DIY telfer gearbox repair

In detail: do-it-yourself repair of the telfer gearbox from a real master for the site my.housecope.com.

The most popular and easy to install and operate device for lifting loads is an electric hoist. Let's consider its device on the example of modern telphers of the MH series produced by Balkancarpodem. General telfer scheme shown in the picture above.

Basic electrical diagrams of the hoist can be found here

The mechanical equipment of the MH electric hoist includes such important structural elements and assembly units as lifting drum, gearbox, coupling, hook suspension, undercarriage, load rope.

Asynchronous two-speed electric motor with tapered rotor and stator and built-in asbestos-free cone brake. The rotor has the ability to move with less resistance in the axial direction. In the event of a power failure, the brake is applied by the force of the coil spring. The wide range of possible combinations between motors and gearboxes with different specifications expands the range of lifting loads and lifting speeds. Additionally, hoists are supplied with two-speed motors - with two stator windings (for working speed and for precise positioning of the load). Another delivery option is with frequency converters for maximum smooth starting and braking of drives.

A two-stage planetary gearbox mounted on the opposite side of the electric motor. This design was preferred due to the need to provide the telpher with compactness in the radial direction. Three stages of the gearbox provide reduction (reduction) of engine speed, as well as smooth starting and braking. High quality materials are used for the manufacture of gear wheels and other gearbox elements. The surfaces of the teeth of the gear wheels are subjected to carburizing and hardening, followed by grinding, which ensures a long service life and quiet operation of the gear wheels with a high efficiency of the gearbox. The extended kinematic chain of transmission of engine torque to the drum reduces dynamic loads during the operation of the electric hoist.

Video (click to play).

The new body is box-shaped. Represents a tightly welded structure such as a flange connection between the motor and the gearbox. The exit of the rope in all possible radial directions along the periphery of the body ensures the operation of the electric hoist in various mounting options and positions.

A special gearbox clutch is used, located inside the drum between the motor shaft and the gearbox shaft. The elastic bag absorbs the peak torque components. The design of the coupling ensures unhindered axial movement of the motor shaft. At the same time, it protects the shafts from any radial or tangential movements. This specificity is due to the fact that the rotor of the lifting electric motor is conical. When the drive is turned on, such a rotor extends along the axis, disengaging from the stator, and when it is turned off, it is pulled back. Thus, the motor itself is already able to brake the drive during standstill, that is, it has a built-in brake. The kinematic connection of the gearbox with the electric motor is non-breaking.

The lifting drum is a cylindrical hollow structure designed for winding a load rope. The surface of the drum is covered with special grooves - "streams", thanks to which the cargo rope is wound in even rows, without overlaps and creases.Together with the rope, the rope-laying device moves on the drum - a device that is necessary not so much for laying the rope in the streams, but for turning on and off the limit switches for over-lifting and over-descent.

On the surface of the drum, helical channels for the rope are made. A special rope wrapping moves in these channels and ensures correct winding and unwinding of the rope, regardless of the size of the suspended load. The drum has two diaphragms. One of them is mounted on the front flange of the electric motor using a roller bearing. The torque of the outgoing hollow shaft of the gearbox is transmitted to the second diaphragm via a splined connection.

New design. No special tools are required to replace the rope tie. The limits of the deviation of the rope to the side to the engine or to the gearbox are ± 4 °. The wire rope activates the switch for the extreme upper and lower positions of the hook.

The MH electric hoist uses a Bulgarian-made metal rope as a load rope. The most common rope storage provides for rigid termination of one end of it on the body of the hoist and clamping of the other end on one edge of the lifting drum. In this case, the load rope itself is thrown through the hook block. This reserving prevents damage to the rope and extends its service life. One end of the rope is fixed to the drum with cable ties. The other end is attached to the body of the hoist, or to the body of the hook or to the drum first, depending on how the load is suspended. The technical characteristics of the rope provide the necessary reliability and minimal wear of the rope itself and the drum channels.

Hook included: a new design that, together with the chain hoist, meets modern technical safety requirements. Operation is facilitated by the minimum dead weight of the hook. There is a reliable protection against arbitrary exit of the rope from the channels of the rope rollers. Hook suspension contains a freely rotating rope block in a metal casing that prevents the rope from falling off. The load hook itself also rotates freely in both directions for the convenience of slinging work.

Three types of trolleys are offered: type N, type K and type D... Electric hoist bodies are attached to them in such a way that optimal distribution of the load on all wheels is ensured. The wheels are designed to move the hoist along the flanges of the I-beam. Carts can also be electric (EK), manual (RK) or free (SK). The electric trolley has a propulsion mechanism of the same type as the lifting mechanism. A normal motor mechanism with an electromagnetic brake is also proposed. The range of travel speeds of the trolleys is very wide. Installation and adjustment of bogies in relation to the profile of the monorail is carried out infinitely. If a double-rail bogie is ordered, the track width and rail dimensions are specified by the customer. Some electric hoists, which are large in axial direction, are equipped with two bogies.

Hoist electrical equipment includes hoist motors, travel motors, pendant control, starter cabinet, limit switch block, brake coil and capacity limiter. The coil and limiter, depending on the configuration, may be missing. The design of the hoist's electrical equipment can be special, for example, for operation in a chemically aggressive environment or in a tropical climate.

The voltage and frequency of the electrical network are supplied by the customer. Operating voltage to the relay and contactor coil - 42 V, frequency -50 Hz. Most of the electrical equipment is located in the command box, which is mainly attached to the body of the hoist. The limit switch for lifting and lowering the load is located in the motor terminal block.

Push-button pendant control has a degree of protection IP65 and can be four-button or six-button for operation as part of an overhead crane. The panel contains a key-mark to exclude unauthorized access to the control of the mechanism, as well as a "mushroom" button for emergency shutdown of the drives. For hoists with two-speed electric drives, the control panel can have two-position buttons (pushers) or a larger number of buttons - up to 12 pieces.

Protected Launcher contains reversible electromagnetic starters for switching on drives, a rectifier for supplying the brake coil (if any), terminal blocks for connections, an electronic unit for a load limiter (if any) and a control circuit transformer 380/42. The starters are DIN rail mounted, but they are not available when controlling frequency converters.

Limit switch contacts lifting and lowering are installed in the terminal box of the lifting motor. The mechanical connection with the rope-laying device is provided by a special traction, on which adjusting crackers are installed.

Braking solenoid coil The MH hoist provides braking of the hoist drive along with the tapered rotor. It is powered by direct current from a rectifier in the starting cabinet.

The capacity limiter for MH electric hoists is available on request. It is electromechanical, and its design is simple and reliable. In the event of an overload, the limiter breaks its contacts in the lifting control circuit and then only lowering is possible. The lifting capacity is adjusted mechanically with a special adjusting screw.

Repair of the gearbox of the electric hoist, telpher "Locksmith's Care" Barnaul

You can contact us by following the link in the channel header.

The black color is most likely nigrol. It was he who was poured when he worked in a similar production

how to remove the electric motor from the frame t33 511

The hardest part of this is to mount the gearbox in place, it is very difficult to get into the splines the first time.

Hello, tell me. There is a crackle from the hoist reducer, and only on the "lane", on the "vira" - everything is fine. In the inspection hatch you can see that the ratchet dog with obvious traces is either work hardened or scored. How to treat. And what to prepare for? What to remove the gearbox is already clear 😉

The reasons turned out to be several: 1 - inside the gearbox housing, the retainer limiting the travel of the ratchet is broken, 2 - the load brake itself (pin) is jammed, 3 - well, and the ratchet pawl is licked that part that should engage with the wheel. Video helped

you would better tell about the work of the load-resistant brake, and if it is advisable to rinse it all with kerosene before troubleshooting the mechanisms, at the same time it didn’t interfere with rinsing the body, as there may be old mechanical shavings left there, and no credit video.

The load brake is an interesting thing. It works due to the frictional force of the brake linings that are attached to the ratchet wheel. Which are pressed by two discs. Works only on the lane, On the "vira" is the opening (departure) of the discs from the ratchet wheel.

Sveta Sokolov, to press the pads, unscrew the two opposite bolts equally a little, thereby the pads will be closer to the pulley, if there is a need to tighten the spring

Telphers, or in other words, electric hoists, are indispensable helpers when lifting and transporting heavy loads at a variety of sites: from very large warehouses and logistics centers to large-scale construction sites.And therefore, the failure of such equipment can seriously interfere with the well-functioning work of the entire enterprise. What should be done to avoid possible risks of breakdowns of such hoists, how to properly maintain them, and what kind of hoist repairs does it take? All about this - read in this material.

Surely anyone who has worked a little with the telfer will confirm how much it simplifies the movement of large, heavy luggage around the territory. The delivery of cargo from one point on the object to another is carried out as quickly as possible in comparison with conventional fork carts or stackers, the operation is very simple, and the electric hoist itself does not take up such a valuable area, being literally suspended above the working platform (it is important that its installation can be organized both indoors and outdoors). But, like any medal, there is a downside.

Although the telfer gives the impression of a simple mechanism, it is still a rather complex device, consisting of many different nodes and blocks. Therefore, there are many places that can cause certain problems during operation. Of course, it all depends on the specific model: serious and well-known manufacturers with quality and reliability have an order of magnitude fewer problems than non-name products from China. However, in general, it is still possible to single out the most important objects of attention from the point of view of future repairs, which most often require replacement or repair:

natural wear of bushings, bearings and various shafts of the hoist;
problems with the cable layer and mechanical breakage of the drum;
failures in the electronic control units of the telfer and the remote control;
interruptions in the operation of the electric motor and burnout of its winding;
wear and malfunction of the brake system as a whole or its parts.

Therefore, if during operation you notice the absence of rotation of the electric motor or drum (with the engine running), arbitrary unwinding of the cable or chain, jamming of the gearbox or brake mechanism, as well as any uncharacteristic extraneous sounds and vibrations in the forklift, not to mention smoke or sparks , urgently seek help from a specialized workshop that offers the repair of hoists and telphers. But keep in mind: attempts to repair yourself can lead to more serious damage - therefore, it is better to immediately entrust this to experienced qualified specialists.

Although, of course, a more correct approach is to organize such operation of the hoist, in which repair can, if not be avoided, then reduce the need for it to a minimum. Moreover, there are no special difficulties and secrets in this matter. The most important thing: this is correct and competent maintenance, as well as careful, accurate and safety-relevant handling when working with such a device (and it, we recall, carries an increased danger for both equipment and people).

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Let's start with scheduled service. On the one hand, the frequency of inspection with diagnostics and replacement of consumables must be determined based on the specific operating conditions of the hoist at the enterprise (you can often come across the opinion that this should be done every 60-70 machine hours). On the other hand, experts say that even with an average load of the lift, it is hardly worth doing this less often than once a month. What should such a service include? The list of exemplary works can be roughly divided into several of the following areas:

wiring: assessment of the insulation condition of all wiring and the reliability of grounding, the operation of current supply buses, magnetic starters, limit switches, current collectors and various security systems;
engine: quality of start-up, stability of operation of the electric motor, gearbox and control electronics (including the push-button panel), absence of breakdowns in the motor winding, etc .;
hoist: checking its cleanliness, the presence of the necessary lubrication, assessing the condition and performance of the rope-laying device, gear transmission, hook suspension (including its mobility during rotation), as well as brakes;
fastenings: study of the reliability of the mechanical part of the telphers in the form of tightening bolts, contact connections, assessing the condition of spring washers and cotter pins with stoppers, fastening a cargo rope, hook and others.

If any problems are found in any of the described nodes, it is necessary to carry out high-quality and, most importantly, urgent repairs. This will avoid serious damage to the hoist - and, accordingly, save a lot of time and money in the future, as well as postpone the need for overhaul (as experience shows, it is required after 3.5-4 thousand machine hours).

As for the aforementioned careful operation, everything in this matter is quite simple and accessible. An approximate list of such conditions for the trouble-free operation of an electric hoist during the entire service life prescribed by its manufacturer consists of the following recommendations:

do not exceed the maximum passport carrying capacity of the hoist;
do not use the device in an unsuitable mode or temperature;
do not lift fixed, frozen or ground loads;
do not drag the load on the ground (be sure to raise it to a height);
do not allow sudden accelerations, decelerations and changes in direction of movement;
do not use the hoist if the chain, rope or hook is damaged;
do not move loads if you find problems with brakes and stoppers;
do not press the opposite buttons on the control panel;
do not turn on the hoist when the electrical equipment cabinet is open;
do not use the limit switch as a work switch;
do not leave the suspended load for a long time (overnight).

All of the above is the basis not only for the durability of the electric hoist itself, but also a guarantee of safety at the facility. After all, non-observance of the described operating standards can lead not only to breakdown and further repair of the hoist, but also, at least, to serious injury to people. Therefore, make sure that the operators of the device comply with all the instructions and regularly, every few months, undergo re-certification of their qualifications for admission to work with such equipment.

DEVICE OF MAIN UNITS

Electric hoists TE320 are manufactured in two versions:

1) for a curved path (Figure 1);
2) for a straight path (Figure 2).

Electric hoists are manufactured with a longitudinal arrangement of the drum relative to the monorail track.

The hoist for a curved path (Figure 1) consists of a lifting mechanism 1 with a hook suspension 2 and a movement mechanism 3, connected by a shackle 4 and a traverse 5.

The hoist for a straight track consists of a lifting mechanism 1 with a hook suspension 2 and a movement mechanism. For a hoist (Figure 2, a) with a lifting height of 6 and 12 m, the movement mechanism consists of a drive trolley 3, connected to a hoist: an arm 5. For a hoist (Figure 2, b) with a lifting height of 18, 24, 30, 36 m, the mechanism movement consists of a driven trolley 3 and a non-driven trolley 4,;: equipped with hoists 5 and 7.

T als with a micro drive, in addition to this, have a micro drive unit 6 and a unit 3), which, along with the main speed, provides a low speed of lifting and lowering the load.

Figure 1 - General view of TE 320 electric hoists for a curved track

Figure 2 - General view of TE electric hoists for a straight track: a) with a lifting height of 6, 12 m.

Figure 3 - General view of the microdrive attachment

The lifting mechanism (Figures 4 and 5) consists of a drum motor 1, a two-stage gearbox 2, an electrical equipment cabinet 3 and a housing 4, which connects all nodes of the lifting mechanism.

The kinematic diagram of the lifting mechanism is shown in Figures 6 and 7. An electric lifting motor is built into the drum.

On the outer surface of the drum motor, a helical groove is cut, onto which the rolling rope is wound and along which the rope layer moves at the hoists with a rope-laying device. The length of the drum was chosen in such a way that when the rpuz was raised to the nominal height, 1.5 - 2.0 free turns of the groove remained in front of the rope guide, and when the rp was lowered to full height, 1.5 - 2.0 turns of uncoiled rope remained on the drum.

The rope is fixed in the annular groove of the right flange of the drum motor with three locking screws (Figure 8). The second ROP of the rope is fixed with a wedge on the body of the lifting mechanism (Figure 13).

Before installing them on the hoist, the ends of the cutting ropes must be prepared in accordance with Figure 9.

The hoist gear reducer has a two-stage spur gear transmission, a shoe brake on the input shaft and a pressure-resistant brake on the intermediate shaft.

Lifting mechanism for TE hoist

Fastening the rope to the drum.

On the finger, fixed in the gear housing, there is a pawl 4, which, turning on the axis, enters or disengages from the ratchet wheel.

When lowering the load, the pawl, resting on the teeth of the ratchet wheel, locks the entire system and does not allow the load to fall. When the electric motor is turned on for descent, the gear wheel moves to the right, and the load begins to descend at an accelerated rate, and the load brake is again turned on. After repeating several such cycles, a smooth and continuous sliding of the rubbing surfaces is established and the load is lowered at a constant speed.

When lifting a load, although the ratchet wheel is clamped, braking does not occur, since the pawl is disengaged from the ratchet.

The entry and exit of the pawl from the engagement with the ratchet is carried out due to the friction force arising under the action of the spring located inside the caps placed in the pawl boss. The axial rotation of the pawl when disengaging from the ratchet is limited by a special stop.

The operability of the load brake is checked with a raised load equal to 1.1 times the rated load and the shoe brake is disengaged. When the load is lifted and braked by both brakes, with the effort of the hands and lift the shoe brake lever up so that the armature of the electromagnet enters the yoke all the way. In this case, the shoe brake is released and the load is held only by the load brake. Spontaneous lowering of the load is not allowed.

The rope-laying device (Figure 12) is an annular device covering the drum, assembled from four sectors 2 and 1, fastened with special strips. The inner surface of the sectors is rounded and fits into the helical groove of the drum. Sector 1 of the UST'd rope-laying device is updated between the flanges of the welded body, which excludes the rotation of the ring device during operation. On sector 1, a guide bar 5 and a roller 3 are mounted.notnaya spring 4. Load rope 6 passes between the sector and the guide bar for the spring, which presses it against the groove of the drum. When the lifting mechanism is operating, the rope-layer moves along the drum, placing the rope in the groove or freeing it.

Hook suspension

Hook hanger (Figures 14 and 15) - single-block, open type. It consists of 2 jaws 1, block 2 with an axis 3, a hook 4 with a safety lock 5 and a traverse 6.

The block and hook supports in the suspension are made on ball bearings, which ensures their easy rotation.