Milwaukee 9562, 9565, 9566, 9560, 9568 User Manual

...

The use of any hoist presents some risk of personal injury or property damage.That risk is greatly increased if proper instructions and warnings are not followed.Before using this hoist, each operator should become thoroughly familiar with all warnings, instructions, and recommendations in this manual.

Retain this manual for future reference and use. Forward this manual to the hoist operator. Failure to operate the equipment as directed in the manual

may cause injury. Before using the hoist, fill in the information below.Model and

serial numbers are stamped into the aluminum hoist housing.

Model Number Serial Number Purchase Date

ollow all instructions and warnings for

inspecting, maintaining and operating this hoist.

ELECTRIC CHAIN HOIST

The equipment described and illustrated in these instructions is intended for industrial use only and should not be used to lift, support or otherwise transport people.

Catalog No. Rated Load 9560 1/2 Ton 9561 9562

9565 1 Ton 9566 9567 9568

9570 2 Ton 9571 9572 9573

OPERATOR’S MANUAL

Milwaukee Electric Tool Corporation

A company within the Atlas Copco Group

13135 West Lisbon Road • Brookfield, WI, U.S.A. 53005

Alterations or modifications of equipment and use of non-factory repair parts can lead to dangerous operation and injury.

TO AVOID INJURY:

• Do not alter or modify equipment

• Do not use equipment to lift, support or otherwise transport people

• Do not suspend unattended loads over people

WARRANTY

Every

MILWAUKEE

hoist is thoroughly inspected and tested before leaving the manufacturing facilities.Should any trouble develop, return the complete hoist prepaid to the Factory, Branch or nearest Authorized

MILWAUKEE

Service Station. If inspection shows the trouble is caused by defective workmanship or material, all repairs will be made without charge and the hoist will be returned, transportation prepaid.

This warranty does not apply where: (1) repairs or attempted repairs have been made by persons other than

MILWAUKEE

personnel or Authorized Service Station Personnel; (2) repairs are required because of normal wear; (3) the hoist has been abused or involved in an accident; (4) misuse is evident such as caused by overloading the hoist beyond its rated capacity; (5) the hoist has been used after partial failure; (6) the hoist has been used with an improper accessory.No other warranty, written or verbal, is authorized.

58-12-9560d1 06/02 Printed in USA

Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield, Wisconsin 53005 TEL: (800) 729-3878

SAFETY PRECAUTIONS

Each

MILWA UKEE

Electric Chain Hoist is built in accordance with the specifications contained herein and at the time of manufacture complies with our interpretation of applicable sections of *American Society of Mechanical Engineers Code (ASME) B30.16 “Overhead Hoists,” the National Electrical Code (ANSI/NFPA 70) and the Occupational Safety and Health Act (OSHA). Since OSHA states the National Electrical Code applies to all electric hoists, installers are required to provide current overload protection and grounding on the branch circuit section in keeping with the code.Check each installation for compliance with the application, operation and maintenance sections of these articles.

*Copies of this standard can be obtained from ASME Order Department, 22 Law Drive, Box 2300, F airfield, NJ 07007-2300, U.S.A.

1. NOT operate a damaged, malfunctioning or unusually performing hoist.

2. NOT operate the hoist until you have thoroughly read and understood the manufacturer’s Operating and Maintenance Instructions or Manuals.

3. NOT operate a hoist which has been modified without the manufacturer’s approval or without certification that it is in conformity with ANSI/ASME B30 volumes.

4. NOT lift more than rated load for the hoist.

5. NOT use hoist with twisted, kinked, damaged, or worn load chain.

6. NOT use the hoist to lift, support, or transport people.

7. NOT lift loads over people.

8. NOT operate a hoist unless all persons are and remain clear of the supported load.

9. NOT operate unless load is centered under hoist.

10. NOT attempt to lengthen the load chain or repair damaged load chain.

11. Protect the hoist’s load chain from weld splatter or other damaging contaminants.

12. NOT operate hoist when it is restricted from f orming a straight line from hook to hook in the direction of loading.

13. NOT use load chain as a sling, or wrap chain around load.

14. NOT apply the load to the tip of the hook or to the hook latch.

15. NOT apply load unless load chain is properly seated in the chain sprocket(s).

16. NOT apply load if bearing prevents equal loading on all load supporting chains.

17. NOT operate beyond the limits of the load chain travel.

18. NOT leave load supported by the hoist unattended unless specific precautions have been taken.

19. NOT allow the load chain or hook to be used as an electrical or welding ground.

20. NOT allow the load chain or hook to be touched by a live welding electrode.

21. NOT remove or obscure the warnings on the hoist.

22. NOT operate a hoist on which the safety placards or decals are missing or illegible.

23. NOT operate a hoist unless it has been securely attached to a suitable support.

24. NOT operate a hoist unless load slings or other appro ved single attachments are properly sized and seated in the hook saddle.

25. Take up slack carefully - make sure load is balanced and load holding action is secure before continuing.

26. Shut down a hoist that malfunctions or performs unusually and report such malfunction.

27. Make sure hoist limit switches function properly.

28. Warn personnel of an approaching load.

1. Maintain firm footing or be otherwise secured when operating the hoist.

2. Check brake function by tensioning the hoist prior to each lift operation.

3. Use hook latches. Latches are to retain slings, chains, etc. under slack conditions only.

4. Make sure the hook latches are closed and not supporting any parts of the load.

5. Make sure the load is free to move and will clear all obstructions.

6. Avoid swinging the load or hook.

7. Make sure hook travel is in the same direction as shown on the controls.

8. Inspect the hoist regularly, replace damaged or worn parts, and keep appropriate records of maintenance.

9. Use

MILWA UKEE

recommended parts when repairing the

unit.

10. Lubricate load chain per hoist manufacturer’s recommendations.

11. NOT use the hoist’s overload limiting clutch to measure load.

12. NOT use limit s witches as routine oper ating stops .They are emergency devices only.

13. NOT allow your attention to be diverted from operating the hoist.

14. NOT allow the hoist to be subjected to sharp contact with other hoists, structures, or objects through misuse.

15. NOT adjust or repair the hoist unless qualified to perform such adjustments or repairs.

Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could result in death or serious injury. To avoid such a potentially hazardous situation, THE OPERATOR SHALL:

Improper operation of a hoist can create a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. To avoid such a potentially hazardous situation, THE OPERATOR SHALL:

MILWAUKEE

Electric Chain Hoists are rugged, portable hoists that provide quick, precise lifting.The hoists are constructed of tough, but lightweight, die cast aluminum alloy housings .An oil bath transmission, equipped with heat-treated, alloy steel gears and an overload limiting clutch, provides smooth and reliable operation.

With a pushbutton station that fits comfortably in one hand, the operator can safely control the hoist while the other hand is free to guide the load.The electrical controls, which are readily accessed under the electrical cover , utiliz e quick connections for easy voltage con versions and a 24V control circuit for added safety.

Other features that ensure the safe operation of

MILWAUKEE

Electric Chain Hoists include a magnetic disc brake that delivers sure stopping and secure holding of the load. Adjustable upper and lower limit switches regulate the load travel.As a standard, hooks are supplied with safety latches . For additional safety, a chain stop is attached to the slack end of the load chain.

MILWAUKEE

Electric Chain Hoists are designed and tested in accordance with the American Society of Mechanical Engineers Code B30.16, “Safety Standard for Overhead Hoists.”Hoists are built in compliance with CSA, file number LR 44484.Made in U.S.A.

Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield, Wisconsin 53005 TEL: (800) 729-3878

TABLE OF CONTENTS

Safety Precautions......................................................................................................................................................................2

Hoist Specifications.....................................................................................................................................................................3

Application Information ...............................................................................................................................................................4

Safety Information.......................................................................................................................................................................4

Installation...................................................................................................................................................................................4

Operation ....................................................................................................................................................................................5

Maintenance ...............................................................................................................................................................................6

Wiring Diagrams .......................................................................................................................................................................12

Trouble Shooting.......................................................................................................................................................................13

Inspection and Maintenance Check List...................................................................................................................................14

Recommended Lubrication Schedule.......................................................................................................................................15

Replacement Parts List.............................................................................................................................................................16

Parts Depot & Warranty Repair Centers...................................................................................................................................28

Warranty.....................................................................................................................................................................Back Cover

Lifting Control Cord Full Load

Model Capacity Speed Lift Length Reeving HP Voltage Motor Amps

* Phase

(tons) (fpm) (ft) (ft) (AC)

Table 1 - Hoist Specifications

9560 1/2 16 10 6 Single-chained 1/2 115/230V 7.6/3.8 Single

9573 2 8 20 16 Double-chained 1 115/230V 14/7** Single

9570 2 8 10 6 Double-chained 1 115/230V 14/7** Single

9567 1 16 15 11 Single-chained 1 115/230V 14/7** Single

9568 1 16 20 16 Single-chained 1 115/230V 14/7** Single

9566 1 16 10 6 Single-chained 1 230/460V 3.2/1.6 Three

9565 1 16 10 6 Single-chained 1 115/230V 14/7** Single

9562 1/2 16 20 16 Single-chained 1/2 115/230V 7.6/3.8 Single

9561 1/2 16 15 11 Single-chained 1/2 115/230V 7.6/3.8 Single

9572 2 8 15 11 Double-chained 1 115/230V 14/7** Single

9571 2 8 10 6 Double-chained 1 230/460V 3.2/1.6 Three

* At full load, it is not unusual for the hoist to draw in excess of

the values listed when lifting.It is critical to ensure that the voltage at the hoist contactor does not drop below 10% of the nominal voltage of the hoist while it is lifting a load.Low voltage will result in higher amp draw, damage to the hoist, and potential fire hazards.

MILWAUKEE

is not responsible

for any damages caused by an inadequate po w er source .

**The 1HP, 115/230V models must have a dedicated power

circuit rated for at least 20A, 125V when they are wired for 115V. It is not unusual for these models to draw up to 20 amps at 115V when lifting at rated capacity.Refer to Table 3 before installation.

HOIST SPECIFICATIONS

APPLICATION INFORMATION

This hoist is intended for general industrial use for lifting and transporting freely suspended material loads within its rated capacity.

MILWAUKEE

cannot be responsible for applications

other than those for which

MILWAUKEE

equipment is recommended.Prior to installation and operation, we caution the user to review his application f or abnormal environmental or handling conditions and to observe the applicable recommendations as follows:

ADVERSE ENVIRONMENTAL CONDITIONS

Do not use the hoist in areas containing flammable vapors, liquids, gases or any combustible dusts or fibers .Refer to Article 500 of the National Electrical Code. Do not use this hoist in highly corrosive, abrasiv e or wet environments.Do not use this hoist in applications involving e xtended exposure to ambient temperatures below -10°F or above 130°F.

LIFTING OF HAZARDOUS LOADS

This hoist is not recommended for use in lifting or transporting hazardous loads or materials which could cause widespread damage if dropped.The lifting of loads which could explode or create chemical or radioactive contamination if dropped requires fail-safe redundant supporting devices which are not incorporated into this hoist.

LIFTING OF GUIDED LOADS

This hoist is not recommended for use in the lifting of guided loads, including dumbwaiters and elev ators.Such applications require additional protective devices which are not incorporated into this hoist. For such applications, refer to the requirements of applicable state and local codes, and the American National Safety Code for ele vators, dumbwaiters, escalators and moving walks (ASME A17.1).

SAFETY INFORMATION

1. Follow all local electrical and safety codes, as well as the National Electrical Code (NEC) and the Occupational Safety and Health Act (OSHA) in the United States.

2. Hoist must be securely and adequately grounded.The hoist power cable is provided with an additional lead (green) for grounding purposes.

3. Be careful when touching the exterior of an operating motor; it may be hot enough to be painful or cause injury. With modern motors this condition is normal if operated at rated load and voltage (modern motors are built to operate at higher temperatures).

4. Protect the power cable and control cable from coming in contact with sharp objects.

5. Do not kink power cable and control cable and never allow the cable to come in contact with oil, grease, hot surfaces, or chemicals.

6. Make certain that the power source conforms to the requirements of your equipment.

7. Inspect the unit daily before operating hoist.

8. Cluttered areas and benches invite accidents.

9. The operator should not engage in any practice which will divert his attention while operating the hoist.

10. Before using the hoist, the operator should be certain that all personnel are clear.

11. Do not operate hoist with loads exceeding its rated capacity.

12. Supporting frames or beams used as a hoist hanger must have a greater load capacity than the hoist.

13. Do not attempt to operate hoist beyond normal maximum lift range.

14. Align hoist for a straight line pull.Avoid side pull or end pull.

15. Do not operate hoist with twisted or damaged chain.

16. Do not operate a damaged or malfunctioning hoist until necessary adjustments or repairs have been made.

17. Do not use hoist to lift people or to carry loads over people.

18. Do not leave a load suspended in the air unattended.

19. Always remove load before making repairs.

20. Do not remove or obscure capacity or warning decals.

INSTALLATION

1. Before installing the hoist, check the following:

a. Make sure all supporting structures and attaching devices

are strong enough to hold your intended loads.If in doubt, consult a qualified structural engineer.

b. Provide proper branch circuit protection for the hoist as

recommended in the National Electrical Code.

c. The power supply should be within plus or minus 10% of

the voltage specified on the motor nameplate.It is critical to use adequate sized power cables, especially with 1-phase hoists (See T able 3). Be sure dual voltage hoists are connected or wired to correspond with your power supply (See WIRING, page 9).

d. Installation area must provide operating conditions for the

operator including sufficient room for the operator and other personnel to stand clear of the load at all times.

e. For installations where the slack chain hanging from the

unit may be objectionable or hazardous, the use of a chain container is recommended.See INSTALLATION OF CHAIN CONTAINER ASSEMBLY.

Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield, Wisconsin 53005 TEL: (800) 729-3878

Always disconnect the power source before working on or near a hoist or its connected load. If the power disconnect point is out of sight, lock it in the open position and tag to prevent unexpected application of power.

Failure to comply with Safety Precautions outlined throughout this manual can result in serious injuries or death. Before using this hoist, each operator should become thoroughly familiar with all warnings, instructions and recommendations in this manual.

Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield, Wisconsin 53005 TEL: (800) 729-3878

2. Before operating the hoist, be sure to observe the following: a. ALWAYS DISCONNECT HOIST FROM POWER SUPPLY

before removing the electrical cover or when making an y electrical connection in the hoist or pushbutton station.

b. The ground wire (green colored) of the power cable

should always be connected to a suitable ground by means of a screw or clamp.An alligator clip does not make a safe ground connection.

c. When installing a three-phase hoist, make only temporary

connections at the power source.Push the “UP”button and observe the direction of the load block.If it raises, the phasing is correct and permanent connections may be made at the power source.If the load block lo w ers when the “UP”button is pushed, release the button immediately since the limit switches will not operate to protect the hoist from over-travel.Reverse any tw o wires (except the green ground wire) at the power source to correct the load hook direction (phasing).Do not change connections in the hoist or pushbutton assembly.

d. Make sure load chain is not twisted as it travels into the

hoist.

e. Operate hoist in a hanging position only.Hoist should be

permitted to align itself for a straight line pull.Do not attempt to pull around corners.

f. Read ASME-B30.16 Safety Code for Hoists .

3. If necessary, lubricate the chain, see LUBRICATION, page 9.

4. Check the function of the limit switches.Before placing hoist in operation, check limit switch adjustment.Operate pushbutton until near stop point and inch into stop limit both top and bottom.If either switch is not correct, adjust according to LIMIT SWITCH ADJUSTMENT, page 8.

INSTALLATION OF CHAIN CONTAINER ASSEMBLY (OPTIONAL ACCESSARY)

Refer to Figure 1 and Table 2.

1. Remove dead end screw and w ashers and let chain hang free.

2. Place chain container bracket flush against housing. Replace washers and screw.Tighten securely.

3. Attach chain container to bracket with two open links and then close the links.

4. Run the load hook down to its lowest position. Place the slack end of the chain in the chain container.Feed the remainder of the chain into the container by operating the hoist in the “UP” direction to the top limit.This will permit the chain to pile freely and eliminate the possibility of fouling which may occur if the chain is placed in the container by hand.

OPERATION

This hoist is designed for safe operation within the limits of its rated capacity.It is controlled with the “UP”and “DOWN” buttons of the pushbutton station.There are many safety features to protect the operator from injury due to failure of the hoist.Here are some points which should be observed to maintain safe operation.

1. Do not overload the hoist.

2. Do not make extreme side pulls with the hoist.

3. Operate the hoist only in a hanging position with adequate support.

4. Do not “sling” the load hook and chain around the load. Use an approved sling.

5. Be sure there are no twists in the load chain as it travels into the hoist housing.This condition should be constantly checked on double chain hoists because it is possib le f or the load block to be “capsiz ed”or turned over one or more times.

6. Before raising a load, always check to see that it is held securely in the hook or sling chains, etc.Raise the load only until the load chain is taut and then double check the rigging before continuing to raise the load.

7. Do not stand beneath a load! Do not move a load in such a manner as to endanger personnel.

8. Do not lower into areas where visibility is obscured unless someone else is guiding the operation.

9. Use common sense at all times when operating a hoist.

10. Do not operate if direction of hook travel is not the same as indicated on button being pushed.

Do not allow load to come in contact with chain container. If this situation exists reset the “UP” limit switch (See LIMIT SWITCH ADJUSTMENT, page 8) so that hook block stops below chain container.

Standard Shipping

Hoist Lifts Chain Container Weight Dimensions in Inches

Capacity (ft) Required (lbs) Width Length Depth

Table 2 - Optional Chain Container

1/2 & 1 Ton 10, 15, & 20 48-12-0111 3 3 6½ 11½

2 Ton 10 48-12-0111 3 3 6½ 11½

2 Ton 15 48-12-0112 4 3 6½ 18½

2 Ton 20 48-12-0113 5 6 6½ 27

Figure 1 — Installing Chain Container Assembly

Dead-end Screw

11. Do not operate unless hook travel limit devices function. Test without load each shift.

12. Do not operate when hoist is not centered over load.

13. Do not operate if chain is not seated properly in sprockets or sheave grooves.

14. Do not operate damaged or malfunctioning hoist.

OVERLOAD LIMITING PROTECTION

This hoist is equipped with a factory-calibrated overload limiting clutch that will permit the lifting of loads within its rated capacity, but will prevent the lifting of damaging overloads while the hoist is being operated.If the load being lifted exceeds the lifting capability of the overload clutch, the hoist motor will continue to run, causing overheating of both the clutch and hoist motor.This condition should be avoided by immediately releasing the “UP”button and reducing the load to within the rated capacity of the hoist.See GEARING, page 10, for additional instructions on this device.

MAINTENANCE

INSPECTIONS

A planned inspection routine should be established for this hoist based upon frequency of use, severity of use, and environmental conditions, (Reference ASME Standard B30.16).Some inspections should be made frequently (daily to monthly) and others periodically (monthly to yearly). It is strongly recommended that an Inspection and Maintenance Check List and an Inspector’s Report, similar to those shown in Figures 10A and 10B, be used and filed for ref erence .All inspections should be performed or overseen by a designated inspector.Special inspections should be made follo wing an y significant repairs or any operating occurrence leading one to suspect that the hoist’s capability ma y have been impaired.

LOWERING WITHOUT POWER

If the power fails with a load suspended, the hoist will automatically stop.In an emergency the load can be lowered without power as follows:

1. DISCONNECT HOIST FROM POWER SUPPLY AND REMOVE ELECTRICAL COVER.

2. Open disc brake manually by using two screwdriver blades , one on each side of the brake at a point close to the brake spring posts.Apply pressure to the underside of the armature plate (points “X”, Figure 6, page 9) to close the solenoid and release the brake.

3. Use several quick releases instead of holding brake open continuously.Do not exceed normal lowering speed.

HOOKS

Refer to Figure 2.

1. Inspect hooks once daily for cracking, extreme wear or spreading.Replace hooks showing any of these signs.If the throat openings are spread wider than the maximum permissible 15% increase listed here, the hooks have been overstressed and must be replaced.Any hook that is bent or twisted more than 10° from the plane of an unbent hook must also be replaced.

2. The hook latches should be inspected to ensure that they close the hook throat opening in a secure manner when a load is applied.Inspect the hook shank and nut for any stripping of the threads or other damage.The hook nut should be fully restrained by the retaining pin.

3. In addition to above, load hooks should be inspected for cracks by the magnetic particle, dye penetrant or other suitable crack testing inspection method.This should be done at least once a year.

1 Ton & Under 1

/32"1

/32"

2 T on 1

/32"1

/32"

(*) Maximum permissible throat opening of hook.

Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield, Wisconsin 53005 TEL: (800) 729-3878

Do not allow screw driver blades to touch rotating friction disc “C”.

Do not allow the load to descend rapidly. This causes the motor to race and serious damage may result.

“X” Dimension*

Hoist Top Bottom Capacity Hook Hook

The overload limiting clutch is an emergency protective device and should not be used to measure the maximum load to be lifted, or to sense the overload imposed by a constrained load. While the overload limiting clutch will protect the hoist from damaging overloads, it will not ensure that a load is within the rated capacity of the hoist.

Do not use hoist to lift, support or otherwise transport people.

Figure 2 — Hook

Inspection

CHAIN

Chain is to be kept clean and lubricated (See LUBRICATION, page 9).Visually check chain every time hoist is used.Hoist must not be operated when chain is twisted or kinked.An important phase of hoist maintenance is chain inspection. Check individual links and check for chain elongation.

1. Check the chain for overall wear or stretch b y selecting an unworn, unstretched length of chain (at the slack end for example).Let the chain hang vertically with a light load (about 20 pounds) on the chain to pull it taut.Use a large caliper to measure the outside length of a convenient number of links (about 12").Measure the same number of links in a used section of chain and calculate the percentage increase in length of the worn chain.

2. If the length of the worn chain is more than 1½% longer than the unused chain (0.015" per inch of chain measured), then the chain should be replaced.If the chain is worn less than 1½%, check it at sev eral more places along its length.If any section is worn more than 1½%, the chain should be replaced.

Chain Replacement with Chain in Hoist

Refer to Figures 3 & 4.

1. Run hook up to its top limit.

2. DISCONNECT HOIST FROM POWER SUPPLY and remove the electrical cover.

3. Using a screwdriver, pry the spring guide plate out of the slots in the limit switch nuts (See Figure 3).T urn the slotted nut nearest you, the gold nut, back to about the center of the threaded screw .Do not disconnect the wires from the limit switches.

4. Remove the load block assembly from the old chain.On double-chained hoists detach the chain from the chain support and pull it through the load block assembly (See Figure 4).

5. Make a “C”shaped chain link by grinding through the end link on the load end of the old chain.

6. Using the “C” link, attach the new chain to the load end of the old chain.Be sure that the welds of the upstanding links of the new chain will face outward from the load shea ve. The end links must be oriented for attachment to the deadend screw and the chain support (double-chained only) without any twist in the chain.

7. With the electrical cover off, connect the hoist to the power supply.Be sure that the green ground wire is properly grounded (See INSTALLATION, page 4).

8. Carefully jog the “UP” button and run the joined pieces of chain into the hoist until about 15" of the new chain comes out the other side.

9. DISCONNECT HOIST FROM POWER SUPPLY.

10. Remove the “C”link and the old chain.Remove the chain stop from the old chain by prying off its retaining ring with a flathead screwdriver .If attached, remove the old chain from the side of the hoist by removing the dead-end screw and washers (note placement of washers).

11. Attach the chain stop to the slack end of the new chain by capturing the 12

link with the two stop halves positioned with their tapered ends pointing towards the hoist.Slide the sleeve over the halves and attach the retaining ring.If you are not using a chain container, attach the slack end of the new chain to the side of the hoist using the dead-end screw and washers.With factory supplied hardware there should be six washers between the hoist and chain link and two washers between the chain link and screw head.DO NOT allow twists in the chain.

12. Adjust the lower limit switch (See ADJUSTING LOWER LIMIT, page 8).

13. Attach the bottom block on single-chained hoists using a new load block scre w (See Figure 20).On double-chained hoists, feed the chain through the load bloc k (w elds of the upstanding links will be in towards the sheav e) and fasten the end of the chain to the chain support using a new chain support pin (See Figure 20). Be sure there are no twists in the chain.

14. Adjust the upper limit switch (See ADJUSTING UPPER LIMIT, page 8).

Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield, Wisconsin 53005 TEL: (800) 729-3878

Figure 3 — Limit Switch Assembly

Silver Nut

(Down)

Gold Nut

(Up)

Spring

Guide Plate

Single-chained

Hoist

Double-chained

Hoist

Chain Support

Figure 4 — Chain Replacement Diagram

TON TON

Dead-End Screw

Slack End

Load End

The chain used on this hoist has very carefully controlled dimensions and has been heat treated. Do not attempt to substitute other manufacturer’s chain.

Note Position of Hook

Chain Replacement with No Chain in Hoist

Refer to Figures 4 and 5.

1. DISCONNECT HOIST FROM POWER SUPPLY and move hoist to a work table.Do not remove the electrical cov er.

2. Lay the hoist on its side and remove the four screws that attach the sheave housing to the gear housing (See Figure 12, Ref.No.2).

3. Carefully pull the sheave housing and motor assemb ly loose from the gear housing.

4. Turn the two hoist sections at right angles and remov e the chain guide screws on the nearest chain guide (Ref.No .1, Figure 5).

5. Remove the two chain guide plate screws (Ref.No .2) and the nearest chain guide plate.Be careful not to lose the two spacers that are between the chain guide plates.

NOTE: Inspect chain guides and load sheave for wear, replace as needed.

6. Lay the new chain over the load sheave .Allow about 15" of chain below the hoist on the slack end (See Figure 4).Be sure the welds of the upstanding links are out awa y from the load sheave and that proper orientation is observed for attachment of the dead end.Also be sure the load hook assembly (if already attached to the chain) is toward the center of the hoist or to your right as you face the load sheave.

7. Replace the chain guide plate and the chain guide. Grease the splined shafts that project from both the housing and the motor.

8. Place the motor coupling on the splined shaft and carefully fit the two hoist sections together.Be sure the dead-end nut, the top hook and the support screw (double-chained hoists only) are all in place.On single-chained hoists, the hook shank goes in the center hole; on double-chained hoists, it goes in the off-center hole (See Figure 4).Be careful not to pinch any of the wiring.Turn the hoist on its side and replace the four screws and tighten securely.

9. Follow steps 11 through 14 in the previous section, CHAIN REPLACEMENT WITH CHAIN IN HOIST, to complete the chain replacement procedure.

LIMIT SWITCH ADJUSTMENT

IMPORTANT:Before placing hoist in operation, check the limit switch adjustment.Limit switches are provided to protect the hoist against damage resulting from overtravel or to allow setting the hook travel within the f actory-set limits of travel.For easy identification and association with the proper direction of travel, the upper and low er limit switch adjusting nuts are colorcoded gold and silver respectively. Each limit nut has 10 slots for fine adjustment, and the increment of adjustment is such that one slot is equivalent to approximately one link of chain travel.Mov ement of the limit switch nuts toward or away from each other increases or decreases the hook travel respectiv ely. Care should be exercised when adjusting either limit of travel.

Adjusting Upper Limit (Gold Nut)

Refer to Figure 3.

1. Suspend the hoist. For single-chained models raise the load block until there is a minimum clearance of 2" from the hoist housing and the top of the block.Double-chained models require a minimum clearance of 1" from the chain support to the top of the load block.

2. DISCONNECT HOIST FROM POWER SUPPLY and remove the electrical cover.

3. With a screwdriver, pry the spring guide plate out of the slots in the limit switch nuts.

4. Turn the slotted gold nut tow ard its limit switch until the switch “clic ks”then turn two slots farther.Release the spring guide plate and be sure it slips back into the slots in both limit switch nuts.Do not disturb the silver slotted n ut if it has been set previously.

Adjusting Lower Limit (Silver Nut)

Refer to Figure 3.

1. Suspend the hoist. Carefully lower the load block to a point where the slack-end loop of the chain hangs down 6" or more from the hoist housing (or the limit desired in any particular application allowing the minimum 6").There should be a minimum clearance of 1½" between the chain stop and the bottom of the hoist.

2. DISCONNECT HOIST FROM POWER SUPPLY and remove the electrical cover.

3. With a screwdriver, pry the spring guide plate out of the slots in the limit switch nuts.

4. Turn the slotted silver n ut to ward its limit switch until the switch “clic ks ,” then turn two slots farther.Release the spring guide plate and be sure it slips back in the slots in both limit switch nuts.Do not disturb the gold slotted nut if it has been set previously.

Check Both Upper and Lower Limits

1. Connect the hoist to the power supply.Be sure the green ground wire is properly grounded .

2. Check load hook direction (See INST ALLATION 2-c, page 5).

Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield, Wisconsin 53005 TEL: (800) 729-3878

If the wires running to the limit switches are ever disconnected for any purpose, be sure to replace wires in accordance with the correct wiring diagram (See WIRING DIAGRAMS, page 12).

Figure 5 — Chain Replacement with No Chain in Hoist

There are wires running through the hoist. Carefully ease the hoist sections apart. Do not jerk them apart.

3. Carefully raise load block to upper limit and observe if it stops automatically at desired level.Do not allow load b loc k to run into hoist housing — this will damage the hoist. Maintain a minimum clearance of 2" from the hoist housing and the top of the load block on single-chained models and 1" from the chain support to the top of the load block on double-chained models.

4. Carefully lower load block to lower limit and observe if it stops automatically at the desired level.Do not allow slac kend loop of chain to become taut against hoist housing.This will damage the hoist.There should be a minimum clearance of 1½" between the chain stop and the bottom of the hoist.

5. If upper and lower limits operate satisfactorily, hoist is ready for use.If they are not as desired, repeat adjustment.

BRAKE

Properly adjusted, this brake will release promptly when energized.It is capable of both smoothly stopping and securely holding the rated capacity of the hoist.If the hoist develops either undesirable over-tr avel after the pushbutton is released (this condition is most noticeable in the lowering direction) or hesitates to lift the load promptly when the pushbutton is depressed (this condition is most noticeable in the hoisting direction), the brake should be adjusted.

Brake Adjustment

Refer to Figure 6.

1. DISCONNECT HOIST FROM POWER SUPPLY and remove the electrical cover.

2. With reference to Figure 6, the gap between the brake armature “A” and the field “B” should be checked.The correct gap is 0.015".Adjustment should not be necessary until gap reaches 0.040".

3. Adjust gap by adjusting the 3 locknuts “F”and checking with a feeler gauge to be sure gap is the same on both ends of the solenoid.

4. Adjustment is now complete and the brake properly set. Replace the electrical cover , reconnect the po w er supply, and check hoist brake action.

HOIST CONTROLS

Both the pushbutton and the rev ersing contactor are mechanically interlocked to prev ent shorting the circuit and causing serious damage.As part of maintenance, always check for proper closure of contact points as well as for burned contacts.If replacement is necessary, see Figures 16 & 18 for replacement parts.

WIRING

Refer to Figures 9A and 9B

MILWAUKEE

Electric Chain Hoists, which are available for 115/230V or 230/460V, are shipped wired for 115V and 460V respectively. Conversion of dual voltage hoists to either the higher or lower voltage can be done simply and quickly as follows:

1. DISCONNECT HOIST FROM POWER SUPPLY and

remove the electrical cover.

2. Each dual-voltage hoist has a terminal block assembly for

the interconnection of the electrical components of the hoist. To conv ert voltage, reconnect the leads to the terminal blocks according to the wiring diagram located inside the electrical cover and also in Figures 9A & 9B.DO NOT move

any wires or make any changes to the electrical circuit except at the terminal block assembly. Tug on wires to

ensure they are securely connected.

3. After converting voltage, recheck phasing and limit switch

operation (See INSTALLATION 2-c & 4, page 5).

IMPORTANT: Always refer to the wiring diagram located on the inside of the electrical cover or Figures 9A and 9B when performing electrical repairs.Make sure all connections are secure and check for damaged insulation.It is also imperative that the power circuit has conductors of adequate size (See Table 3).

LUBRICATION

Refer to Figure 11. Proper lubrication is necessary for a long and relatively trouble-

free hoist operation.Refer to the following and the RECOMMENDED LUBRICATION SCHEDULE for lubrication points, type of lubricant, and frequency of lubrication.

Load Chain

Clean the load chain with acid-free solvent and coat with SAE 90 gear oil. Wipe excess oil to prevent dripping.Never apply grease to the chain.

Gearing

The gear case of this hoist is filled at assembly with approximately 1½ pints of SAE 90 EP gear oil.Check oil level by removing the oil level check plug from the side of the hoist. With the hoist hanging level, gear oil should be e ven with the hole.Change oil periodically depending on the severity of the application and the environmental conditions (at least ev ery 200 hours of run time).

Bearings

All bearings except hook and idler sheave bearings are lubricated at the factory and should not require additional lubrication. Noisy or worn bearings should be replaced.

Milwaukee Electric Tool Corporation 13135 West Lisbon Road Brookfield, Wisconsin 53005 TEL: (800) 729-3878

Be sure the bottom of the armature does not bear against the splined adapter “H”. As adjustments are made, the built-in clearance will be reduced. When this clearance is gone REPLACE BRAKE DISCS. Minimum allowable disc thickness is .162". See Figure 15 for further illustration.

Gap

Figure 6 — Brake Assembly

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