MRO Today - Lift equipment deserves attention

Lift equipment deserves attention

You can expect decades of service from well-maintained lifts, hoists and cranes, but when it’s time to replace them, new features make operation and maintenance easier.

by Kay Falk

Do you have an old noisy, balky hoist in your manufacturing facility? Or an industrial lift with fraying wire rope or damaged chain? Are wires exposed in the pendant pushbutton station?

If you answered yes to any of these questions, it’s time to maintain that lift or hoist, or possibly replace it. To learn more, MRO Today talked with leading manufacturers in the field.

Get long life
“A well-maintained hoist will last for many years,” Joe Ingle, North American sales manager for R&M Materials Handling, says. “The safe working period should be based on 10 years of service. After 10 years, the unit should undergo a complete teardown inspection and overhaul, if needed.”

Mike James, vice president industrial cranes and distribution for Morris Material Handling, supplier of P&H hoist and overhead crane equipment, agrees. “This type of industrial equipment should last a minimum of 10 years. Of course life varies by brand and maintenance techniques, but many P&H hoists are still in service after 50 years or more.”

Dana Andrews, vice president of industrial cranes in the United States for Konecranes, points out, “Wear items will require regular replacement, depending on application, but with proper maintenance you can expect 20 years of service from powered lifts, hoists and cranes.”

According to these experts, the biggest mistake maintenance people make with lift equipment is ignoring it. “If routine preventive maintenance is performed and wear measurements are recorded, major repairs can be delayed,” Ingle says. “When a repair is needed, you can plan in advance, assure safety and experience minimal production delays.”

A lack of required inspections and the failure to remedy defects noted on inspection reports in a timely fashion can cause unexpected downtime, James notes. “Other mistakes we run into are improper (or a lack of) lubrication and allowing improper operation, which would include side pulling or lifting items over the hoist’s capacity,” he adds.

Andrews adds, “Most common mistakes we see are wiring related and, if ignored, this can cause component failure.”

To see what these men recommend to include in preventive maintenance, check out the Lift PMs section.

Time for new
Even with a good maintenance program, cranes, hoists and other lifting equipment eventually wear out or do not fit your current manufacturing needs for load capacities and/or duty cycles. The major sign that it’s time to replace or upgrade your industrial lift is when repairs become frequent and expenses rise.

“When the maintenance costs become excessive, you have accidents or frequent ‘surprise’ breakdowns, it’s time for new lift equipment,” James says.

Andrews agrees, adding, “When the replacement cost equals 50% of your annual maintenance cost, you can easily justify a new model, and you’ll probably see a two-year payback!”

What to look for
There are certain details to have on hand when you go shopping for a new crane or hoist so you can match the equipment to your application. These include:

the number of daily production shifts and hours per shift
the lifting cycles per hour required (one cycle = lift, transport and lower)
the average weight of the loads handled
if there’s a below-the-hook lifting device, how much it weighs
the required lifting height per hoisting cycle and the maximum lifting height, as well as clearance restrictions or other building obstacles
needed lifting speed
your operators’ preference for control type (single-, two- or variable-speed, pendant control, radio remote)
if there are any unusual ambient requirements, as well as the usual ambient temperature and working environment.

Get references
A good distributor will want to know this information and will also “perform an analysis of your requirements to determine the best equipment for the job,” Ingle says. “In your discussion, be sure to ask if the hoist manufacturer is a member of the Hoist Manufacturers Institute. HMI is an organization of all of the major hoist manufacturers who have engineering expertise in this field.”

James adds, “Ask for references from other satisfied customers, and then call them. You can get an idea of the supplier’s reputation and find out if reality and after-sales service agree with that reputation. It’s also a good idea to visit the manufacturer’s plant, if possible.” He also recommends reviewing either first-hand photos or visiting plants in your area with similar applications.

Apples to apples
“When you are comparing equipment features and specifications, be sure to ask about speeds, horsepower and construction details so you can accurately compare models,” he adds.

“Another point to remember is that some suppliers focus on specific industries. Choose from suppliers with experience in your industry.”

In addition to what’s already been suggested, Andrews says, “Don’t forget to ask about warranty period, the pricing and availability of replacement parts, and the nearest service location. The financial strength of the company is also important. Given the life you can expect from lift equipment, you want a supplier who can sustain a long-term relationship.”

Ingle points out that planning and a solid project specification are the keys to making a successful purchase. “R&M has put together a comprehensive hoist specification which is posted on our Web site: www.rmhoist.com. It’s available for anyone to use to develop a project specification. More information on Konocranes can be found at www.konecranes.com. For P&H cranes, visit www.phmining.com.

What’s new? A lot.
It may seem that overhead cranes, lifts and hoists don’t change much, but these manufacturers say there are new features to check out.

Andrews points to electronic overload protection, slack rope detection, anti-sway load movement alarms and crane data recording for predictable scheduled maintenance as types of new features.

“Today’s standard in powered wire rope hoists and cranes is an adjustable frequency control,” James says. “As a minimum these controls should be used on trolley and bridge (traversing) motions. Hoists with straight two-speed magnetic controls can offer a good compromise between initial cost and control compared to an adjustable frequency control on the hoist motion.”

He points to Morris’ new P&H G-series Hoist and Crane Select Plus standard industrial crane line as an example of new features previously considered optional extras, such as overload limit switches, redundant hoist upper travel limit switches and heavy-duty cast-iron rope guides. “These models have all gears, including driven wheels on trolleys and bridges, totally enclosed to retain lubricants,” James notes. “Their brakes are totally enclosed and NEMA 4/IP66 rated to keep out contaminants. They also have trolley and bridge travel limit switches.”

Ingle emphasizes that controls have really been improved. “The R&M Hoist Monitor System, for example, can be added to our Spacemaster SX hoist controls to assist in the safe operation, maintenance and performance of the hoist,” he says. “It constantly monitors and records selected functions from overload protection to number of hoist starts. You can record hours of hoist run time and count hoist cycles, calculate the mean load and see brake safe working period percentage. The Hoist Monitor functions allow for more efficient planning and scheduling of preventative maintenance and repairs.”

Lift PMs: What to check
Manufacturers recommend you follow the operation and maintenance manual instructions when you establish a good lift equipment PM program. If that manual is long gone, contact the manufacturer for a replacement, and be sure to include these in your PMs:

wire rope inspections to make sure the rope is not kinked, frayed or showing signs of wear or assessment of the chains for wear,
a set lubrication interval
load-bearing component check (wheels, drum and sheaves)
a travel limit switch function test, especially the hoist’s upper one
pendant pushbutton station check to look for exposed wiring
brake function test and inspection.

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