RED ROOSTER AT2S-LF, Manual

Page 1: ...LUBE FREE AIR HOIST TROLLEY USER MANUAL MODEL TCS 980 AT2S LF...

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Page 3: ...IFTING GEAR BELOW THE HOIST 3 4 OPERATIONAL BREAKDOWN OR ACCIDENT SECTION 4 MAINTENANCE 4 1 GENERAL 4 2 REPAIRS 4 3 TROLLEY VANE MOTOR MAINTENANCE 4 4 SILENCING 4 5 CHANGING HOIST SILENCERS 4 6 CHANGI...

Page 4: ...is manual which are relevant to them This manual should be accessible at all times to the relevant person in case of loss ask your dealer for a new copy Air pressure 6 bar Specification sheet gives fu...

Page 5: ...ion In the UK the use of non electrical equipment in a hazardous area is covered by Products Intended for use in Potentially Explosive Atmospheres 2016 UK SI 2016 No 1107 as amended by UK SI 2019 No 6...

Page 6: ...with corrosion protection and can work in temperatures of 20 C to 60 C When used outdoor or offshore hoists should be protected against the weather and examination and maintenance interval should be r...

Page 7: ...llation of an in line air service unit although essential cannot in itself compensate for serious contamination in the air supply When operating the compressor in moist humid or dusty atmospheres seek...

Page 8: ...ads along a runway beam or swing jib It must be correctly adjusted for the flange width and thickness Site the hoist immediately above the load which is to be lifted Ensure that the point from which t...

Page 9: ...n is fed out of the collector to ensure that it is not twisted or knotted Chain bags and buckets are fitted with one or two brackets depending on the model and HOL of the hoist See additional instruct...

Page 10: ...ey should be run weekly where the hoist is outside and not protected it should be checked lubricated and run daily The emergency stop button valve operates immediately Upper and lower limit switches l...

Page 11: ...unloaded condition due to the centre line of the hoist having been affected by the weight of chain the upper limit switch may fail to operate In addition the slack load chain may on some modules foul...

Page 12: ...dows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH13 ATLF REV1 GETTING STARTED STANDARD HOSE CONNECTION PENDANT CONTROL OR HOIST WITH EXTERNAL EMERGENCY STOP VALVE STANDARD HOSE CONNEC...

Page 13: ...ited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH13 ATLF REV1 GETTING STARTED Some hoists are fitted with internal emergency stop valves The hose clamp can als...

Page 14: ...olley To move left pull hand chain clockwise To move right pull hand chain counterclockwise Pneumatic Trolley The trolley direction is controlled by the pendant buttons or levers Face the trolley moto...

Page 15: ...nd stop MOUNTING BY DISASSEMBLING THE MAIN TROLLEY BODY 2 By opening the trolley up so that the inner part of the wheels will pass over the beam flange and then sliding the trolley side plates back al...

Page 16: ...o the beam width plus 2 or 3mm 3 Distribute on each side of the side plates washers and adjusting collars that are remaining and screw a nut on each extremity 4 Tighten the nuts and lock nuts on the l...

Page 17: ...to the hoist as the fittings and filter are not designed to take a load and may not support the weight of the hose DON T use hydraulic fittings as these tend to have a reduced orifice size resulting...

Page 18: ...or gear travel and are based on a standard trolley fitted with blocks or pads to lock the trolley in location when the chain wheel is turned The chain is then turned the other way to release the troll...

Page 19: ...de plates are positioned at either side of the runway beam Position one or two hoists at either side of the runway beam connect the bottom hooks the lifting points on the trolley side plates and lift...

Page 20: ...damaged Hand chain used on geared trolleys does not normally require lubrication In areas of high corrosion plated chain can be used along with special lubricants to prevent corrosion from sea water...

Page 21: ...and make sure the pendant hangs vertically and cannot swing or get blown against anything When there is a longer break in the lifting operation and the load has been landed then the emergency stop bu...

Page 22: ...ate the hoist smoothly Do not suddenly change direction as this may exert both shock loads acceleration forces may well in excess of the weight of the load being lifted Do not use the hoist to lift lo...

Page 23: ...orking then it should be removed from location and sent for repair if none of the remedies in the trouble shooting guide have an effect When the hoist is still holding a load then an additional hoist...

Page 24: ...r distortion the chain should be replaced Any wear should be measured and checked against section 10 1 BRAKE With a load applied check the brake efficiency If there is any delay in actuation or slippa...

Page 25: ...de good support on the inner bearing track as the shaft fit is very tight to provide rotor location Place blade ejector ring central on cover and press rotor shaft assembly down until there is a clear...

Page 26: ...CS 500 TCS 980 Located at the end of the motor the silencers are behind the exhaust plate ADJUSTMENTS AND MAINTENANCE OPERATIONS Before carrying out any work on the hoist the main air supply should be...

Page 27: ...it over the load wheel If damaged remove the damaged link s REPLACING EXISTING CHAIN Cut away the centre portion of a link of the old chain to allow a chain diameter to pass through Connect the spare...

Page 28: ...d is being lifted at the time how long it will be until the air supply is available again and if it is necessary and safe to travel lower the load to a safe position If the problem is a burst hose thi...

Page 29: ...N FITTINGS TCS 980 HOIST PARTS 1 Hook Safety Latch 2 Upper Hook 3 Motor Section 4 Silencer Section 5 Valve Section 6 Brake Section 7 Chain 8 End Stopper 9 Gear Box 10 Chain Lever 11 Hook Safety Latch...

Page 30: ...5mm Replace if any of the width length and thickness is less than the stated minimums 152 Brake Disc STD T 8mm MIN T 7 3mm STD W 2 4mm MIN W 2 9mm Below minimum for replacement 209 Cage Replace when t...

Page 31: ...28 8mm Check dimensions as casting size can vary Replace if beyond maximum L or H There is some variation in the H size on hooks so it is best to measure the hook when new and then allow up to 0 5mm o...

Page 32: ...the hoist is contaminated with dirt or chemicals wash with a propriety mild solvent or detergent and thoroughly rinse off with fresh water Allow to dry and spray lightly with penetrating fluid Lubrica...

Page 33: ...ottom hook is not twisted through the chain fall on multi fall blocks Hoists with long drops of chain and heavy loads in the chain collectors will require a secondary suspension point to hold the hois...

Page 34: ...R MANUAL Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH13 ATLF REV1 CHAIN COLLECTORS TCS 980 TCS 980 1 M8 x 65 2 M6 x 25 3 Chain Bag...

Page 35: ...g HOW TO ADJUST THE SPEED Referring to the diagram below looking at the hoist from the valve side the speed adjustment screw for lifting is on the RIGHT and the lowering adjustment screw is on the LEF...

Page 36: ...ck compressor output against hoist requirements Check air hose size against table Ensure fittings are matched to hose size Replace incorrect items Reduce to 6 bar Fit regulator Check connections of ai...

Page 37: ...Y OFFSHORE INSPECTION Arrange to have the hoist examined by a person specifically trained and experienced in the examination of lifting machines This can be done by a Red Rooster engineer or an indepe...

Page 38: ...protect other components or to function by means of friction generation They require periodic inspection and replacement and comprise of the rotor vanes and the brake disc Inadequate lubrication serio...

Page 39: ...or use in Zones 21 and 22 Mining Ex Group I M2 Ex h I Mb Mechanical equipment de energised in an emergency TROLLEYS AND OVERHEAD CRANES Red Rooster trolleys and overhead cranes use standard steel whee...

Page 40: ...static charge Hose safety whip cables should be used to prevent hoses flying if a connection fails to limit the dust cloud and the flying hose Red Rooster hoists should only be operated with compresse...

Page 41: ...LEYS 12 1 TABLE 1 Beam trolley flange ranges for four wheel trolleys FLANGE WIDTH RANGE LIFTING CAPACITY TONNES 0 25 to 2 Tonne R1 55 to 140 mm R2 140 to 220 mm R3 220 to 330 mm TABLE 2 LIFTING CAPACI...

Page 42: ...with a filter regulator AVAILABLE OPTIONS Marine specification Special paint systems UK Ex scheme or ATEX zone 1 specification Chain collectors PVC galvanised or stainless steel Articulated trolley L...

Page 43: ...Aitken T Mikolajewski T Mikolajewski not to scale Scale Surname Surface Roughness Angular 0 5 Linear If In Doubt Ask 1 1 45kg Weight 0 Title of Part TCS 980 AT2S Date Material Sheet Size A4 0 98T Hoi...

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Page 45: ...45 USER MANUAL Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH13 ATLF REV1 DRAWINGS AND PARTS LISTS...

Page 46: ...g Weight 0 Title of Part TCS 980 AT2S Date Material Sheet Size A4 0 98T Hoist And Trolley Date Revision Profile Number Replaces Drawing 29 01 2018 Signature Part Number DRG 1500 24 up to 5 0 05 over 5...

Page 47: ...55 140mm Load Bar Range II Flange 140 220mm Load Bar Range III Flange 220 300mm DRG 1500 15 or DRG 1500 16 or DRG 1500 17 1 25 0 Pinion Shaft for NORD Gearbox DRG 1500 37 1 26 Hex Nut ISO 4032 M10 8...

Page 48: ...near If In Doubt Ask 1 1 1 2 kg Weight 0 Title of Part 0 98TE HOIST AND TROLLEY Date Material Sheet Size A3 1TE TOP EYE Date Revision Profile Number Replaces Drawing 30 01 2018 Signature Part Number D...

Page 49: ...D01 AH13 ATLF REV1 Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 Brake Gears Suspension Body TCS 980 AT2S LF 17 09 15...

Page 50: ...ND STAR GEAR 3 207 426230E40 SECOND PIN 3 208 426230E50 SECOND RING GEAR 1 209 426230240 CAGE 1 210 426230890 LOCK SCREW 1 211 426230900 BRAKE PLATE 1 212 130113001 BEARING 6009 2 213 130120004 BEARIN...

Page 51: ...D01 AH13 ATLF REV1 Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 Motor Valve Body TCS 980 AT2S LF 17 09 15...

Page 52: ...6230160 CYLINDER 1 053 426230150 ROTOR 1 054 426230170 FRONT PLATE 1 055 137102032 VANE 8 056 130802235 LIFT SPRING 8 057 426230460 LIMIT SHAFT 1 058 426230A40 LIMIT SHAFT BUSHING 1 059 426230140 LIMI...

Page 53: ...Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 8721...

Page 54: ...ACHINE SCREW M5X14 4 M 132904221 SELF TAPPING SCREW 4X20 6 N 132105305 HEX SOCKET HEAD CAP SCREW M5X5 4 P 131309206 WASHER M6 1 Q 130301912 RETAINING RING H 12 1 R 131109001 O RING S 3 HS90 4 S 131103...

Page 55: ...55 USER MANUAL Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH13 ATLF REV1 A13740105NL...

Page 56: ...LECT A MANIFOLD C7M 4 4 0 MANIFOLD TYPE VALVE SIZE VALVE TYPE CYLINDER PORT SIZE PORT TYPE C7M 1 4 4 Four Way 4 3 8 0 NPT Every letter and digit in the product number has a significant meaning The pro...

Page 57: ...PE VALVE SIZE VALVE TYPE CYLINDER PORT SIZE PORT TYPE C7M 1 4 4 Four Way 4 3 8 0 NPT Every letter and digit in the product number has a significant meaning The product number shown below C7M 440 which...

Page 58: ...mited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH13 ATLF REV1 Part No CJJ 4313 02 03 2012 visit http www versa valves com dlegal html for terms on using this...

Page 59: ...59 USER MANUAL Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH13 ATLF REV1...

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Page 61: ...61 USER MANUAL Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH13 ATLF REV1 ACCESSORIES...

Page 62: ...oist As a mains emergency stop valve we use a range of 3 2 normally closed valves on pendant control hoists These range from 0 5 to 1 5 depending on the hoist capacity Valve models 0 5 VSA 3135 04 0 7...

Page 63: ...63 USER MANUAL Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH13 ATLF REV1 ACCESSORIES...

Page 64: ...age to the internal parts 2 Do not use tools on the pressure regulator knob as this may cause damage It must be operated manually MOUNTING ADJUSTMENT CAUTION 1 Be sure to unlock the knob before adjust...

Page 65: ...65 LOG BOOK Red Rooster Lifting Limited Nauta House The Meadows Oldmeldrum Aberdeenshire AB51 0EZ Tel 44 0 1651 872101 M01 AH13 ATLF REV1 LOG BOOK...

Page 66: ...REQUIREMENTS The items listed below are intended as a guide for performing daily visual inspections of the components that have a direct bearing on the safety of the hoist and or trolley where the st...

Page 67: ...test hoists running speed and control operation without load and then check lifting a load of around 50 of SWL to check brake operation and controls when loaded LIMIT SWITCHES Check operation of upper...

Page 68: ...YEAR DAY 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 AIR HOIST CHECKS HOOK SWIVEL AIR LEAKS AIR REGULATOR SAFETY CATCHES NOISE OPERATION PENDANT OPERATION E ST...

Page 69: ...S TO BE CARRIED OUT MONTHLY IN PRODUCTION OPERATIONS WHERE HEAVILY USED OR IN HARSH WORKING CONDITIONS TO BE CARRIED OUT THREE MONTHLY WHEN THE HOIST IS ONLY USED OCCASIONALLY PLEASE CONTACT RED ROOST...

Page 70: ...651 872101 Nauta House Oldmeldrum E sales redroosterlifting com The Meadows Aberdeenshire AB51 0EZ W www redroosterlifting com Depot Unit 26 Kelvin Way T 44 0 121 525 4162 Kelvin Way Trading Estate We...