JET 1SS-1C-10, 1SS-1C-15, 1SS-1C-20, 1/2SS-1C-15, 1/2SS-1C-20 Operating Instructions and Parts Manual

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Operating Instructions and Parts Manual

Electric Hoist

Models SS-1C, SS-3C

WALTER M EIE R (Manufac turing) Inc.

Warranty and Service

Walter Meier (Manufacturing) Inc., warrants every product it sells. If one of our tools needs service or repair, one of our Authorized Service Centers located throughout the United States can give you quick service. In most cases, any of these Walter Meier Authorized Service Centers can authorize warranty repair, assist you in obtaining parts, or

perform routine maintenance and major repair on your JET your area call 1-800-274-6848.

MORE INFORMATION

Walter Meier is consistently adding new products to the line. For complete, up-to-date product information, check with your local Walter Meier distributor, or visit waltermeier.com.

WARRANTY

JET products carry a limited warranty which varies in duration based upon the product (MW = Metalworking, WW = Woodworking).

WHAT IS COVERED?

This warranty covers any defects in workmanship or materials subject to the exceptions stated below. Cutting tools, abrasives and other consumables are excluded from warranty coverage.

WHO IS COVERED?

This warranty covers only the initial purchaser of the product.

WHAT IS THE PERIOD OF COVERAGE?

The general JET warranty lasts for the time period specified in the product literature of each product.

WHAT IS NOT COVERED?

Five Year Warranties do not cover woodworking (WW) products used for commercial, industrial or educational purposes. Woodworking products with Five Year Warranties that are used for commercial, industrial or education purposes revert to a One Year Warranty. This warranty does not cover defects due directly or indirectly to misuse, abuse, negligence or accidents, normal wear-and-tear, improper repair or alterations, or lack of maintenance.

HOW TO GET SERVICE

The product or part must be returned for examination, postage prepaid, to a location designated by us. For the name of the location nearest you, please call 1-800-274-6848.

You must provide proof of initial purchase date and an explanation of the complaint must accompany the merchandise. If our inspection discloses a defect, we will repair or replace the product, or refund the purchase price, at our option. We will return the repaired product or replacement at our expense unless it is determined by us that there is no defect, or that the defect resulted from causes not within the scope of our warranty in which case we will, at your direction, dispose of or return the product. In the event you choose to have the product returned, you will be responsible for the shipping and handling costs of the return.

HOW STATE LAW APPLIES

This warranty gives you specific legal rights; you may also have other rights which vary from state to state.

LIMITATIONS ON THIS WARRANTY

WALTER MEIER (MANUFACTURING) INC., LIMITS ALL IMPLIED WARRANTIES TO THE PERIOD OF THE LIMITED WARRANTY FOR EACH PRODUCT. EXCEPT AS STATED HEREIN, ANY IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS ARE EXCLUDED. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG THE IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

WALTER MEIER SHALL IN NO EVENT BE LIABLE FOR DEATH, INJURIES TO PERSONS OR PROPERTY, OR FOR INCIDENTAL, CONTINGENT, SPECI AL, OR CONSEQUENTIAL DAMAGES ARISING FROM THE USE OF OUR PRODUCTS. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU.

Walter Meier sells through distributors only. The specifications in Walter Meier catalogs are given as general information and are not binding. Members of Walter Meier reserve the right to effect at any time, without prior notice, those alterations to parts, fittings, and accessory equipment which they may deem necessary for any reason

whatsoever. JET

branded products are not sold in Canada by Walter Meier.

tools. For the name of an Authorized Service Center in

Warranty and Service ............................................................................................................................................ 2

Table of Contents .................................................................................................................................................. 3

Warning ................................................................................................................................................................. 4

Introduction ........................................................................................................................................................... 5

Description ............................................................................................................................................................ 5

Specifications – Single Phase ............................................................................................................................... 6

Specifications – Three Phase ............................................................................................................................... 7

Unpacking ............................................................................................................................................................. 8

Contents of the Shipping Container ............................................................................................ ...................... 8

Installation ............................................................................................................................................................. 8

Installing Top Hook ............................................................................................................................................ 8

Installing Power and Pendant Cords ................................................................................................................. 8

Electrical Instructions ........................................................................................................................................ 9

Installing Chain Container ............................................................................................................................... 10

Pre-Operation Inspection .................................................................................................................................... 11

Inspecting the Load Chain ............................................................................................................................... 11

Inspecting the Hooks ....................................................................................................................................... 12

Operating the Hoist ............................................................................................................................................. 12

Adjustments ........................................................................................................................................................ 13

Safety Clutch Adjus tment ................................................................................................................................ 13

Replacing Load Chain ..................................................................................................................................... 14

Brake Adjustment ............................................................................................................................................ 16

Inspection Schedule A ..................................................................................................................................... 17

Inspection Schedule B ..................................................................................................................................... 17

Inspection Procedures: Allowable Limits ............................................................................................................. 18

Load Chain ...................................................................................................................................................... 18

Hooks (Top and Bottom) ................................................................................................................................. 18

Brake Friction Pad ........................................................................................................................................... 19

Chain Container Chart for Standard or Custom Lifts .......................................................................................... 19

Troubleshooting .................................................................................................................................................. 20

Replacement Parts .............................................................................................................................................. 21

Power Cord Assembly ..................................................................................................................................... 21

Control Pendant Assembly .............................................................................................................................. 22

1/2-Ton, 1-Ton and 2-Ton Chain Hoists .......................................................................................................... 23

Parts List: 1/2-Ton Chain Hoist ...................................................................................................................... 24

Parts List: 1-Ton and 2-Ton Ch ain Hoists ...................................................................................................... 27

3-Ton Chain Hoist ........................................................................................................................................... 30

Parts List: 3-Ton Chain Hoist ................................................................................................ ......................... 31

5-Ton Chain Hoist ........................................................................................................................................... 34

Parts List: 5-Ton Chain Hoist ................................................................................................ ......................... 35

Hook Assemblies (1/2-Ton , 1-Ton and 2- Ton) ................................................................................................ 38

Parts List: Hook Assemblies (1/2-Ton only) ................................................................................................... 39

Parts List: Hook Assemblies (1-Ton only) ...................................................................................................... 39

Parts List: Hook Assemblies (2-Ton only) ...................................................................................................... 40

Hook Assemblies (3-Ton only) ........................................................................................................................ 41

Parts List: Hook Assemblies (3-Ton only) ...................................................................................................... 42

Parts List: Hook Assemblies (5-Ton only) ...................................................................................................... 43

Parts List: Hook Assemblies (5-Ton only) ...................................................................................................... 44

Electrical Connections: Single Phase On ly ..................................................................................................... 45

Electrical Connections: 3-Phase, Single Speed Only ...................................................................................... 46

Warning

1. Read and understand the entire owner’s manual before attempting assembly or operation.

2. Read and understand the warnings posted on the machine and in this manual. Failure to com ply with all of

these warnings may cause serious injury.

3. Replace the warning labels if they become obscured or removed.

4. This chain hoist is designed and intended for use by properly trained and experienced personnel only. If

you are not familiar with the proper and safe operation of a chain hoist, do not use until proper training and knowledge have been obtained.

5. Do not use this chain hoist for other than its intended use. If used for other purposes, Walter Meier

(Manufacturing) Inc., disclaims any real or impl ied warranty and holds itself harmless f rom any injury that may result from that use.

6. Do not install this chain hoist where explosive hazards may exi st.

7. Give your work undivided attention. Looking around, carrying on a conversation and “horse-play” are

careless acts that can result in serious injury.

8. Do not use to lift people, or loads over people. Warn others in the vicinity when lifting or transporti ng a

load. Avoid swinging load and hook.

9. Do not exceed the rated capacity of the chain hoist.

10. Make sure limit switches are operating properly. Do not use limit switches as routine operating stops; they

are emergency devices only.

11. Do not use the load chain as a sling; this may cause damage to the chain.

12. Maintain firm footing when operating the hoist.

13. Always inspect the chain hoist for damage prior to use. Do not use a chain hoist wit h twisted, kinked, worn

or otherwise damaged chain. If the chain hoist is damaged, do not use until it has been repaired or replaced.

14. D o not use more than one chain hoist to lift or move a load. If this is unavoidable, each c hain ho ist m us t

have the same capacity as the load to be moved.

15. Never allow the load chain to “set” over sharp edges. All lifts must be made with straight chain that is free

of obstacles.

16. Do not use a chain hoist unless load is centered between top and bottom hooks.

17. Protect load chain from weld splatter and other contaminants. Do not allow the hook or chain to be

contacted by a live welding electrode.

18. Always take time to study the job to be perform ed and choose the safest m ethod. Do not place yourself or

other people in an unsafe position.

19. Leave all internal maintenance to a qualified Walter Meier service center.

20. Replace the chain with factory replacement chain only. Do not use any other type of chain.

21. Never use the chain hoi st if either hook is stretched, deform ed, or has a broken or missing safety latch.

Always replace the safety latch and/or the hook before placing the chain hoist back into service.

22. Do not operate this hoist while tired or under the influence of drugs, alcohol or any medication.

23. Understand and follow all procedures as set forth in American National Standards titled “Performance

Standard for Hand Chain Manually Operated Chain Hoists.” ANSI/ASME HST-2M. This standard is available through the American Society of Mechanical Engineers, www.asme.org.

Familiarize yourself with the following safety notices used in this manual:

This means that if precautions are not heeded, it may result in mi nor i nj ur y and/or

possible machine damage.

This means that if precautions are not heeded, it may result in serious injury or possibly

even death.

Introduction

This manual is provided by Walter Meier (Manufacturing) Inc., covering the safe operation and maintenance procedures for a JET Electric Chain Hoist. This manual contains instructions on installation, safety precautions, general operating procedures, maintenance instructions and parts breakdown. This machine has been designed and constructed to provide years of trouble-free operation if used in accordance with instr uctions set forth in this manual. If there are any questions or comments, please contact either your local suppl ier or Walter Meier. Walter Meier can also be reached at our web site: www.waltermeier.com.

Description

JET electric chain hoist models SS-1C and SS-3C are available in a variety of voltages and lifting and traversing configurations. Model SS-1C features single lift speed, 115/230V 60Hz single-phase power requirement. Model SS-3C features single lift speed, 230/460V three-phase power requirement.

The SS-series chain hoists comply with OSHA and ANSI/ASME B30.16 and HST-1 standards. All chain hoists are available in custom configurations to meet your specifications. Contact your dealer or

Walter Meier for more information.

Record your purchase information here for quick reference:

Model No.: Stock No.: Serial No.: Purchased From : Date Purchased: Date Installed: Installer:

Specifications – Single Phase

Available in 10’, 15’ and 20’ lifts.

Load (mm)

8x24

Net Wt.

(lbs.)

149.91

A B C D E F Hmin.

4.67

20.43 11.16

11.81

5.28

24.41

10.96

Rated

Model

1/2SS-1C 1/2 19.70 20.16

1SS-1C 1 19.70 24.41 2SS-1C 2 9.80 28.15 2 156.53 5.18 4.43 28.15 3SS-1C 3 6.60 31.5 3 213.85 5.71 6.38 31.50 5SS-1C 5 4.90 30.71 4 220.46 6.57 8.25 30.71

Cap’y

(ton)

Hoisting

Speed

(f/min.)

Headroom

(in.)

Motor

.87HP,

115/230

V 60Hz

1.74HP, 115/230

V 60Hz

Duty

Cycle

Rating

(25%)*

No. of

Chain

Falls

1 6.3x19 102.5 17.72 9.84 4.09 10.24 4.43 9.45 20.16

* 25% duty cycle = 12 minutes continuous in 1 hour; or 1 minute on, 4 minutes off.

The above specifications were current at the time this manual was published, but because of our policy of continuous improvement, Walter Meier (Manuf acturing) Inc., reserves the right to change specificatio ns at any time and without prior notice, without incurring obligations.

Specifications – Three Phase

Available in 10’, 15’ and 20’ lifts.

Model

1/2SS-3C 1/2 31.50 20.16

1SS-3C 1 24.80 24.41 2SS-3C 2 12.40 28.15 2 8x24 156.53 20.43 11.16 5.18 11.81 4.43 10.96 28.15 3SS-3C 3 8.30 31.5 3 8x24 213.85 20.43 11.16 5.71 11.81 6.38 10.96 31.50 5SS-3C 5 6.20 30.71 4 8x24 220.46 20.43 11.16 6.57 11.81 8.25 10.96 30.71

Rated Cap’y

(ton)

Hoisting

Speed

(f/min.)

Head-

room

(in.)

Motor

1.34HP

230/460V

60Hz

2.15HP

230/460V

60Hz

Duty

Cycle

Rating

(30%)*

Load

No. of

Chain

Falls

(mm)

1 6.3x19 102.5 17.72 9.84 4.09 10.24 4.43 9.45 20.16

1 8x24 149.91 20.43 11.16 4.67 11.81 5.28 10.96 24.41

Net Wt.

(lbs.)

A B C D E F Hmin.

* 30% duty cycle = 18 minutes continuous in 1 hour; or 1 minute on, 4 minutes off.

The above specifications were current at the time this manual was published, but because of our policy of continuous improvement, Walter Meier (Manufac turing) Inc.,reserves the right to change spec ifications at any time and without prior notice, without incurring obligations.

Unpacking

Open shipping container and check for shipping damage. Report any damage immediately to your distributor and shipping agent. Do not discard any shipping material until the Chain Hoist is installed and running properly.

Missing parts, if any, should be reported to your distributor. Read this owner’s manual thoroughly for assembly, maintenance and safety instru ctions.

Contents of the Shipping Container

1 Electric Chain Hoist 1 Chain Container with Bracket and fastener s 1 Power Cord 1 Pendant Cord 1 Top Hook Assembly 1 Owner's Manual 1 Warranty Card

Installation

Support for the hoist may be hook, clevis pin, trolley, or beam clamp. Whatever method of suspension is chosen, the support components must be rated equal to, or greater than the capacity of the chain hoist. Supporting structures (such as I-Beams, etc.) should be installed by properly licensed professional installers.

Installing Top Hook

Figure 1

Figure 2

1. Rem ove the two screws, lock washers and flat

washers (A, Figure 1), the hook-pin plates (B) and the hook pins (C).

2. Place the top hook assembly (D) i nto position

between the body plates, and re-install pins, hook-pin plates, screws and washers. Firmly tighten the screws.

3. Place the hoist assembly into position on the

supporting structure.

If you are using the hoist with a trolley, refer to the trolley manual for instructions on securing the pendant cord and maintaining proper slack in the cord during operation.

Installing Power and Pendant Cords

NOTE: If you need to convert the voltage requirements of the hoist, it will be more convenient to do that now before installing the power cord or pendant cord. See “Voltage Conversion” on page 9.

1. Attach the power cord and pendant cord to the

cable holder, as follows.

Power Cord Assembly

Cable Holder

Control P e ndant Assembly

Connector Cap

Loop Attached to Pendant Cord

Figure 3

2. Open the connector caps on the two female

connectors (Figure 2) and two male plugs (Figure 3).

If repair or replacement of the electric cord or plug is necessary, do not connect the equipmentgrounding conductor to a live terminal.

3. Check orientation of notches on the female

connectors and male plugs, and correctly insert the 4p plug into the 4p f em ale connector on the left, insert the 7p plug into the 7p female connector on the right with sufficient force (see Figure 3).

4. Tighten the two cover nuts with fingers (see

Figure 4).

Cover Nut

Figure 4

Electrical Instructions

Electr ical connections must be

made by a qualified electrician in compliance with all relevant codes. This machine must be properly grounded to help prevent electrical shock and possible fatal injury.

Grounding

In the event of a malfunction or breakdown, grounding provides a path of least resistance for electric current to reduce the risk of electric shock.

This machine’s power cord must be fitted with an appropriate UL/CSA listed plug, or it can be “hardwired” directly to a control panel. If hard-wired, make sure a disconnect is available for the operator.

Check with a qualified electrician or service personnel if the grounding instructions are not completely understood, or if in doubt as to whether the tool is properly grounded.

Repair or replace damaged or worn cord immediately.

Voltage Conversion

The single phase model SS-1C is designed for 115 volt or 230 volt operation. It is pre-wired for 230 volt. To switch voltage:

1. Disconnect hoist from power supply, and unplug the power cord and pe ndant cord from the hoist.

2. Remove the motor cover and move the plug from the 230Vsocket to the 115V socket.

3. Re-install the motor cover.

The three phase model SS-3C is designed for 230 volt or 460 volt operation. It is pre-wired for 460V. To change to 230V proceed as follows.

1. Disconnect hoist from power supply, and unplug the power cord and pe ndant cord from the hoist.

2. Remove the motor cover and make the following exchanges on the SS-3C:

Move the plug XP1 from socket XS2 to XS1. Move the plug XP2 from socket XS6 to XS5.

3. On the phase protector, slide the switch S1 from the 460 volt position to the 230 volt position.

4. Re-install motor cover.

Refer to the diagrams at the back of this manual for any clarification of these procedures.

NOTE: When connecting plug to socket, check that the connector notch is fully engaged. To remove a plug, press on the notch tail to disengage notch.

If a plug is installed, it must have an equipmentgrounding conductor and a grounding prong. The plug must be plugged into a matching outlet that is properly installed and grounded in accorda nce with all local codes and ordinances.

Do not modify the plug – if it will not fit the outlet, have the proper outlet installed by a qualified electrician.

Improper connection of the equipment-grounding conductor can result in a risk of electric shock. The cond uctor with insulation having a n outer surf ace that is green with or without yellow stripes is the equipment-grounding connector.

Figure 5

(single speed model shown)

Inspecting Hoist Motion

1. Before closing the circuit breaker and testing the hoist, check that wiring has been complete. If the hoist cannot be observed when the circuit breaker is closed, station an observer within sight of the hoist to report any movement when power is applied to the hoist. Be prepared to disconnect power if hoist motor starts when the power is applied. The hoist must remain motionless when power is applied. Find and correct any problems before continuing.

2. With no load on the load hook, press the UP button very briefly and observe hoist action. The hook should move upward.

3. If no motion occurs when the UP button is pressed and the hoist is co nnected to a three phase power supply, the power supply wires are incorrectly positioned. Switch any two of the three supply wires at the power source. Do

not attempt to rewire the hoist circuit or pendant controls for this problem. Use the

same safety precautions when reversing two of the supply wires as was used when the wires were originally connected.

4. Re-connect power and test hoist movement again without load. Run hoist to the complete lifting height to ensure limit switches are operating properly.

Installing Chain Container

Your hoist is supplied with a canvas chain container (Figure 7) designed to fit the particular length of chain. If a different length chain is ever installed on this hoist, the chain container must be replaced by one of proper size. See chart on page

19.

Do not overfill chain container.

If chain should overfill and begin to fall, the entire chain container may empty without warning, resulting in serious personal injury or property damage.

To assemble the chain container to the hoist:

1. Hang hoist in position on the I-Beam or trolley. Do no t inst all c hain c onta iner ye t. Al low s lack side and load side of chain to hang freely from hoist.

2. Apply power to the hoist and press t he DOWN button until the lower limit switch is tripped.

3. Check the chain container to ensure that the seam is inside the bag. The bag must not be inside out.

4. Insert bracket prongs into interior bag slots (Figure 7) as far as they will go.

Extension Cords

If an extension cord is necessary, make sure the cord rating is suitable for the amperage listed on the hoist's motor plate. An undersized cord will cause a drop in line voltage resulting in loss of power and overheating.

The chart in Figure 6 shows the correct size cord to use based on cord length and motor plate amp rat ing . If in d o ubt , use t he ne xt he a v ier ga ug e. T he smaller the gauge number, the heavier the cord.

Recommended Gauges (AWG) of Extension Cords

Extension Cord Length *

100

150

200

Amps

< 5 16 16 16 14 12 12

5 to 8 16 16 14 12 10 NR

8 to 12 14 14 12 10 NR NR 12 to 15 12 12 10 10 NR NR 15 to 20 10 10 10 NR NR NR 21 to 30 10 NR NR NR NR NR

*based on limit ing th e lin e volt ag e drop to 5V at 15 0% of the rated amp eres.

NR: Not Recommended.

feet

Figure 6

feet

Figure 7

5. Push the bracket down into the bag, making sure the flaps are raised (Figure 8).

6. Push the flaps over and down until they are secure (Figure 9).

Figure 8

Procedures: Allowable Limits” on page 18 for the

maximum pitch allowed for chain length. If the chain exceeds this amount, it must be replaced.

Figure 10

Figure 9

7. Remove the screw and washer holding the end chain to the hoist (Figure 10). Mount the bracket of the chain container in that location as shown in Figure 11.

8. Put the chain stop into the container (Figure

11), and operate the hoist to bring the load hook up until the upper limit switch is tripped.

9. Check the chain to ensure that all the nonloaded chain is completely in the container.

Do not put chain into the chain

con tai ner by ha nd ! By not foll owi ng t he a bo ve steps, the chain can become twisted or kinked and can damage the hoist.

Pre-Operation Inspection

Inspecting the Load Chain

Clean the chain with a solvent, and carefully inspect the entire load chain. Replace damaged chain before using the chain hoist. See “Inspection

Figure 11

Also replace the load chain if any of the following are identified:

1. Seriously rusted or cracked.

2. Marks on the chain surface are deeper than 5% of the link’s diameter.

3. Links are twisted or deformed.

4. The links are stretched too long or seriously worn on the surface, especially at the points where links contact each other.

Never extend load chain by welding a second piece to the original.

Do not operate the hoist with a

twisted, kinked or damaged load chain. Do not splice the load chain.

Check that the chain does not twist along its length from hoist to hook. If twist is present on units with multiple falls, the hook must be passed back through the chain loop to remove all twist in the chain.

The load chain supplied with

your JET chain hoist is designed, manufactured, and tested for proper fit and

durability. Over a period of time, the chain may need to be replaced. For your own safety, use factory replacement chain only. Use of other than factory replacement chain may cause serious injury and/or damage to the hoist.

If the hoist is connected to a m anual trolley, move the hoist by pushing on the suspended load. Move an unloaded hoist by pulling on the empty hook. Do NOT move the hoist by pulling on the pendant cord.

A light coat of 30-weight oi l applied periodically to the chain will create easier operatio n and pro long the life of the chain.

Inspecting the Hooks

It is important to check top and bottom hooks for proper opening and other signs of deformation or damage. Replace a hook immediately if any of the following problems are identified:

1. The safety latch no longer contacts the hook opening.

2. The vertical angle at the neck of the hook reaches 10° (see Figure 12).

Figure 12

3. Chemical corrosion or cracks on the hook.

4. Excessive wear on the inside surface.

5. The throat opening has enlarged. (See page 18 for the maximum allowable limits for the throat opening.)

NOTE: Excessive hook throat opening or twist indicates abuse or overloading of the hoist. If suc h deformation is discovered, inspect hoist, chain and all supporting members very caref ully for additio nal indications of excessive hoist loading.

Do not attempt repair of a hook

by heat treating, bending or attaching anythi ng by welding. Such procedures will weaken and may cause failure of the hook.

Operating the Hoist

Allow the hoist to come to a full stop before changing direction. Rapidly reversing or catching a falling load can overload the hoist system and cause a failure in the hoist and/or chain, resulting in injury or property damage.

The brake mechanism must be kept clean and free from dirt, water, and oil. Never allow oil to penetrate the brake mechanism. Always keep your hoist clean, and store in a clean, dry location.

Follow this general procedure for hoisting loads:

1. Secure the upper hook to the supporting structure.

2. Place load sling or chain in the center of the bottom hook, making sure the safety latch is secure. Never load the hook i n front of t he safety latch. See Figure 13.

Figure 13

3. Avoid lifting one load with two hoists. If this is unavoidable, apply equal weight to both hoists and use hoists with the proper lift capacity.

Capacity of each hoist must be equal to t he total load to be lifted.

4. Press UP button and remove all slack in load chain. Increase tension in the load chain until the hoist is about to raise the load.

5. Check again that the load is properly slung, directly under hoist, and will not suddenly swing or twist.

6. Raise load an inch or two above the ground and stop. Observe load for a few moments, looking for signs that the load or hoist system is unstable, or other indications that there is a problem.

7. Check that the chain is not twisted at the bottom hook. All welds should fac e the same direction (see Figure 15). For hoists with two or more falls of chain, make sure the bottom hook is not turned over. This may cause the chain to twist.

8. Raise load to the traveling height. Raise only to the height necessary to safely clear all obstacles.

9. Lower load at destination. If both UP and DOWN commands must be used during lowering, pause for a moment between each reversal of load direction.

10. Slowly allow weight to shift from hoist to ground or new support. Do not approach load until all tension is out of chain and load is stable.

Adjustments

Safety Clutch Adjustment

The load limitation of the safety clutch has been set to within 1.3 to 1.8 times the rated load of the hoist. Generally, the safety clutch will not require adjustment. But if the hoist ever fails to lift the rated load while the rotor is turning, the safety clutch must be re-adjusted. Proceed as follows (see Figure 14):

1. Suspend the rated load in the bottom hook.

2. Push the UP button to create tension on the load chain, but do not raise the load off the ground.

Figure 14

3. Disconnect the power source, and remove the gear side cover.

4. Loosen the screw (G), open the plate (J), and push down the adjusting shaft (K) until it ful ly engages the adjusting circle nut (L). Rotate the nut (H) clockwise to tighten the adjusting circle nut (L).

5. Pull the adjusting shaft (K ) out of engagement with the adjusting circle nut (L). Then close the plate (J) and tighten screw (G).

6. Connect hoist to power source, and push the UP button on the pendant control. The hoist should now lift the rated load. If it will not lift the load, disconnect power and repeat steps 4 and 5 to tighten the adjusti ng circle nut until it can lift the rated load.

7. Now c hange the load to within 1.3 to 1.8 times the rated load, then push the UP button. T he hoist should NOT be able to lift the load. If it can lift the load, repeat steps 4 and 5, rotate the adjusting nut (H) and loosen adjusting circle nut (L) until the hoist cannot lift the load.

8. Unload the hoist and repeat step 6 with the original rated load. The hoist should now be able to lift the original rated load. If it does not, repeat steps 6 and 7 until the hoist operates with the rated load only, but not with the 1.3 to

1.8 times rated load.

9. Unload the hoist, and re-install the gear side cover.

Replacin g Loa d Ch ai n

Over time, the load chain will wear or elongate. This can cause damage to the hoist, breakage, or non-engagement of the load sheave. The following procedures describe replacing the load chain for single and m ultip le fall hoists. These procedures

should be perform ed by exper ienced per so nnel only.

How to Cut Chains

Use a bolt cutter with special cutter j aws for c utting hardened chain. Cut only one side of the link at a time. When making the second cut, place a mat over the chain to catch the flying chain section.

Making a C-Link

Replacing load chain will require the use of a C-link (in som e ca ses, t wo C -link s), w hic h you ca n easi ly make as follows:

1. Cut a link from the old chain.

2. Cut the weld from the link leaving a n opening approximately 1.25 times the diameter of the link material. See Figure 15.

3. Grind the cut areas smooth and remove all burrs.

Figure 16

6. Stop hoist when 1 to 2 feet of new chain remains on the slack side.

7. Install the spring and chain stop on the slack end of the chain.

8. Remove the load hook and the spring from the old chain, and install them on the new chain. Inspect condition of both spring and hook.

9. Lower load hook until the limit switch stops hoist movement. Inspect the chain for any signs of twist.

10. Install chain container following the instructions in this manual. Do not fill chain cont aine r b y hand.

11. It is recommended that after installing new chain, the first few lifts be limited to no more than 25-50% of the rated load. Thoroughly Inspect chain for twist before placing hoist in routine service.

Figure 15

Single Fall C hain Hoist

1. Lower the load hook until only 1 to 2 feet of slack chain remains in the chain container.

2. Remove chain container.

3. On the slack side of the chain, remove the chain stop and the spring (Figure 16). Keep these handy for later re-installing.

4. Using a C-link, connect the new chain to the old chain. Be sure vertical link welds face away from load sprocket (see Figure 17).

5. Keep tension on both sides of the chain and lower the load hook to pull the new chain through the hoist. Do not let the chain twist or bind as it is being pulled through the hoist.

Vertical and Horizontal Links

Vertical and horizontal are determined by the relationship with the load sprocket. Vertical links will be guided by the center slit in the load sprocket. Horizontal links will engage in the oval pockets on the sprocket. See Figure 17.

Figure 17

Figure 18

Dual/Multiple Fall Chain Hoists

The link on the load side end

must be a vertical link. If it is a horizontal link, the chain will have a twist in it.

1. Lower hook until only 1 to 2 feet of slack chain remains in the chain container.

2. Remove chain container.

3. On the slack side of the chain, remove the chain stop, and remove the black spring(s). (see Figure 16). Keep these ha ndy f or later reinstalling.

4. Using a C-link(s), connect the new chain to the old chain. If the end link of the old chain is horizontal, use two C-links. If the end link of the old chain is vertical, use one C-link See Figure 19. Using the correct number of C-links will properly orient the c hain, and e nsure that the first link on the load side end is a vertical link.

5. Install the spring(s) and chain stop on the opposite end of the new chain.

6. Support the load hook so that the load chain can pass through the chain sheaves smoothly. Figure 16 shows the load chain path for the various sizes of hoist.

7. Press the DOWN button to move the chain through the hoist. Keep tension on the chain as you pull it through to the load side, until the C-link(s) clears the hoist at the load side.

Figure 19

8. Place the first link of the new chain into the load side end holder. Be sure that there is no twisting of chain between last chain sprocket and load side end holder.

9. Rem ove the chain stop bolt from the old chain and install on the new chain. Do not substitute any other bolt in this applica tio n. Use a new cotter pin to secure bolt.

10. Install chain container following instructions in this manual. Do not fill chain container by hand.

11. Lower hook until limit switch stops hoist movement, then raise hook until limit switch stops hoist movement. Inspect chain for any signs of twist and correct before continuing.

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