals over shafts. Avoid getting excessive amounts of sealant on gear case paint surfaces. Apply Loctite Ultra Black #598 RTV (21Z587D11) sealant using a sufcient bead to enable the spreading of the sealant over the entire width of the anges on the gear case base bores via a hand or automated dispensing means Spread the bead evenly over the entire ange width of the bore. Lower the shaft assemblies onto the sealant covered bores. Apply sealant on the gear case base parting face between the bores and on each end of the base. Completely encircle each bolt hole. Again, spread the sealant over this surface. Apply the sealant over the top of each retainer spreading the bead over the entire width of the retainers. Position the cleaned cover over the top of the gear case base and carefully lower it onto the rest of the assembly. Bolt the cover to the base using the torque value found on Table: 7-1 on page 717. Follow a cross bolting pattern similar to that shown in Figure 7-9 on page 7-17 when tightening the bolts. Smooth the sealant overage as though caulking around the parting lines.

Sealing of Gear Cases Introduction

This procedure is to be used for sealing all gear cases used on non-gasketed Morris Material Handling products. All hoist and drive gear cases will be sealed per this specication. If the particular gear case being sealed does not have a retainer simply disregard implications to the retainers. 1. Surface Preparation: All surfaces to be sealed must be cleaned to obtain the most effective formed-in-placegasket (FIPG). Remove all oil, machining lubricants, burrs, etc. from the parting surfaces of the gear case cover, base and retainers. Use non-petroleum based cleaner such as Stabiline or equivalent to remove the dirt and oils from the sealing surfaces of the gear case. If resealing, remove all old sealant. 2. Sealant Application Procedure: Notes: Do not wait longer than 15 minutes to assemble sealant covered parts (after applying sealant) Apply Loctite Ultra Black #598 RTV (Morris Part #21Z587D11) sealant on the outside diameter of all shaft seals before installing the seals into the retainers or the drum shaft seal into the gear case

7-16

HOIST SYSTEMS

Morris Material Handling Table: 7-1

Figure 7-9

7-17

Revised 10/25/04

Crane Hoist Motion Gearcases I & PH Type

Crane Hoist & Traverse Motion Gearcases CI Type

Crane Traverse Motion Gearcase TH Type

Crane Traverse Motion Gearcase I & PH Type

7-18

HOIST SYSTEMS

Morris Material Handling

Crane Hoist Motion Gearcase - Bucket Trolley

MACK GRAPPLE
See Section 18 for MACK Grapple Catalog .

DEAD END ASSEMBLY INFORMATION

See following pages.

7-19

Revised 10/25/04

7-20

HOIST SYSTEMS

Section 8 DRIVE MOTORS

GENERAL
Information on the Main Hoist Motor is contained on the Toshiba Information Page following this page. Operating Instructions for Traverse Motors (P&H) can be found following this page. (Bulletin ED-11-4)

NOTICE
O p e r a t i n g I n s t r u c t i o n s fo r Tr a ve r s e GearReducers (Brook Hansen) can be found in Section 5.

NOTICE
Operating Instructions for Traverse Brakes (P&H) can be found in Section 9.

Rev. Date 10/25/04

8-1

Revised 10/25/04

8-2

DRIVE MOTORS

Section 9 BRAKES
GENERAL Information on the Hoist Brake is contained in ED-12-12 following (hardcopy only). Bulletin ED-12-12 is include in this section (hard copy only) to assist you in maintaining your Electric shoe brakes. Operating Instructions for the Trolley Drive Motor Brake follows and is listed as 8SBE100ASC1. Operating Instructions for the Gantry Drive Motor Brake follows and is listed as 13SBE330ASC1.

Rev. Date 10/25/04

9-1

Revised 10/25/04

9-2

BRAKES

Section 10
BUMPERS, SHOCK ABSORBERS AND RAIL SWEEPS

GENERAL
This section describes the removal, repair, and installation of the bumpers, shock absorbers, and rail sweeps which may be utilized on this crane.

Morris Material Handling Call 800-633-1163 For Return Authorization Number.

TROLLEY BUMPERS AND RAIL SWEEPS GANTRY BUMPERS AND RAIL SWEEPS
Each crane is equipped with four bumpers, one on each corner of the gantry. These bumpers act to absorb the shock encountered when the crane comes into contact with the crane end stops. Each trolley is equipped with bumpers (two or four depending on the bumper type). These bumpers act to absorb the shock encountered when the trolley comes into contact with the trolley end stops.

General General
These hydraulic bumpers are intended for maintenance free operation. No grease or oil ller ports are provided. Under normal operation no maintenance is required for the life of the bumper. This bumper and rail sweep assembly consists of a Hydrualic Buffer secured directly to the crane.

Repair
The bumper must be repaired or replaced should the bumper become damaged. Remove the capscrews, and lockwashers which secure the bumper to the crane member, and remove the bumper. Position a new bumper onto the crane, and secure it using the capscrews and lockwashers provided. Securely tighten the capscrews.

Inspection
Occasional inspection of the bumper is recommended. Make sure the plunger is in fully extended position. If the bumpers retaining cable appears to be loose or sagging, then the plunger is not properly extending and the bumper may require replacement.

Repair
All Buffers utilize a cartridge type of construction, and replacement cartridges are shelf stocked at our factory in most sizes. Cartridge replacement is a minimal task and involves no handling of uid, seals, coil springs, etc. All Hydraulic crane Buffers have the Shock Absorber cartridge sealed at the factory and no eld repair or maintenance can be performed on the internal cartridge parts. Cartridges can be factory repaired and restored to as new condition at a fraction of their replacement cost. All complete buffers or cartridges needing factory repair should be shipped prepaid to the following address:

Rev. Date 10/25/04

10-1

Revised 10/25/04

10-2

BUMPERS, SHOCK ABSORBERS AND RAIL SWEEPS

Section 11
LIMIT SWITCHES AND LIMITING DEVICES

GENERAL
This crane is equipped with various limit switches, and limiting devices. The purpose of these devices is to provide safe and efcient operation of the crane. A description of the function, and maintenance requirements, of each device follows.

Adjustments
Use the following procedure to adjust the geared limit switch assembly (see Figure 11-1 on page 11-3):

! WARNING DANGER
At the lower travel limit, the grapple should be at rest at the oor level, and at least two wraps of rope must be remaining on the hoist drum. If these conditions are not met, an unsafe operating condition will exist which can lead to the injury or death of personnel. 1. Lower the grapple to the desired lower limit of travel.

MAIN HOIST LIMIT SWITCHES

There are two types of Main Hoist limit switches, geared limit switches and weight limit switches. A description of the function, and maintenance requirements, of each device follows.

GEARED LIMIT SWITCH Description

The geared limit switch on this crane functions primarily as a lower limit switch. The geared limit switch is driven off the drum shaft through an eccentric pin and crank arrangement. As the switch drive shaft (D, Figure 11-2 on page 11-4) rotates, it turns the two cam gears. Cam screws (A) lock the cam wheels (B) to their respective cam gears. The snap switches are actuated when the lobes (F) on their associated cam wheels contact the switch pushers (H). There are two snap switches in the geared limit switch assembly. Each snap switch (J) has one set of normally open contacts and one set of normally closed contacts. The normally closed contacts of one of the snap switches are connected in series with the lower contactor coil; therefore, when this switch is actuated, the switch contacts open and de-energize the lower contactor coil. The normally open set of contacts can be connected to perform a plugging function or for other purposes, such as illuminating an indicator light to show that the travel limit has been reached. As an option, the second snap switch can be used as the upper limit switch. Separate adjustments are provided for each of the two snap switches.

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied while repairs are being performed. Before beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed. 2. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 3. Remove the screws which secure the limit switch cover, and remove the cover. 4. Identify the snap switch and cam mechanism used to set the lower travel limit. Loosen the appropriate cam screw (A). 5. Insert cam adjusting tool (G) into hole (C) nearest the cam wheel (B) to be adjusted, turn the cam wheel until the lower limit snap switch actuates.

Rev. Date 10/25/04

11-1

Revised 10/25/04 6. Verify the switch actuation using a ohmmeter. The normally closed contacts connect to the terminals of the snap switch. 7. Tighten the cam screw, using care not to overtighten. 8. If the second snap switch is used to set the upper travel limit, repeat the above procedure with the grapple at the desired upper limit. 9. Test the settings by lowering and raising the grapple into the travel limit a number of times under power (at slow speed). 10. Replace the limit switch cover when the limit switch settings have been completed. A. Disconnect the electrical wires from the snap switch terminals. Tap each wire as it is removed to ensure proper connection to the new snap switch. B. Remove the two screws, and washers which secure the snap switch to the mounting plate, and remove the snap switch. C. Secure the replacement snap switch to the mounting plate using the two screws, and washers. D. No readjustment is required if a snap switch is replaced. However, a test must be conducted to ensure that the switch operates properly after replacement. E. Replace the limit switch cover, and secure it using the screws provided. 5. Remove the two screws which attach the switch mounting plate to the switch housing.

Maintenance
The geared limit switch must be tested for proper operation at the start of each working shift as described in Section 3 of this manual. The portion of the geared limit switch used as a lower travel limit mechanism need only be tested once a month. No other regular periodic maintenance is required on this limit switch.

NOTICE
One of these screws also secures the adjuster tool clip. 6. Lift the mounting plate assembly from the switch housing using care to avoid stretching the electrical wires. Lay the mounting plate assembly aside. 7. Lift the cam gear/wheel assemblies off the gear plate. 8. Install the new cam gear/wheel assemblies. 9. Reinstall the switch mounting plate assembly, and secure it using the two screws provided. Make sure that the adjuster tool clip is secured by one of the two screws.

Repair
Only the snap switches and the cam gear/wheel assemblies are considered replaceable. To replace either the snap switches, or the cam gear/wheel assemblies, proceed as follows (see Figure 11-2 on page 11-4): 1. Lower the grapple to the desired lower limit of travel.

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied while repairs are being performed. Before beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed. 2. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 3. Remove the screws which secure the limit switch cover, and remove the cover. 4. If one, or both of the cam gear/wheel assemblies is to be replaces, proceed to step 5. If only a snap switch is to be replaces, proceed as follows:

NOTICE
During the installation of the mounting plate assembly, make sure that the OUTLET arrow is pointing toward the threaded outlet of the housing. 10. If the cam gear/wheel assemblies have been replaced, adjust the limit switch as described under the topic, Adjustment. 11. Install the limit switch cover using the screws provided. Make sure that the cover gasket is straight and tight.

11-2

LIMIT SWITCHES AND LIMITING DEVICES

Morris Material Handling

Figure 11-1 Geared Limit Switch

11-3

Revised 10/25/04

WEIGHT OPERATED LIMIT SWITCH, TYPE HB Description

This weight-operated switch is the nal upper limit switch, and will be actuated only if the grapple contacts the hanging weight, and raises it to the point where the limit switch counterweight opens the limit switch. The HB limit switch has a normally-open contact which is held in the closed position by a hanging weight. When the grapple is raised past the limit set by the geared limit switch, the grapple will raise the hanging weight, thus removing the tension on the tiller rope. With the tension thus removed, the limit switch contacts will snap open, interrupting power to the crane, thus applying the hoist brake. The grapple may be lowered away from the limit using the down hoist control push button or controller. The upper limit switch operates as follows: 1. The normally open contacts of the switch are connected in series with the hoist directional contactor. 2. The contacts are actuated by cams mounted on the shaft that carries the counterweighted sheave wheel. In the free state, the counterweight tends to rotate the sheave wheel counterclockwise (looking at the wheel). This rotation opens the normally open contacts. 3. The hanging weight assembly, attached to the sheave wheel through a tiller rope, has sufcient w e i g h t t o o ve r c o m e t h e s h e a ve w h e e l counterweight while hanging free, thus closing the contacts. 4. As the grapple approaches its preset upper travel limit, it will contact the hanging weight. Continued upward travel of the grapple will lift the hanging weight. As the weight is lifted, the counterweight on the sheave wheel rotates the sheave wheel counterclockwise. 5. The switch contact arm shaft rotates with the sheave wheel. The contact arm rotates away from the stationary contacts, breaking the circuit to the directional contactor coils. Power is then removed from the motor primary windings and the holding brake coil, causing the holding brake to set, thereby stopping the upward movement of the grapple.

Figure 11-2 Geared Limit Switch, Exploded View

Adjustment
The actuation point of a weight-operated limit switch is set during initial crane installation. No attempt should be made to alter the actuation point in the eld. The initial

11-4

LIMIT SWITCHES AND LIMITING DEVICES

Morris Material Handling setting allows for normal upward drift of the grapple past the switch actuation point. H.Place the rear switch box cover back onto the limit switch assembly. The shaft holding the insulating plate and contacts must be inserted into the bushing on the cover. Secure the cover in place. I. Unlock, and close the main disconnect switch and test the limit switch by lowering and raising the grapple several times to ensure the limit switch is working properly. 2. Replace tiller rope as follows: A. Raise or lower the sheave wheel counterweight to a safe position where tension is not applied to the tiller rope. B. Measure the wire rope carefully before removing it. C. Rig the replacement rope to obtain an effective length as close as possible to that of the old rope. D. Lift or lower the counterweight to its operating position.

Maintenance
The limit switch should be tested periodically, as described in Section 3. In addition, a visual inspection should be made periodically, to determine the condition of the switch contacts. The tiller rope which holds the hanging weight suspended should also be periodically inspected for wear, damage, and binding. Make any necessary repairs as instructed below.

Repair
Use the following instructions to repair the weight operated limit switch: 1. Replace burned or worn switch contacts as follows: A. Slowly raise the grapple to its upper limit, thereby tripping the upper limit switch.

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied while repairs are being performed. Before beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed. B. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. C. Remove the rear cover on the limit switch box (see Figure 11-3 on page 11-6). D. Using an offset screwdriver, remove the four screws holding the carbon contact holder assembly to the insulating plate on the rotating shaft. E. Push the carbon contact from the holder and insert a new carbon in its place. Discard the used contact. F. Using #000 sandpaper, polish the face of both contact plugs located in the switch box. After sanding, the face of the plugs should be clean and essentially perpendicular to the sides of the plug. G.Replace the contact holder assembly on the insulating plate using the four screws removed previously.

! CAUTION DANGER
Do not over lubricate the pivot points of the switch lever assembly. Oil or other lubricants will only lead to a buildup of contaminants, which can eventually cause the pivot points to bind. The binding of pivot points on this limit switch may cause the switch to malfunction, thus leading to possible damage of the crane and/or the supporting structure. 3. Unless an accident has occurred which has damaged the assembly, no repair should be required of this assembly over long periods of service. If the assembly must be dismantled for some reason, use care to avoid overtightening the capscrews at the pivot points. Binding can occur if the capscrews are over tightened. Cotter pins are provided to prevent the slotted nuts from working off of the capscrews. Lubricate the pivot points of the limit switch using motor oil.

11-5

Revised 10/25/04

Figure 11-3 HB Limit Switch Assembly

END OF DRUM LIMIT SWITCHES General

This section provides a general description of the endof drum limit switches, as well as procedures on the maintenance and adjustment of the limit switches.

wire rope path and the end of the drum (see Figure 114 on page 11-7):

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while r e p a i rs a r e b e i n g p e r fo r m e d . B e fo r e beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed. 1. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 2. Loosen capscrews (12) which secure limit switch (11) to switch mounting plate (01). 3. Adjust the limit switch as necessary. 4. Secure the limit switch by tightening capscrews (12).

Description
The End-of-Drum limit switches are used to detect the presence of the hoist wire ropes at the end of the drum. Under normal operating conditions, the wire ropes would not come near the limit switch lever. However, should the hoist wire ropes jump the drum grooves for some reason, the ropes may travel toward the end of the drum at an accelerated rate. If this should happen, the wire ropes would travel too close to the end of the drum, and thus come into contact with the end-of-drum limit switch lever, shutting down the hoist motion.

Adjustment
Use the following procedure to adjust the limit switch itself, and to adjust the limit switch lever in relation to the

11-6

LIMIT SWITCHES AND LIMITING DEVICES

Morris Material Handling 5. Loosen capscrews (04) which secure the limit switch assembly to the base plate. 6. Adjust the limit switch assembly such that the limit switch will trip when the wire rope is within 1 inch of the end of the drum. 7. Tighten capscrews (04) to secure the limit switch assembly to the base plate.

Repair
Repair of the limit switch assembly is limited to the replacement of worn, or damaged components, or a faulty limit switch. Remove the hardware necessary to remove the worn, or damaged component, and remove the component. Install the new component onto its mounting, and secure with the original mounting hardware. Adjust the limit switch as described under the topic, Adjustment.

Figure 11-4 End-of-Drum Limit Switch

MISCELLANEOUS LIMIT SWITCHES General

Several additional limit switches are used in a variety of applications throughout the crane. These switches are used to monitor operating conditions.

Maintenance
The limit switches themselves require no maintenance; however, in some cases, the linkage actuating them m ay. L u b r i c a t e t h e a c t u a t i n g l i n k a g e o f a l l miscellaneous limit switches, pin, levers, etc. as described in Section 3.

11-7

Revised 10/25/04

Repair
Repairs are limited to the replacement of faulty limit switches.

Adjustments
After initial set up, limit switches should never need additional adjustments. If by some chance a limit switch is accidentally moved, adjustments should be made to the support bracket or the actuator arm to properly align the limit switch with its actuating mechanism.

Hoist Overload Load Cell System (Optional)

See Miscellaneous section 16.

11-8

LIMIT SWITCHES AND LIMITING DEVICES

Section 12
COLLECTOR / CONDUCTOR / SPAN BAR SYSTEMS
GENERAL
This section covers the maintenance and repair of the collector and conductor systems used on this crane. Disassembly, repair, and assembly of the conductor system components is provided when necessary, as well as procedures on the replacement of the conductor bars and/or cables. components. Refer to the following topics for p r o c e d u r e s o n c a r r i e r, a n d c o n d u c t o r c a b l e replacement. CABLE REPLACEMENT. Use the following procedure to remove and replace a damaged conductor cable: 1. Move the crane to a suitable maintenance area.

GANTRY COLLECTOR / CONDUCTOR SYSTEM

Festoon Conductor System
GENERAL . The festoon cables carry the primary power, and communications to the crane motion. Power travels from a stationary junction box to the junction box mounted on the lead festoon carrier. Power is then distributed from the carrier junction box to the appropriate crane functions. LUBRICATION . The carrier wheel bearings are provided with grease ttings. Periodically lubricate the carrier wheel bearings as described in Section 3, under the topic, Lubricate, Festoon Carriers. Periodically, lubricate the carrier swivel pins using motor oil to provide the limited lubrication needed. MAINTENANCE. Inspect the conductor cables on a regular basis. Look for signs of chang, cracking, or other insulation damage. The cause of any damage must be located, and corrected as soon as possible. Conductor cables which are cracked or otherwise damaged should be replaced as described under the topic, Cable Replacement. Inspect the machine chains which link the carriers together. Make sure that they are not worn or broken. Replace weak or broken chains immediately. REPAIRS. Repair of the festoon conductor system is limited to the replacement of worn or damaged
Rev. Date 10/25/04

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while r e p a i rs a r e b e i n g p e r fo r m e d . B e fo r e beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed. 2. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 3. Locate the damaged conductor cable where it enters the carrier junction box, or tow arm. Tag the conductor cable for easy identication. 4. Trace the damaged conductor cable back towards t h e xe d j u n c t i o n b ox . M a r k t h e c a bl e fo r identication at the point where it passes through each carrier. 5. Locate the damaged cable where it enters the xed j u n c t i o n b ox . Ta g t h e c o n d u c t o r c a bl e fo r identication. 6. Remove the cover on the xed junction box, and locate the damaged cable inside the junction box. 7. Disconnect, and tag each individual cable lead from its internal junction box connection. 8. Loosen the cable clamp which secures the conductor cables to the xed junction box.

12-1

Revised 10/25/04 9. Pull the damaged conductor cable from the xed junction box. 10. Working toward the carrier junction box, loosen the carrier cable clamps which secure the conductor cables, and remove the damaged cable from each carrier. 11. Remove the cover from the carrier junction box, or tow arm. Locate the damaged conductor cable inside the carrier junction box. 12. Disconnect, and tag each individual cable lead from its internal carrier junction box connection. 13. Loosen the cable clamp which secures the conductor cables to the carrier junction box, or tow arm. Pull the damaged conductor cable from the carrier junction box. 14. Cut a new piece of conductor cable to the same length as the old cable. 15. Work one end of the new conductor cable into the xed junction box connection. 16. Identify, and connect the individual leads of the conductor cable to the leads inside the xed junction box. 17. Adjust the conductor cable where it passes through the xed junction box, and tighten the cable clamp to secure the new conductor cable. 18. Working toward the carrier junction box, or tow arm, feed the new conductor cable through each carrier. Make sure that the carrier spacing remains the same as with the old cable. 19. Tighten the cable clamp to secure the conductor cables to each carrier. 20. Feed the loose end of the conductor cable into the carrier junction box, or tow arm. 21. Adjust the cable loop such that it is the same as the old cable, and tighten the junction box cable clamp. 22. Cut the end of the new conductor cable to suit. 23. Connect each individual lead to the internal carrier junction box, or tow arm leads. 24. Double check all wire connections. 25. Install both the xed junction box cover, and the carrier junction box, or tow arm cover. 26. Apply power to the crane. 27. Operate the crane to test the installation of the conductor cables. All cable should lag at without binding, or contacting other obstructions. Make adjustments to the cable loops as necessary. CARRIER REPLACEMENT. Use the following procedure to remove, and replace a damaged or worn carrier: 1. Move the crane to a suitable maintenance area.

! DANGER
Disconnect, lock open, and tag the power source which feeds the crane to prevent power from being applied to the crane while r e p a i rs a r e b e i n g p e r fo r m e d . B e fo r e beginning repairs, try the operational controls to verify that the intended power source is disconnected. Injury or death of personnel will result if this precaution is not observed. 2. Disconnect, lock open, and tag the disconnect switch which feeds the crane to prevent power from being applied while repairs are being made. 3. Support the conductor cables, by securing them to the festoon beam using rope or wire. 4. Remove the hex nuts, and bolts which secure the cable clamps to the carrier. 5. Remove the hew nuts, and bolts which secure the carrier halves together. 6. Remove the carrier from the festoon beam by rotating the carrier halves away from the festoon beam. 7. If only the carrier wheel assemblies are to be replaced, remove the carrier wheel assemblies from the cable clamp. 8. Install new carrier wheel assemblies to the cable clamp. 9. Assemble the carrier to the festoon beam, and install and tighten the bolts, and locknuts. 10. Position the conductor cables onto the cable clamp, and install the clamp saddle, the bolts, and the hex nuts. Tighten the hex nuts just enough to secure the cables, but not so much as to damage them. 11. Lubricate the carrier swivel pins as described in Section 3, under the topic, Lubricate, Festoon Carriers.

12-2

COLLECTOR / CONDUCTOR / SPAN BAR SYSTEMS

Morris Material Handling

POWER CABLE REPLACEMENT General

The following procedure describes the necessary steps which are required to replace the power conductor cable.

directly from the transport reel onto the cable reel without passing over any guide rollers or making any changes in direction. The transport reel to cable reel transfer should be performed slowly, and with a minimum of tension to avoid torsional inuence on the cable during installation. The crane should be moved to the end of its travel and the cable anchor point released if detectable torsion is evident during installation. A cylinder roller should then be inserted underneath the cable at the point where the twist is detected. Two persons should then walk with the roller until the free end of the cable is met. The roller used for this procedure should have a diameter between six inches and nine inches. This procedure should be repeated until the detected torsion has been released at the free end of the cable. The cable can then be reattached. Note: Refer to the Insul 8 Instruction Manual in Section 15, for additional start-up, installation and maintenance infor mation relating to the cable reel assembly (hardcopy only).

NOTICE
To obtain reliable cable reel performance, be sure to wind the cable onto the cable reel without tension or torsion.

NOTICE
Whenever possible, use a fork truck, or a crane to lift the cable transport reel. Avoid, or at least minimize, rolling the reel on its anges. If rolling is necessary, always roll the reel in the direction of the arrow shown on the reels ange. Observing these suggestions will keep the cable coils tight on the reel, and will help prevent any torsion or tension from acting on the loose coils or cable.

NOTICE
Store reels of spare cable on their anges to prevent slumping of the cable coils. This should be considered whenever long term storage of operating spares is anticipated.

Cable Replacement
The preferred method for on site cable installation is to jack up the transport reel and unwind the cable onto the cable runway along the entire length of the cranes travel route. Conventional cable pulling equipment and rollers can be used for this purpose. If the marking or jacket imprinting on the cable shows a slight spiraling around the cable along its length, do not attempt to straighten the cable. The spiraling is a natural effect of the manufacturing process, and is sometimes evident over long cable lengths. In many cases, this procedure cannot be used due to the site conditions. Direct transfer of the cable onto the cable reel can be used whenever long runs of large diameter cable are installed. This method is also recommended when the cable reel location and/or cable runway are not accessible. Avoid introducing S bends in the cable between the transport reel and the cable reel during this procedure. Whenever possible, the cable should be transferred
12-3

Revised 10/25/04

12-4

COLLECTOR / CONDUCTOR / SPAN BAR SYSTEMS

Section 13 CAB
GENERAL
A full description of the operators station armchair controls is provided in Section 2 of this manual. Specic instructions for the removal and replacement of the push buttons and indicator lamps, which are mounted in the operators armchair, are not provided in this manual due to the relative ease of such tasks. Removal, repair, and installation of the foot operated switches is also not covered.

AIR CONDITIONER
The air conditioner which is used in the cab of this crane is Morris part number R66042D1. Information relating to this unit follows (hardcopy only).

Rev. Date 10/25/04

13-1

Revised 10/25/04

13-2

CAB

Section 14 CONTROL SYSTEMS

GENERAL
This crane uses P&H Bull.425 / Siemens Master VFD Drive System for the Gantry, Trolley & Hoist. Supporting Documentation for this includes: Layout Drawing, Gantry Control House . . . . . . R68111 Cat.425-1 Control Rect/Regen. RRU Appl. . . . . . . . . Supp.#1 Block Diagram of Regen Appl. . Supp.#1/Attach.#1 RRU Setup Procedure . . . . . . . Supp.#1/Attach.#2 Board Cable Connection . . . . . . Supp.#1/Attach.#3 RRU Recommended Trouble-Shooting Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supp.#1/Attach.#4 Use of OP1-S Keypad . . . . . . . . . . . . . . . . Supp.#2 Saving Regen Parameters . . . . . . . . . . . . Supp.#3 Express Speed Operation . . . . . . . . . . . . . Supp.#4 Plugging Control Operation. . . . . . . . . . . . Supp.#5 Communications COM Card Appl. . . . . . . Supp.#7 Load Float Operation . . . . . . . . . . . . . . . . Supp.#8 Flux Off Delay . . . . . . . . . . . . . . . . . . . . . . Supp.#9 SIMOVIS Software Use. . . . . . . . . . . . . . Supp.#11 Gantry Scalar Control . . . . . . . . . . Supp.#12 & #13 Hoist Control . . . . . . . . . . . . . . . . . . . . . . Supp.#15 Start-Up Trouble Shooting. . . . . . . . . . . . Supp.#16 SIMOVIS Operation. . . . . . . . . . . . . . . . . Supp.#17

Rev. Date 10/25/04

14-1

Revised 10/25/04

14-2

CONTROL SYSTEMS

Section 15 CABLE REELS

GENERAL
This section covers the maintenance and repair of the cable reels installed on this crane.

MAIN POWER CABLE REEL

This crane uses an Insul 8 electric motor driven power c a bl e r e e l ( M o r r i s p a r t n u m b e r R 6 8 1 5 6 D 1 & R68087F1). Additional information on this reel follows (hardcopy only).

Rev. Date 10/25/04

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CABLE REELS

Section 16 MISCELLANEOUS COMPONENTS

GENERAL
This section covers the maintenance and repair of the components which have not been covered under any previous section of this manual (hardcopy only).

ADDITIONALLY, THE FOLLOWING PUBLICATIONS HAVE BEEN PROVIDED (hardcopy only):

HSC-106-B Straight Track Portal Crane ED-52-4 Torque Lock Nut Bulletin

WIND SPEED INDICATOR SYSTEM

The wind speed indicator system which is used on this crane is from Texas Electronics, Inc., part number 50Z113D3. Information on it follows.

LOAD CELL - (Optional)

CONTROL HOUSE AIR CONDITIONER

The crane control enclosure is cooled with a Friedrich room-type air conditioner (Morr is par t number R66042D2). The Owners Guide can be found in Cab Section 13, as both the cab and control house utilize the same AC unit.

Rev. Date 10/25/04

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MISCELLANEOUS COMPONENTS

Morris Material Handling 1-800-727-8774

Section 17 STORM BRAKES

This section covers all available information on the storm brakes for this crane.

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STORM BRAKES

Section 18 GRAPPLE
This section covers all available information on the grapple for this crane.

Rev. Date 10/25/04

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GRAPPLE

Section 19 TV CAMERA
This section covers all available information on the TV Camera for this crane.

Rev. Date 10/25/04

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TV CAMERA

Section 20 WIRING DIAGRAMS

Schematic Diagram - R68560 1-Line Diagram - R68505 Wiring Diagram - R68678

Rev. Date 10/25/04

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