Manufacturing of material Handling Equipments

Operation and
Maintenance Manual
Dual-Machinery Hoist System

Client : M/s Vijay M. Mistry Construction Pvt. Ltd.

Job : 100 Ton x 25 M Lift Hoist Trolley Machinery - 2 Set
Job No. : 24/HT/VMMCPL/14
Year of Manufacture: 2024-2025

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Table of Contents

1. Introduction Page 03

2. System Overview Page 03

3. Technical Specifications Page 04

4. Operation Instructions Page 05

o 4.4 Post-Operation Procedures

5. Operating the Hoist Page 06

o 5.1. Control Methods

 5.1.1 Pendant Push-Button Control
 5.1.2 Radio Remote Control (RRC)

o 5.2. Switching Between Control Methods

6. Safety Precautions Page 08

7. Maintenance Guidelines Page 09

o 6.1 Regular Maintenance

o 6.2 Annual Maintenance

8. Troubleshooting Page 10

9. Lubrication Chart Page 11

10. Company Information & Acknowledgment Page 12

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1. Introduction
Welcome to the Operation and Maintenance Manual for the Dual-Machinery Hoist System
designed by HEBENKRAFT. This hoist system is specifically engineered for construction
companies, featuring dual hoist mechanisms at both ends, controlled via a single push-
button interface, and optimized for vertical (up and down) operations.

This manual provides detailed instructions on the safe operation, routine maintenance, and
troubleshooting of your hoist system. It is essential that all operators and maintenance
personnel familiarize themselves with this manual to ensure efficient and safe usage.

2. System Overview
2.1 General Description

The Dual-Machinery Hoist System is a robust lifting device designed for heavy-duty
construction applications. It incorporates two synchronized hoisting mechanisms located
at each end of the load-bearing structure, ensuring balanced and precise lifting of materials.
This design minimizes the risk of load imbalance and enhances operational efficiency.

2.2 Key Components

 Main Hoist Rope Drum

 Pulley System

 Main Members (Flange and Web)

 Hoist Motors

 Gear Boxes

 Brakes (Electro Hydraulic Thruster and DCEM Shoe)

 Pendant push Bottom

 Limit Switches

 Control Panel

 VVVF Drive

 Dynamic Breaking Resistor

 Line Choke

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3. Technical Specifications

Component Specification
Main Hoist Rope Drum Dia. φ 589 mm Root Dia.
Main Hoist Rope Drum
3672 mm
Length
Pulley 500 Root Dia. (590 mm Dia. OD x 95 mm Thk)

Main Member Fabrication Flange - 25 x 300 x 4982 mm & Web 16 x 850 x 4982 mm

Speed - Main Hoist 0.8 M/Min. / ∼ 4.24 revolutions per minute

Ø 24 mm, 10 Falls, 37 x 7 Un-galvanised Const., steel core,

Main Hoist Wire Rope Powerform 35, Non-rotating type, Tensile Strength - 1960
N/mm², Breaking Load - MBF 531 KN, Usha Martin Make

22.00 Kw, 6 Pole, 40% Cdf, 15 Starts, 970 RPM, Frame –

200L, FLC – 41.2 Amp, SQ. Cage Type, S4 Duty, Foot
Main Hoist Motor
Mounted, Crane Duty, Insulation Class – F-B, Bharat Bijlee
Make

Make - HEBENKRAFT, Size HR - 650+150, Ratio 228.34, Qty.

Main Hoist Gear Box - 1 No., Coupling Input - FGC (Alliance Make) - 103, Output -
DGC-11

- Electro Hydraulic Thruster Brake, Size - 300-18 Kg,

Torque - 42.0 Kg.M., Make - Speed-O-Control, Qty. - 1 No.
Main Hoist Brakes
- DCEM Shoe Brake, Size - 250, Torque - 27.7 Kg.M., Make -
Bhartia Cutler Hammer, Qty. - 1 No.

- Rotary Geared Type, 2 NC Contacts, Ratio - 96:1, 40 Amp.,

500 VAC, IP-54 Enclosure, Make - Speed-O-Control, Qty. - 1
No.
Main Hoist Limit Switches
- Counter Weight Operated Gravity Type Shunt Limit
Switch, 2 NC Contacts, 10 Amp., 500 VAC, IP-54 Enclosure,
Make - Speed-O-Control, Qty. - 1 No.
Control Panel 1200 mm H x 1000 mm W x 350 mm D

VVVF Drive 22 Kw, ATV340 Model, Schneider Make

Dynamic Breaking Resistor 22 Kw, Smisen Make

Line Choke 22 Kw, Smisen Make
4. Operation Instructions

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4.1 Pre-Operation Inspection

Before initiating any operation, perform the following inspections to ensure the hoist
system is in optimal condition:

1. Visual Inspection:
o Check the entire hoist system for any visible damage, wear, or abnormalities.
o Inspect the main hoist rope drum and pulleys for signs of wear or damage.
o Ensure that the main members (flanges and webs) are free from cracks or
deformities.

2. Control Panel Functionality:

o Verify that the push-button control panel is functioning correctly.
o Test all buttons (Up, Down, Emergency Stop) to ensure they respond
appropriately.

3. Wire Rope Inspection:

o Examine the main hoist wire rope (Ø 24 mm) for any signs of fraying,
corrosion, or broken strands.
o Ensure the wire rope is properly lubricated and free from excessive wear.

4. Limit Switches:
o Test the rotary geared limit switch and gravity type shunt limit switch to
confirm they stop the hoist at designated positions.
o Ensure all limit switches are securely mounted and operational.

5. Brakes:
o Inspect both the Electro Hydraulic Thruster Brake and DCEM Shoe Brake for
proper installation and functionality.
o Ensure brakes engage and release smoothly without any delays.

6. Lubrication:
o Confirm that all moving parts, especially the gearboxes and wire ropes, are
adequately lubricated as per the lubrication chart.

7. Safety Devices:
o Ensure that all safety devices, including emergency stop buttons and limit
switches, are in place and operational.

5. Operation of Hoist

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5.1. Control Methods

The hoist system can be operated using two different control methods:

1. Pendant Push-Button Control

2. Radio Remote Control (RRC)

5.1.1 Pendant Push-Button Control

The pendant control station is hardwired to the hoist system and allows the operator to
control the hoist operations with tactile feedback. The pendant includes the following
controls:

 ON Signal: Indicates that the system is powered on and ready for operation.
 Main ON: Activates the hoist for operations.
 Emergency OFF: Immediately cuts power to the hoist in case of an emergency.
 Selector Switch (1 Pole, 2 Way with OFF): Selects the operational mode or
direction of the hoist.
 Selector Switch (2 Pole, 2 Way with OFF): Adjusts the operational speed or mode.
 UP 10% / DOWN 10%: Allows fine control of the hoist's movement with 10%
speed increments.

The pendant control is ideal for precise movements and when the operator is in close
proximity to the hoist system.

5.1.2 Radio Remote Control (RRC)

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The hoist system is also equipped with a Radio Remote Control (RRC) unit, which allows
wireless operation from a distance. The RRC system is designed for enhanced mobility and
safety, giving the operator freedom to move around the workspace.

RRC Specifications:

 Encoding/Decoding: Microprocessor-based technology ensures reliable

communication between the transmitter and receiver.
 Range: Operates at a distance of approximately 100 meters, suitable for large-scale
operations.
 Temperature Range: Functional within a wide temperature range of -35°C to
+80°C, making it robust for various environmental conditions.
 Transmitter Details:
o Buttons: 2 double-step push buttons for UP/DOWN movements and 1 Start
button.
o Power Supply: Operates on 3V, powered by 2 AA alkaline or rechargeable
batteries.
o Size: Compact with dimensions of 130 x 45 x 22 mm.
o Weight: Lightweight at approximately 120 grams.
o Housing: Durable nylon fiber housing for shock absorption and long-lasting
performance.
o Additional Features: Includes LED for self-diagnosis, magnetic security key
for emergency stops, and shock-absorbing elbow guard.
 Receiver Details:
o Power Supply: Compatible with 110/220VAC at 50 Hz.
o Relay Output: Capable of handling 10A/250V.
o Size: 84 x 82 x 48 mm.
o Weight: Approximately 550 grams.
o Housing: Nylon fiber for durability and protection.
o Antenna: External antenna for enhanced signal reception.

The RRC system enhances operational flexibility and safety by allowing the operator to
maintain a safe distance from the hoist while still maintaining full control.

5.2. Switching Between Control Methods

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The hoist system can be operated using either the Pendant Push-Button Control or the RRC.
To switch between control methods, ensure that the hoist is in a safe, non-operational state
and follow these steps:

1. Pendant to RRC: Deactivate the pendant control by turning the selector switch to
OFF, then activate the RRC by pressing the START button on the remote.
2. RRC to Pendant: Power off the RRC by holding down the emergency stop button,
and then activate the pendant control by switching the selector switch to the
desired mode.

Both methods ensure reliable control of the hoist, but the RRC is especially useful when
mobility or distance is a concern.

6. Safety Precautions
Adhering to safety protocols is paramount to prevent accidents and ensure the longevity of the
hoist system. Follow these safety measures diligently:
1. Load Capacity:
o Do not exceed the rated load capacity of 2.0 Tons.
o Always verify the weight of the load before lifting.
2. Operator Training:
o Only trained and authorized personnel should operate the hoist.
o Ensure all operators are familiar with the manual and safety procedures.
3. Personal Protective Equipment (PPE):
o Operators must wear appropriate PPE, including helmets, gloves, and safety
boots.
4. Clear Area:
o Ensure the lifting area is free from unauthorized personnel and obstructions.
o Maintain a safe perimeter around the hoist during operation.
5. Avoid Side Pulling:
o The hoist is designed exclusively for vertical lifting. Side pulling can cause load
imbalance and potential equipment failure.
6. Regular Inspections:
o Conduct daily inspections to identify and address any safety issues promptly.
o Do not operate the hoist if any components are damaged or malfunctioning.
7. Brakes and Limit Switches:
o Ensure that all brakes engage correctly and limit switches function as intended.
o Never bypass safety features.
8. Weather Conditions:
o Avoid operating the hoist in adverse weather conditions such as heavy rain, high
winds, or lightning storms.
9. Emergency Protocols:
o Familiarize all operators with emergency stop procedures and evacuation
routes.

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7. Maintenance Guidelines
Regular maintenance is essential to ensure the safe and efficient operation of the hoist
system. Follow the guidelines below to maintain your hoist in optimal condition.

7.1 Regular Maintenance

7.1.1 Daily Maintenance:

 Visual Inspection:

o Check for any visible signs of wear, damage, or corrosion on all components.
o Ensure that the wire ropes are free from fraying and are properly lubricated.
 Lubrication:

o Lubricate all moving parts as per the lubrication chart provided in Section 8.
o Pay special attention to the gearboxes, pulleys, and wire ropes.
 Brakes and Limit Switches:

o Test the functionality of both Electro Hydraulic Thruster Brake and DCEM
Shoe Brake.
o Verify the operation of all limit switches to ensure they stop the hoist at
designated positions.
 Control Panel:

o Ensure all buttons and indicators on the control panel are functioning
correctly.
o Check for any loose connections or signs of electrical wear.

7.1.2 Weekly Maintenance:

 Wire Rope Tension:

o Inspect and adjust the tension of the main hoist wire ropes to prevent slack
and excessive wear.
 Gearboxes:

o Check the gearboxes for proper lubrication levels.

o Inspect for any unusual noises or vibrations during operation.
 Fasteners:

o Inspect and tighten all bolts and fasteners to ensure structural integrity.

7.2 Annual Maintenance

Comprehensive Inspection:

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 Hoist Machinery:

o Disassemble and thoroughly inspect both hoist mechanisms.

o Replace any worn or damaged parts immediately.
 Electrical Systems:

o Conduct a complete electrical inspection, including wiring, connectors, and

control systems.
o Test all electrical components for functionality and safety compliance.
 Structural Components:

o Inspect the main members (flanges and webs) for any signs of fatigue or
deformation.
o Reinforce or replace structural components as necessary.
 Professional Servicing:

o Engage a certified technician to perform a detailed maintenance check.

o Update any firmware or software in the VVVF Drive if applicable.

8. Troubleshooting
Problem Possible Cause Solution

- Overloaded load - Reduce load to within rated

Hoist Not Lifting capacity
- Motor malfunction - Inspect and repair motor

- Misalignment of hoist ends - Realign hoist machinery

Uneven Lifting
- Uneven load distribution - Ensure load is balanced

- Inspect and replace the push-

- Faulty push-button
Control Panel button control
Unresponsive
- Electrical issues
- Check electrical connections

- Lubricate all moving parts

- Lack of lubrication
Strange Noises During - Tighten all fasteners
- Loose components
Operation
- Inspect and replace worn
- Worn gears
gears

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- Check hydraulic fluid levels

- Hydraulic issues
Brakes Not Engaging
- Inspect electrical
- Electrical faults
connections and components

- Clear any obstructions

- Mechanical obstruction
Limit Switch Failure - Test and repair electrical
- Electrical failure
circuits

9. Lubrication Chart
Proper lubrication is crucial for the smooth operation and longevity of the hoist system.
Follow the lubrication chart below to maintain all moving parts effectively.

Method of Recommended Brand of

Application
Lubrication Lubrication
IOC - Servo Mesh SP 60 or Servo Cy 1
Gear Boxes Splash Circulation C 60
(Helical) (Spray) HP Cyndol TC-140 or Enklo 140
Bharat Engol J77

IOC-Servo Coat-120 for Ambient

Temp. >40°C
Wire Ropes Hand Application
HP-Hytak F-1500
Bharat-Camex Compound-D

IOC Servogem Grease-2

Drum Pedestal Pack / Grease HP-Lithon 2
Bharat-MP Grease-2

IOC Servogem Grease-2

Anti-Friction Bearings Pack / Grease HP-Lithon 2
Bharat-MP Grease-2

IOC Servo Coat 120 for Ambient

Temp. <40°C
IOC Servo Coat 140 for Ambient
Brakes IInd Application
Temp. >40°C
HP Hytak F-1500
Bharat-Campex Compound D

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Lithium base grease IOC Servogen-3

Electric Motors Grease Charge HP Lithon-3
Bharat MP Greases

Notes:

 IOC: Indian Oil Corporation Limited

 HP: Hindustan Petroleum Corporation Limited
 Bharat: Bharat Refineries Limited

10. Company Information & Acknowledgment

About HEBENKRAFT
Founded in 1986, HEBENKRAFT has established itself as a leader in the design and manufacturing
of material handling equipment. With decades of experience, our professional engineers have crafted
solutions that meet the rigorous demands of industrial environments. Our product portfolio includes:
 E.O.T Cranes
 Jib Cranes
 Portal & Semi Portal Cranes
 Ship Unloaders
 Bucket Wheels
 Grab Buckets
 Winches
 Capstans
 Ladle Transfer Cars
 Scrap Transfer Cars
 Hoist Blocks
 Steel Mill Equipment

At HEBENKRAFT, we pride ourselves on delivering durable, reliable, and low-maintenance

products, tailored to meet your specific operational needs. Our commitment to quality and innovation
ensures that each piece of equipment is built to the highest standards.

Thank You
We thank you for purchasing a HEBENKRAFT Hoist Block. Your hoist has been meticulously
designed with your maintenance requirements in mind, by a team of engineers who bring extensive
experience in material handling equipment design and manufacturing.
With HEBENKRAFT, you are not just buying equipment; you are investing in the assurance of
quality, reliability, and exceptional customer support.

Contact Us
For any support, queries, or further information about our products and services, please do not
hesitate to contact us:

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HEBENKRAFT
Address Line 1 - Office: A‐215, Omega Business Park, Near Kamgar Hospital Naka,
Wagle Estate, Thane (W)‐400604
Address Line 2 - Factory: A‐29, Anand Nagar, MIDC, Additional Ambernath,
Maharashtra – 421506
Phone: 09323035598 / 9323439686
Email: [email protected] ; [email protected]
Website: www.hebenkraft.com

We look forward to continuing to serve your material handling needs with the quality and care that
HEBENKRAFT has been known for since 1986.

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