Tractel Tirak Series User manual

1
Electrically powered endless hoist
for materials handling
TIRAK®
series
T 1000
tirak®
TIRAK®
series
X 300
X 400
X 500
X 700
X 800
X 1020
TIRAK®
series
X 3050
Original Operating Instructions
This instruction manual must be available
for the user at all times.
Additional copies may be obtained on request.
With TIRAK®wire ropes
of different lengths
on winders
www.tractel.com

2
Contents
Information for this manual 2
Notes for manufacturers of installation 3
with built-in TIRAK
®
Explanation of symbols used 3
1. Safety advice 4
2. Exclusion of non intended use 5
3. Machine description
3.1 Purpose 5
3.2 Working principle 5
3.3 Allowed TIRAK
®
wire rope for
materials handling 5
3.4 Noise emission 5
3.5 Main components and
operating controls 6
3.6 Technical data 7
3.7 Increasing the capacity 7
3.8 Anchoring examples 8
3.9 Safety devices
3.9.1 Primary brake 8
3.9.2 Emergency stop 8
3.9.3 Phase control relay 8
3.9.4. Load limiting device 8/9
3.9.5 Manual operation
3.9.5.1 Emergency descent 9
3.9.5.2 Manual lifting 9
3.10 Residual risks 10
4. Setting up
4.1 Required equipment 10
4.2 Anchoring the TIRAK
®
hoist
4.2.1 Anchoring devices and
dimensions 10/11
4.2.2 Anchoring of the TIRAK
®
hoist 12/13
4.3 Wire rope exit
4.3.1 Slack wire rope 13
4.3.2 Use of wire rope winders 13
4.4 Electric connections 14
4.5 Electric controls 15
Page
4.6 Wire rope installation
4.6.1 Preparing the wire ropes 15
4.6.2 Wire rope installation 16
5. Operation
5.1 Checks before starting 17
5.2 Weekly check of wire rope and cable 17
5.3 Operation
5.3.1 Stop/EMERGENCY STOP 17
5.3.2 Service operation 17
5.4 Securing moving loads 18
5.5 Manual operation
5.5.1 Emergency descent 18
5.5.2 Manual lifting 18
6. Troubleshooting 18/19/20
7. Out of Operation
7.1 Temporary stoppage 20
7.2 End of operation 20
8. Maintenance/Checks/Repair
8.1 Maintenance
8.1.1 Hoist 21
8.1.2 Wire ropes 21
8.1.3 Motor, brake, and gear box 21
8.2 Checks
8.2.1 Essential checks 22
8.2.2 Safety inspection 23
8.3 Repair 23
9. Spare Parts 23
9.1 Hoist 23
9.2 Motor and brake 23
9.3 Electrical control 23
9.4 Nameplates and labels 23
Page
Date of edition
2nd Edition: February 2004
Copyright
The copyright of these assembly and operating
instructions shall remain with the manufacturer.
Address of the manufacturer:
GREIFZUG Hebezeugbau GmbH
Scheidtbachstraße 19-21
51469 Bergisch Gladbach
Germany
Phone: +49 / 22 02 / 10 04-0
Fax: +49 / 22 02 / 10 04-50 or -70
e-Mail: [email protected]
For addresses of other TRACTEL Group Companies see page 28.

3
Notes for manufacturers of an installation with built-in TIRAK®
Important!
The manufacturer of an installation for lifting/
pulling/driving loads in which a TIRAK
®
hoist is
built in must indicate all instructions for the safe
use of this installation at the corresponding points
of the instructions which must be prepared for
the installation by the manufacturer.
STOP
Merely enclosing these instructions does not
satisfy the requirements of the EC Machinery
Directive or the applicable standards!
(without code word)
Explanation of symbols used
Safety advices
Symbol Code word Meaning Possible consequences of non-compliance
IMMEDIATE or
DANGER possibly imminent Fatal or serious injuries!
danger:
IMMEDIATE or
DANGER possibly imminent
danger through Fatal or serious injuries!
dangerous
voltage:
Possibly
CAUTION dangerous Injuries to persons
situation: or damage to property.
Other advices
Possibly
Attention dangerous Damage to appliance.
situation: or its surroundings.
Important Useful tips for
optimum working: None
Directions
Instruction to operation/
documentation in writing.

4
Follow all instructions and safety regu-
lations contained in this
manual to avoid injuries.
a) DO NOT overload the TIRAK
®
hoist.
b) DO NOT stand below a suspended load.
c) TIRAK
®
hoists must only be used for lifting, pull-
ing, lowering, and moving back-and-fro of loads
1)
.
Use for other purposes is not allowed.
d) TIRAK
®
hoists with standard electric equipment
must not be used in a potentially explosive at-
mosphere
2)
.
e) Anchoring, maintenance, and/or the operation of
TIRAK
®
hoists must only be done by persons,
who are familiar with it. Employees must have
received the instruction to anchor, maintain, and/
or operate the hoist by their employer.
f) The operator has to know and to follow all rel-
evant local safety regulations, and maintenance
recommendations, as well as this operating in-
struction, and the operator must have been
instructed.
g) The operator must not start any movement of the
load until he has checked that the hoist and the
load are properly anchored, and that no person is
stood in the danger zone below any suspended
load, or until he has got a starting signal from the
slinger.
h) The operator must watch the load during all move-
ment operations of the hoist. If the operator is
unable to watch the complete working area, the
danger zone must be cordoned off, or a second
person must be positioned to enable the com-
plete working area to be watched and have
adequate means of communication with the hoist
operator during the whole operation.
i) The TIRAK
®
hoist has to be anchored so that the
wire rope under load is vertically entering the
hoist.
k) Use only the recommended TIRAK
®
rope in good
condition. Use only normally commercially avail-
able multi-purpose grease for the lubrication of
the rope. Do not use lubricants containing disul-
phide (e.g. Molycote
®
).
l) When using a rope other than the recommended
TIRAK
®
rope the warranty entitlement given by
GREIFZUG Hebezeugbau GmbH or other com-
pany of the TRACTEL Group shall not apply.
1) TIRAK
®
-Hoists for man riding on request.
2) TIRAK
®
-Hoists can be supplied for these applications on request.
1. Safety advice
m) Before starting the assembly check all parts for
completeness and error-free quality.
n) Only anchor the TIRAK
®
hoist at the points pro-
vided for this purpose (connection rods, anchor
points, or load pins).
o) When using self-securing nuts please observe
the following:
–the screw must protrude from the nut with at
least half its thread diameter;
–do not re-use nuts if they can be unscrewed
by hand!
p) Do not use the wire rope to fix the load, and do
not pull it over sharp edges.
q) Do not fix any load to the free wire rope end,
which exits from the winch at the opposite side to
the wire rope under load.
Exception: Use of a TIRAK
®
hoist of the type
series T 1000 in to-and-fro travel.
r) Never use a rope which is too short for the job
you are doing. When the load or machine is at its
lowest point, a minimum length of 1meter of wire
rope should be below the rope exit of the TIRAK
®
.
s) The ferrule of the wire rope hook must not reach
the TIRAK
®
-casing during lifting/pulling the load.
Exception: A limit switch for lifting limitation is
attached to the TIRAK
®
hoist (see accessories on
page 25).
t) The electrical connection of the TIRAK
®
as well
as of electrical accessories must be carried out
in accordance with EN 60204-1.
u) Checks and repairs to the electrical system must
only be carried out by qualified electricians.
v) Other checks and repairs must only be carried
out by GREIFZUG Hebezeugbau GmbH, an other
company of the TRACTEL Group or by a hoist
workshop.
w) GREIFZUG Hebezeugbau GmbH or other com-
pany of the TRACTEL Group shall assume no
liability for damages resulting from conversions
or alterations to the devices supplied by itself or
as a result of the use of non-original parts.

5
2. Exclusion of non-intended use
3. Machine description
3.1 Purpose
TIRAK
®
hoists of the series
X 300 , X 400 / X 500 , X 700 , X 800,
T 1020, X 1000, X 3050
are portable, electric driven hoists for
lifting, lowering, pulling, and
movement of loads
by means of a TIRAK
®
wire rope prescribed by the
manufacturer.
This wire rope is mandatory for the safe and trouble-
free working with TIRAK
®
hoists.
DIN
G
B
8
Fig. 1
3.3 Allowed TIRAK®wire rope for
materials handling
for TIRAK
®
-series Wire rope-Ø
X 300 8 mm
X 400
X 500
X 700
X 800
T 1000
X 1020 9 mm
X 3050 14 mm
Identification: one red strand.
Diamater indication on the ferrule:
3.4 Noise emission
TIRAK
®
series (Distance 1 m)
X 300/400:............................................................................max. 72 dB(A)
X 500/700/800/1020, T 1000:....................max. 70 dB(A)
X 3050................................................................................. max. 78,5 dB(A)
3.2 Working principle
Provided that TIRAK
®
hoists are aligned in the direc-
tion of pull, they will work in any position and in any
direction.
For either lifting or lowering there is one correspond-
ing push button. The wire rope is driven through the
winch with constantly equal safety, and the length of
wire rope i. e. the possible pulling length, is practi-
cally unlimited.
TIRAK
®
hoists with a capacity of 1000 kg or more
have an integrated load limiting device.
TIRAK
®
hoists of T 1000 series can pull in both
directions.
Indication
on the ferrulle:
example for
8 mm dia.
Use of standard TIRAK
®
hoists and other equipment for materials handling
under the following conditions is prohibited:
–at temperatures below -10
 Cor above +50  C,
for X 1030 to 2050 P series below -15
 Cor above +80  C
(for advice regarding gearbox oils for lower/higher temperatures
see chapter 8.3);
–in potentially explosive atmosphere.
Machines for these conditions can be supplied on request.
Table 1