Vestil ACH-100 User Manual

Page 1
Operating, Maintenance & Parts Manual
Capacities
250 lbs (113 kg) 300 lbs (136 kg) 500 lbs (226 kg) 600 lbs (272 kg)
1000 lbs (453 kg)
Follow all instructions and warnings for
inspecting, maintaining and operating this hoist.
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.
Forward this manual to the hoist operator. Failure to operate the equipment as directed in the manual may cause injury.
Should you have any questions or have problems with this product, please call Product Standards and Service at 1-800-634-4647.
Before using the hoist, fill in the information below. Model and serial numbers are stamped into the aluminum hoist housing.
Retain this manual for future reference and use.
®
20944
Air Chain Hoist
Columbus McKinnon Corporation Industrial Products Division 140 John James Audubon Parkway Amherst, New York 14228-1197
Manual No. A620-H
Page 2
Note: When ordering parts, always furnish Rated Load and Serial Number of hoist on which the parts are to be used. For the location of the nearest Repair Station, see the list located on the inside front cover.
LIMITATION OF WARRANTIES, REMEDIES AND DAMAGES
THE WARRANTY STATEDBELOW IS GIVEN IN PLACE OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED,OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR OTHERWISE, NO PROMISEOR AFFIRMATION OF FACT MADE BY ANYAGENT OR REPRESENTATIVE OF SELLER SHALLCONSTITUTEA WARRANTY BY SELLER OR GIVE RISE TOANY LIABILITYOR OBLIGATION.
Seller warrants that on the date of delivery to carrier the goods are free from defects in workmanship and materials.
SELLER’S SOLE OBLIGATION IN THE EVENT OF BREACH OF WARRANTY OR CONTRACT OR FOR NEGLIGENCE OR OTHERWISE WITH RESPECT TO GOODS SOLD SHALL BE EXCLUSIVELY LIMITED TO REPAIR OR REPLACEMENT, F.O.B. SELLER’S POINT OF SHIPMENT, OF ANY PARTS WHICH SELLER DETERMINES TO HAVE BEEN DEFECTIVE or if Seller determines that such repair or replacement is not feasible, to a refund of the purchase price upon return of the goods to Seller.
Any action against Seller for breach of warranty,negligence or otherwise, must be commenced within one year after such cause of action occurs.
NO CLAIM AGAINST SELLER FOR ANY DEFECT IN THE GOODS SHALL BE VALID OR ENFORCEABLE UNLESS BUYER’S WRITTEN NOTICE THEREOF IS RECEIVED BY SELLER WITHIN ONE YEAR FROM THE DATE OF SHIPMENT. Seller shall not be liable for any damage, injury or loss arising out of the use of the goods if, prior to such damage, injury or loss, such goods are (1) damaged or misused following Seller’s delivery to carrier; (2) not maintained, inspected, or used in compliance with applicable law and Seller’s written instructions and recommendations; or (3) installed, repaired, altered or modified without compliance with such law, instructions or recommendations.
UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES AS THOSE TERMS ARE DEFINED IN SECTION 2-715 OF THE UNIFORM COMMERCIAL CODE.
INDEMNIFICATION AND SAFE OPERATION
Buyer shall comply with and require its employees to comply with directions set forth in instructions and manuals furnished by Seller and shall use and require its employees to follow such instructions and manuals and to use reasonable care in the use and maintenance of the goods. Buyer shall not remove or permit anyone to remove any warning or instruction signs on the goods. In the event of personal injury or damage to property or business arising from the use of the goods, Buyer shall within 48 hours thereafter give Seller written notice of such injury or damage. Buyer shall cooperate with Seller in investigating any such injury or damage and in the defense of any claims arising therefrom.
If Buyer fails to comply with this section or if any injury or damage is caused, in whole or in part, by Buyer’s failure to comply with applicable federal or state safety requirements, Buyer shall indemnify and hold Seller harmless against any claims, loss or expense for injury or damage arising from the use of the goods.
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 use only factory replacement parts.
ColumbusMcKinnon Corporation • Industrial Products Division• 140 John JamesAudubonParkway
Amherst,New York 14228-1197 • 1-800-888-0985 • Fax 716-689-5644
2008 Columbus McKinnon Corp. Printed in U.S.A.
®
8-1-07
09/08
Page 3
CM HOIST PARTS AND SERVICE ARE AVAILABLE IN THE UNITED STATES AND IN CANADA
As a CM Hoist user, you are assured of reliable repair and parts services through a network of Master Parts Depots and Service Centers that are strategically located in the United States and Canada. These facilities have been selected on the basis of their demonstrated ability to handle all parts and repair requirements promptly and efficiently.
Below is a list of the Master Parts Depots in the Unites States and Canada. To quickly obtain the name of the U.S. Service Center located nearest you, call (800) 888-0985. Fax: (716) 689-5644. In the following list, the Canadian Service Centers are indicated.
MASTER PARTS DEPOT
CALIFORNIA
OTTO SYSTEMS, INC. 12010 Bloomfield Ave. Sante Fe Springs, CA 90670 562/462-1612 or 800/596-7392 Fax 562/462-1617 or 7656 Las Positas Road Livemore, CA 94551 925/245-8800 or 800/508-6886 Fax 925/245-8804
GEORGIA
ACE INDUSTRIES, INC. 6295 McDonough Drive Norcross, GA 30093 770/441-0898 or 800/733-2231 Fax 800/628-3648
ILLINOIS
JOHN SAKASH COMPANY, INC. 700 Walnut Street Elmhurst, IL 60126 630/833-3940 Fax 630/833-9830
INDIANA
HORNER ELECTRIC COMPANY, INC. 1521 East Washington Street Indianapolis, IN 46201 317/639-4261 Fax 317/639-4342
IOWA
VM HOIST & CRANE SERVICES P.O. Box 440 450 Highway 151 Walford, IA 52351 319/846-6040 Fax 319/846-6045
KANSAS
INDEPENDENT ELECTRIC MACHINERY 4425 Oliver Street Kansas City, KS 66106 913/362-1155 or 800-833-2610 Fax 913/904-3330
LOUISIANA
BEERMAN PRECISION, INC. P.O. Box 6018 Metairie, LA 70009 504/207-6000 Fax 504/207-6044
MASSACHUSETTS
ABEL DISTRIBUTORS, INC. 50 Parker Street, Unit 2 Newburyport, MA 01950 978/463-0700 Fax 978/463-5200
NEW JERSEY
SHUPPER-BRICKLE EQUIPMENT CO. P.O. Box 803 2394 Route 130, Suite C Dayton, NJ 08810 732/438-3888 Fax 732/438-3889
UNITED STATES
NEW YORK
VOLLAND ELECTRIC EQUIPMENT CO. 75 Innsbruck Drive Buffalo, NY 14227 716/656-9900 Fax 716/656-8899
NORTH CAROLINA
TEAM SESCO P.O. Box 667489 28266 2225 Freedom Drive Charlotte, NC 28208 704/372-4832 or 800/487-3726 Fax 704/358-1098
OHIO
MAZZELLA LIFTING TECHNOLOGIES 21000 Aerospace Parkway Cleveland, OH 44142-1072 440/239-7000 or 800/362-4601 Fax 440/239-7010
PENNSYLVANIA
AMICK ASSOCIATES, INC. 11 Sycamore Street P.O. Box 529 Carnegie, PA 15106-0529 412/429-1212 or 800/445-9456 Fax 412/429-0191
RAM MOTORS & CONTROLS, INC. 5460-B Pottsville Pike, Docks 8-11 P.O. Box 748 Leesport, PA 19533 610/916-8000 Fax 610/916-7957
SOUTH CAROLINA
ENGINEERED SYSTEMS INC. 1121 Duncan-Reidville Road Duncan, SC 29334 846/879-7438 or 800/879-7438 Fax 864/879-6428
TEXAS
ABEL EQUIPMENT CO., INC. 3710 Cavalier Drive Garland, TX 75042 972/272-7706 Fax 972/272-6955
HYDRAULIC EQUIPMENT SERVICES, INC. 1021 North San Jacinto Street Houston, TX 77002 713/228-9601 Fax 713/228-0931
WISCONSIN
TRESTER HOIST & EQUIPMENT, INC. W136 N4863 Campbell Drive Suite #4 Menomonee Falls, WI 53051 262/790-0700 or 800/234-6098 Fax 262/790-1009
CANADIAN
SERVICE CENTERS
ALBERTA
KRISTIAN ELECTRIC 14236-121A, Edmonton, Alberta T5L 4L2 780/444-6116 Fax 780/483-0533
CERTIFIED HOIST REPAIR 17324-107 Ave, Edmonton, Alberta T55 LE9 780/489-7600 Fax 780/475-0511
BRITISH COLUMBIA
INTERLOK CRANE SERVICE 2227 Hartley Ave., Coquitlam, British Columbia V3K 6W9 604/526-3535 Fax 604/526-3538
MANITOBA
KING’S ELECTRIC MOTORS, LTD. 633 Tyne Avenue Winnipeg, Manitoba R2L 1J5 204/663-5332 Fax 204/663-4059
NOVA SCOTIA
HERCULES S.L.R 520 Windmill Road Dartmouth, Nova Scotia B3B 1B3 902/468-0300 Fax 902/468-8948
ONTARIO
*R & W HOIST REPAIR, LTD. 790 Redwood Square Oakville, Ontario L6L 6N3 905/825-5500 Fax 905/825-5315
*TORONTO ELECTRIC HOIST SALES & SERVICE 9 Condeco Court North York, Ontario M3A 1A1 416/386-0820 Fax 416/386-0821
*MASLACK SUPPLY, LTD. 488 Falconbridge Road Sudbury, Ontario P3A 4S4 705/566-1270 Fax 705/566-4208
QUEBEC
*HERCULES S.L.R. 3800 TransCanada Highway Pointe-Claire, Quebec H9R 1B1 514/428-5511 Fax 514/428-5555
*LEGER HOIST 7995-17th Ave. Montreal, Quebec H1Z 3R2 514/376-3050 Fax 514/376-0657
**ARE ALSO MASTER PARTS DEPOTS
**MASTER PARTS DEPOT ONLY
514/48631-5511
i
Page 4
SAFETY PRECAUTIONS
Each ShopAir 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) Performance Standard for Air Chain Hoists HST-5M, Overhead Hoists B30.16 and the Occupational Safety and Health Act (OSHA). 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, Fairfield, NJ 07007-2300, U.S.A.
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:
1. NOT operate a damaged, malfunctioning or unusually performing hoist.
2. NOT operate the hoist until you have thoroughly read and understood this Operating, Maintenance and Parts Manual.
3. NOT operate a hoist which has been modified without the manufacturer’s approval or without certification that it is in conformity with ANSI/AMSE 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 forming 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 approved 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 devices function properly.
28. Warn personnel of an approaching load.
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:
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 ShopAir recommended parts when repairing the unit.
10. Lubricate load chain as recommended in this manual.
11. NOT use thehoist’s overload limiting clutch to measureload.
12. NOT use limit devices as routine operating 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.
ii
Page 5
iii
Page 6
SPECIFICATIONS
Product
Code
Capacity
Lbs. (kg.)
Full Load
Hoist Speed
fpm (mpm)
Full Load
Lowering
Speed
2178 250 (113) 33 (10.0) 68 (20.7)
2180 300 (136) 30 (9.1) 62 (18.9)
2182 500 (226) 20 (6.1)
)
57 (17.4)
2179 500 (226) 16 (4.8) 52 (15.8)
2181 600 (272) 15 (4.6) 47 (14.3)
2183 1000 (453) 10 (3.0) 28 (8.5)
• Standard Protector™ overload device.
• 10-pocket, oblique lay liftwheel provides longer chain life.
• Epoxy powder coat finish.
• Variable flow, two lever pendant for precise load spotting.
• Threaded external exhaust for piping away exhaust in clean room or painting applications.
• Small, compact design for commercial & industrial applications.
• Industrial duty air motor for tough applications.
• Gear train is lifetime-lubricated with non-oxidizing grease.
• Hardened forged steel, latch-type lower hook rotates
0
.
360
• Hardened forged steel, rigid latch-type upper hook.
• Rugged cast aluminum alloy hoist frame.
• Alloy load chain.
• Lifetime warranty against defects in materials and workmanship.
• Made in USA.
DIMENSIONS IN. (mm)
A
IN. (mm)
7
10
/
(276) 3
8
7
10
/
(276) 3
8
7
10
/
(276) 3
8
15
11
/
(303) 5
16
15
/
11
11
(303) 5
16
15
/
(303) 5
16
Overloading and improper use can result in injury.
• Do not exceed working load limit, load rating or capacity.
• Do not use to lift people or loads over people.
• Use only CM®alloy chain for overhead lifting.
• Read and follow all instructions.
B
IN. (mm)
7
/
(98)
8
7
/
(98)
8
7
/
(98)
8
3
/
(146)
4
3
/
(146)
4
3
/
(146)
4
TO AVOID INJURY:
Number of
Load Chains
1 30 (13.6)
1 30 (13.6)
1 30 (13.6)
2 34 (15.4)
2 34 (15.4)
2 34 (15.4)
Shipping
Weight
LBS. (kg.)
1
Page 7
GENERAL INFORMATION
The ShopAir Hoists are precision, air operated link type chain hoists that are available in five rated capacities: 250, 300, 500 600 and 1000 pounds (113, 136, 226, 272 and 453 kg.). Each unit is supplied with a pendant throttle control station for controlling the lifting and lowering speeds and an upper latch type hook for suspending the hoist from a fixed support or trolley.
The basic design of the ShopAir consists of a lightweight, rugged aluminum alloy frame which houses a vane type air motor, hardened steel gears, hardened steel oblique lay liftwheel, a disc type load brake and a muffler for quiet operation. The gearing includes a Protector™ that is a factory set clutch that prevents lifting dangerous overloads. The lifting medium is alloy, hardened steel link type chain and it connects the lower hook to the liftwheel. The hoists with rated capacity of 250, 300 and 500 pounds (113, 136 and 226 kg.) are single reeved units whereas the units with rated capacities of 500, 600 and 1000 pounds (226, 272 and 453 kg.) are double reeved units. The standard lift of each capacity is 10 feet (3 meters) and units with longer lifts can be provided on a special, per order basis.
The pendant throttle control is suspended from the hoist frame so that the control levers are approximately four feet (1.2 meters) above the lower hook when it is in its lowest position. A unique, three tube hose is provided between the throttle control and the hoist head to control the vane type air motor and the lifting speed. The three tube hose includes an internal, aircraft type wire rope to eliminate strain on the hose connections at the throttle control and at the hoist head.
A quick connect type fitting is provided at the air inlet to easily attach the hoist to the external air supply (refer to INSTALLATION on page 3). At installation, there are no adjustments to be made. Just connect the hoist to the external air supply and the ShopAir Hoist is ready for operation.
REPAIR/REPLACEMENT POLICY
All Columbus McKinnon (CM®) ShopAir Chain Hoists are inspected and performance tested prior to shipment. If any properly maintained hoist develops a performance problem, due to a material or workmanship defect, as verified by CM repair or replacement of the unit will be made to the original purchaser without charge. This repair/replacement policy applies only to ShopAir Hoists installed, maintained and operated as outlined in this manual, and specifically excludes hoists subject to normal wear, abuse, improper installation, improper or inadequate maintenance, hostile environmental effects and unauthorized repairs/modifications.
Alterations or modification of hoist and use of non­original repair parts can lead to dangerous operation and injury.
TO AVOID INJURY:
• Do not alter or modify equipment.
• Do use only original replacement parts.
We reserve the right to change materials or design if, in our opinion, such changes will improve our product. Abuse, repair by an unauthorized person, or use of non-CM replacement parts voids the guarantee and could lead to dangerous operation. For full Terms of Sale, see Sales Order Acknowledgment. Also, refer to the back cover for Limitations of Warranties, Remedies and Damages, and Indemnification and Safe Operation.
®
ACCESSORIES
Chain Container
This accessory item (Figure 1) is used to hold the slack chain and it is supplied with mounting hardware and instructions. Chain containers are recommended for those applications where slack chain will interfere with the load or drag on the floor as may more often be the case with the (500, 600 and 1000 lbs. (226, 272 and 453 kg., Double Reeved units). Chain containers are shipped separately and can be furnished for units already in service.
Figure 1 Chain Container
CM®Series 632 TrolleyCMCMies 63
This lightweight, yet rugged, manual push type trolley (Figure
2) is designed to fit a wide range of monorail beams and negotiate tight curves. Provides mobility for your ShopAir Hoist.
Figure 2 Series 632 Trolley
RReeccooiill AAiirr HHoossee
Se
lf-Storing Air Hose with Fittings
CCaattaalloogg
,
NNuummbbeerr
IINN.. ((mmmm))
901621 901622
Nylon coated supporting recoil air hose (supports by others).
CCaattaalloogg NNuummbbeerr LLeennggtthh
Filter-Lubricator Units
CCaattaalloogg NNuummbbeerr
902960 902961
Filter-Regulator-Lubricator Units
CCaattaalloogg NNuummbbeerr
902966 902967
HHoossee WWoorrkkiinngg
FFiittttiinnggss EEaacchh EEnndd SSiizzee XX LLeennggtthh ((IIDD)) FFTT.. ((mm))
1/2 (12.7) X 15 (4.6) 1/2 (12.7) X 25 (7.6)
3/8 NPTF Male
Swivel Fittings
cable with eyebolt fittings each end for
901629 25 ft. (7.6m)
IInnlleett//OOuuttlleett
SSiizzee ((iinn..))
3/8 1/2
IInnlleett//OOuuttlleett
SSiizzee ((iinn..))
3/8 1/2
BBoowwll SSiizzee
11 oz. 11 oz.
BBoowwll SSiizzee
11 oz. 11 oz.
SShhiippppiinngg WWtt..
LLbbss.. ((kkgg..))
6 (2.7 kg.) 7 (3.2 kg.)
SShhiippppiinngg WWtt..
LLbbss.. ((kkgg..))
14 (6.4 kg.) 15 (6.8 kg.)
2
Page 8
INSTALLATION
UNPACKING
After opening the carton, carefully inspect the hoist frame, control tube, hooks and pendant throttle control for damage that may have occurred during shipment. If there is damage, refer to the packing slip envelope.
Operating the hoist with obvious external damage may cause load to drop and that may result in personal injury and/or property damage.
TO AVOID INJURY:
Carefully check hoist for external damage prior to installation.
All hoists are completely assembled, lubricated and load tested prior to shipment. To place the hoist in service, attach the upper hook to a support or trolley that has sufficient strength to support the hoist and several times the rated capacity of the hoist. If in doubt, consult a registered engineer and local building code.
Be certain that the upper hook is attached to the support so that the support is firmly seated in the center of hook bowl, the latch closes and contacts the tip of the hook, and that the latch does not bear against the support.
Suspending the hoist from an inadequate support may allow the hoist and load to fall and cause injury and/or property damage.
TO AVOID INJURY:
Make sure the structure has sufficient strength to hold several times the hoist and its rated load. Using the upper hook, hang the hoist from the support. hhooiisstt iiss ssoolliiddllyy hheelldd iinn tthhee uuppppeerrmmoosstt ppaarrtt ooff tthhee hhooookk aarrcc
aanndd tthhee llaattcchh iiss ttiigghhttllyy aaggaaiinnsstt tthhee ttiipp ooff tthhee hhooookk..
AIR SUPPLY SYSTEM
Connect hoist to a filtered and lubricated air source using a 1/2” (12.7 mm.) I.D. hose (see Figure 3). Do not use smaller diameter hose, since it will restrict air flow and reduce hoist performance. If the hoist is suspended from a trolley, provide sufficient hose to reach from the source to the farthest point of trolley travel. CM®Hose Trolleys are recommended to keep the hose up and out of the way.
A filter and lubricator (see Figure 3) be
tween the air source and the air hose leading to the hoist. These keep the air flowing free from dirt and add lubricant to the air so internal parts of the motor are constantly lubricated. Use a good grade of oil with a viscosity of 180 SSU at 100
0
F., air powered tool oil or SAE 0W machine oil.
Figure 3 Air Filter and Lubricator Unit
mmuusstt
BBee ssuurree tthhee
be installed
The recommended operating air pressure for the hoist is 90 psig. When line pressure exceeds 100 psig (at the hoist when it is lifting rated load), it is recommended that a pressure regulator be provided in the air supply line to keep the pressure at 90 psig. Although there is a wide range of pressures within which the hoist will operate, motor efficiency decreases as the air pressure drops (refer to the following Chart).
HHooiisstt
CCaappaacciittyy
Air
Pressure
(PSIG)
60
70
80
90
HHooiisstt
CCaappaacciittyy
Air
Pressure
(PSIG)
60
70
80
90
225500 llbbss..
((111133 KKgg..))
((SSiinnggllee RReeeevveedd))
Up
Down
FPM
(MPM)
(6.7)
27.2 (8. 3)
29.6 (9. 0)
32.5 (9. 9)
((DDoouubbllee RReeeevveedd))
FPM
(MPM)
(3.4)
13. 6 (4.1)
14. 8 (4.5)
16. 3 (5.0)
22
550000 llbbss..
((222266 KKgg..))
Up
11
FPM
(MPM)
Max.
46. 2
(14 .1 )
57. 1
(17 .4 )
62. 2
(19 .0 )
68. 3
(20 .8 )
Down
FPM
(MPM)
Max.
35. 2
(10.7)
43. 5
(13.3)12(3.7)
47. 4
(14.4)
52. 2
(15.9)
330000 llbbss..
((113366 KKgg..))
((SSiinnggllee RReeeevveedd))
Up
Down
FPM
FPM
(MPM)
(MPM)
Max.
19. 1
40. 1
(5. 8)
(12 .2 )
23. 9
50. 2
(7. 3)
(15 .3 )
26. 7
56. 1
(8. 1)
(17 .1 )
29. 6
62. 2
(9. 0)
(19 .0 )
660000 llbbss..
((227722 KKgg..))
((DDoouubbllee RReeeevveedd))
Up
Down
FPM
9.6
(3.0)
13. 4 (4.1)
14. 8 (4.5)
FPM
(MPM)
Max.
30.7 (9.4)
38.4
(11.7)
42.9
(13.1)
47.4
(14.4)
(MPM)
550000 llbbss..
((222266 KKgg..))
((SSiinnggllee RReeeevveedd))
Up
Down
FPM
(MPM)
((DDoouubbllee RReeeevveedd))
FPM
(MPM)
11. 1 (3. 4)
14. 8 (4. 5)
17. 3 (5. 3)
19. 5 (5. 9)
11000000 llbbss.. ((445533 KKgg..))
Up
5.6
(1.7)
7.4
(2.3)
8.7
(2.7)
9.8
(3.0)
FPM
(MPM)
Max.
41.6
(12 .7 )
53.7
(16 .4 )
57.1
(17 .4 )
56.6
(17 .3 )
Down
FPM
(MPM)
Max.
20.8 (6.3)
26.9 (8.2)
28.6 (8.7)
28.3 (8.6)
On the (500, 600 and 1000, (226, 272 and 453 Kg.), Double Reeved units), cut and discard the ties used to hold the two strands of chain together. With no load on the lower hook, depress the UP () lever in the pendant throttle control and raise the lower hook until it is about 2 feet (0.61 M) below the bottom of the hoist. Check both strands of chains for twists. Twists occur if the lower hook block has been capsized between the strands of chain during packing, shipment and/or handling. Reverse the capsize to remove twists.
CHAIN CONTAINER
If the chain container is to be used, attach it to the hoist per the instructions provided.
OPERATING INSTRUCTIONS
The hoist is equipped with a Protector™ that is designed to allow the first gear to slip when it is attempted to lift an excessive overload. An overload is indicated when the hoist speed slows down, it raises the load in a jerky manner or if it will not lift the load at all. In addition, some clutching noise may be heard. Should this occur, immediately release the UP () lever to stop the operation of the hoist and reduce the load to the rated capacity of the hoist. When the excessive load is removed, normal operation of the hoist is automatically restored.
CCAAUUTTIIOONN:: TThhee PPrrootteeccttoorr iiss ssuusscceeppttiibbllee ttoo oovveerrhheeaattiinngg aanndd wweeaarr wwhheenn sslliippppeedd ffoorr eexxtteennddeedd ppeerriiooddss.. UUnnddeerr nnoo cciirrccuummssttaanncceess sshhoouulldd tthhee PPrrootteeccttoorr bbee aalllloowweedd ttoo sslliipp ffoorr mmoorree tthhaann aa ffeeww sseeccoonnddss..
oist is not recommended for use in
Due to the above, th any application where there is a possibility of adding to an already suspended load to the point of overload. This includes dumbwaiter installations, containers that are loaded in mid-air, etc. Also, if the hoist is used at unusual extremes of ambient temperatures (above 150
0
F., -90C.), changes in lubricant properties may permit
15 the hoist to raise larger loads than under operating temperatures and could present possibility of property damage or injury. Hoist operation is controlled by depressing the pendant throttle control levers. Depressing the UP () lever will move the lower hook towards the hoist and depressing the DOWN () lever will move the lower hook away from the hoist. The speed of lifting and lowering can be varied by the distance the lever is depressed. To stop lifting and lowering, release the lever. The up and down levers are momentary type and the hoist will operate in the selected direction as long as the lever is held in the depressed direction. Release the lever and the hoist will stop.
e h
0
F., 650C., or below
3
Page 9
1. When preparing to lift a load, be sure the attachments to the lower hook are firmly seated in the hook saddle. Avoid off center loading of any kind, especially loading the tip of the hook or latch.
Black
2. When lifting, raise the load only enough to clear the
White
floor or support and check to be sure that the
Ground
attachments are firmly seated. Continue to lift only after you are assured the load is free of all obstructions.
3. Do not load the hoist beyond the rated capacity as
* Manual
Disconnect Switch
* Thermal
Overload Relay
* Slow Blow Fuses
or Inverse Time Circuit Breakers
Blue
Brown
Hoist Power Cord
Green-Yellow
shown on the brake end cover. Overloading can cause immediate failure of some load-carrying parts or create
*Receptacle Rated for 15 Amps Minimum. (220-1-50 Units Do Not Include Power Cord
a defect causing subsequent failure at less than rated
Plug) Wire Blue and Brown Wires to Fuses or Circuit Breakers and Green-Yellow Wire to Ground.
capacity. When in doubt, use the next larger capacity
Figure 4A
hoist.
4. Do not use this or any other overhead materials handling equipment for lifting persons.
5. Stand clear of all loads and avoid moving loads over heads of other personnel. Warn personnel of your intention to move a load into their area.
6. Do not leave the load suspended in air unattended.
7. Permit only qualified personnel to operate this hoist.
8. Do not wrap the load chain around the load and hook onto itself as a choker chain. Doing so will result in:
• The loss of the swiveling effect of the hook which could
cause twisted chain and jammed liftwheel.
• The chain could be damaged at the hook.
9. On the 500, 600 and 1000 pound (226, 272 and 453 Kg.) double reeved units, check for twists in the load chain. A twist can occur if the lower hook block has been capsized between the strands of chain. Reverse the capsize to remove twist.
10.Do not allow the load to bear against the hook latch. The latch is to help maintain the hook in position while the chain is slack before taking up the slack chain.
Allowing the load to bear against the hook latch and/or hook tip can result in loss of load.
TO AVOID INJURY:
Do not allow a load to bear against the hook latch and/or the hook tip. Apply load to hook bowl or saddle only.
11.Take up slack load chain carefully and start load easily to avoid shock and jerking of the chain. If there is any evidence of overloading, immediately lower the load and remove the excess load.
12.Do not allow the load to swing or twist while hoisting.
13.Never operate the hoist when flammable materials or vapors are present. Contact between steel parts may produce sparks that in turn can cause a fire or explosion.
SSTTAAYY AALLEERRTT!!
14. common sense.
Watch what you are doing and use
Do not use the hoist when you are tired, distracted or under the influence of drugs, alcohol or medication causing diminished control.
4
TO AVOID INJURY:
DDOO NNOOTT OO NNOOTT
DD
DDOO NNOOTT
DDOO NNOOTT
DDOO NNOOTT
Lift more than rated load. Operate with twisted, kinked or damaged chain. Operate damaged or malfunctioning hoist. Lift people or loads ov
er people. Operate hoist when load is not centered under hoist.
DDOO NNOOTT
Permit the lower hook block to contact hoi
st
frame or chain container.
DDOO
DDOO DDOO
Replace damaged or malfunctioning hook latch. Keep load chain well oiled. Read and understand this manual and all
rnings on the hoist.
wa
MMAAIINNTTEENNAANNCCEE
INSPECTION
To maintain continuous and satisfactory operation, a regular inspection procedure must be initiated so that worn or damaged parts can be replaced before they become unsafe. The intervals of inspection must be determined by the individual application and are based upon the type of service to which the hoist will be subjected. The inspection of hoists is divided into two general classifications designated as “frequent” and “periodic”.
Frequent Inspections
These inspections are usually visual examinations by the operator or other designated personnel. Frequent inspections are to be performed daily or monthly and shall include the following items:
a. Operate the hoist, with no load, and check for visual
signs or abnormal noises which could indicate a
potential problem - daily. b. Brake for evidence of slippage - daily. c. Chain for lubricant, wear, damaged links or foreign
material - daily (see below). d. Hooks for damage, cracks, twist, latch engagement
and latch operation - daily (see below).
Any deficiencies must be corrected before the hoist is returned to service.
PPeerriiooddiicc IInnssppeeccttiioonnss
These are
cords apparent external conditions to provide a basis for
re continuing evaluation. Periodic inspections are to be performed semi-annually and they should include the following:
a. All items listed under frequent inspections. b. External evidence of loose screws. c. External evidence of worn, corroded, cracked or
d. External evidence of damage or excessive wear of the
visual inspections by an appointed person who
distorted hook block, gears, bearings, chain stop and
hook retainer.
liftwheel or sheave (double reeved unit). Widening and
deepening of pockets may cause chain to lift-up in the
pockets and cause binding between liftwheel and
chain guide or between lower sheave and hook block.
Check chain guide for wear or burring where the chain
enters the hoist. Severely worn or damaged parts
should be replaced.
Page 10
e. External evidence of excessive wear of brake parts -
see page 7.
f. Check the control station levers to make sure they
operate freely and spring back when released.
g. Check air supply hose and control hose for kinks, cuts,
leaks and damage.
h. Check the chain pin or dead end pin and chain stop
for wear and cracks.
i. Check for lubricant leaks at gasket between main
frame and gear housing. Tighten gear housing screws to stop leak. If leak persists, replace gasket.
j. Inspect splines on first pinion shaft and motor coupling
for signs of wear or deterioration. Replace splined parts if worn or damaged.
k. Check for air leaks at brake end cap. Replace piston
seals to stop leaks.
l. Check for air leaks at the joints of the motor. Tighten
screws to stop leaks. If leaks persist, disassemble motor, see page 8, and replace seals.
m. Check for air leaks at joint between the supply block
and valve body. Tighten screws or replace gasket to stop leaks.
n. Check for air leaks at o-rings on top and under valve
body. Tighten valve bolt or replace o-ring to stop leaks.
NNOOTTEE:: TToo ppeerrffoorrmm ssoommee ooff tthhee ppeerriiooddiicc iinnssppeeccttiioonnss,, iitt iiss nneecceessssaarryy ttoo ppaarrttiiaallllyy ddiissaasssseemmbbllee tthhee hhooiisstt.. RReeffeerr ttoo DDiissaasssseemmbbllyy--AAsssseemmbbllyy ssttaarrttiinngg oonn ppaaggee 88..
Any deficienci
es
noted must be corrected before the hoist is returned to service. Also, the external conditions may show the need for more detailed inspection which, in turn, may require the use of nondestructive-type testing.
Any parts that are deemed unserviceable are to be replaced with new parts before the unit is returned to service. It is very important that the unserviceable parts be destroyed to prevent possible future use as a repair item and properly disposed of.
Hook Inspection
Hook damage from chemicals, deformations or cracks or that have more than a 10
0
twist from the plane of the
unbent hook or excessive opening must be replaced.
Any hook that is twisted or has excessive throat opening indicates abuse or overloading of the unit. Other load­sustaining components of the hoist should be inspected for damage.
On latch type hooks, check to make sure that the latch is not damaged or bent and that it operates properly with sufficient spring pressure to keep the latch tightly against the tip of the hook and allow the latch to spring back to the tip when released. See below to determine when the hook must be replaced.
LOAD CHAIN
Chain should feed smoothly into and away from the hoist or hook block (500, 600 and 1000#, 226, 272 and 453 Kg. units). If chain binds, jumps or is noisy, first clean and lubricate it (see below). If trouble persists, inspect chain and mating parts for wear, distortion or other damage.
Chain Inspection
First clean chain with a non-caustic/non-acid type solvent and make a link by link inspection for nicks, gouges, twisted links, weld spatter, corrosion pits, sitriations (minute parallel lines), cracks in weld areas, wear and stretching. Chain with any one of these defects must be replaced.
Slack the portion of the chain that normally passes over the liftwheel. Examine the interlink area for the point of maximum wear (polishing, see figure 5). Measure and record the stock diameter at this point of the link. Then measure stock diameter in the same area on a link that does not pass over the liftwheel (use the link adjacent to the loose end link for this purpose). Compare these two measurements. If the stock diameter of the worn link is
0.010 inches (0.254 mm.), or more, less than the stock diameter of the unworn link, the chain must be replaced.
FFiigguurree 55.. CChhaaiinn WWeeaarr AArreeaass
On the 500, 600 and 1000# (226, 272 and 453 Kg.) units, repeat this examination of the chain that passes through the hook block.
Also check chain for stretch using a vernier caliper as shown in figure 6. Select an unused, unstretched section of chain (usually at the loose end) and measure and record the length over 11 chain links (pitches). Measure and record the same length on a worn section of chain. Obtain the amount of stretch and wear by subtracting the measurement of the unworn section from the measurement of the worn section. If the result (amount of stretch and wear) is greater than 0.145 inch (3.7 mm.), the chain must be replaced.
Use only a “Knife-edge” caliper to eliminate possibility of false reading by not measuring full pitch length.
FFiigguurree 44.. HHooookk IInnssppeeccttiioonn
FFiigguurree 66.. CChhaaiinn IInnssppeeccttiioonn
5
Page 11
Note that worn chain can be an indication of worn hoist components. For this reason, the hoist’s chain guide, hook block and liftwheel should be examined for wear and replaced as necessary when replacing worn chain.
Also, these chains are specially heat treated and hardened and should never be repaired.
UUssee oonnllyy SSttaarr ((**)) ggrraaddee llooaadd cchhaaiinn aanndd oorriiggiinnaall rreeppllaacceemmeenntt ppaarrttss.. UUssee ooff ootthheerr cchhaaiinn aanndd ppaarrttss mmaayy bbee ddaannggeerroouuss aanndd vvooiiddss ffaaccttoorryy wwaarrrraannttyy..
FFiigguurree 77.. CChhaaiinn EEmmbboossssiinngg
Use of commercial or other manufactures’ chain and parts to repair ShopAir Hoists may cause load loss.
TO AVOID INJURY:
Use only factory supplied replacement load chain and parts. Chain and parts may look alike, but factory original chain and parts are made of specific materials or processed to achieve specific properties. See Figure 7.
IIMMPPOORRTTAANNTT:: DDoo nnoott uussee rreeppllaacceedd cchhaaiinn ffoorr ootthheerr ppuurrppoosseess ssuucchh aass lliiffttiinngg oorr ppuulllliinngg.. LLooaadd cchhaaiinn mmaayy bbrreeaakk ssuuddddeennllyy wwiitthhoouutt vviissuuaall ddeeffoorrmmttiioonn.. FFoorr tthhiiss rreeaassoonn,, ccuutt rreeppllaacceedd cchhaaiinn iinnttoo sshhoorrtt lleennggtthhss ttoo pprreevveenntt uussee aafftteerr ddiissppoossaall..
Lubrication
Chain
small amount of lubricant will greatly increase the life of
A load chain. Do not allow the chain to run dry. keep it clean and lubricate at regular intervals with Lubriplate
®
Chain Oil 10-R (Fiske Bros, Refining Co.) or equal lubricant. Normally, weekly lubrication and cleaning is satisfactory, but under hot and dirty conditions, it may be necessary to clean the chain at least once a day and lubricate it several times between cleanings.
Used motor oils contain known carcinogenic materials.
Never use used motor oils as a chain lubricant. Only use
TO AVOID HEALTH PROBLEMS:
Lubriplate®Bar and Chain Oil 10-R as a lubricant for the load chain.
When lubricating the chain, apply sufficient lubricant to obtain natural run-off and full coverage, especially in the interlink area.
LUBRICATION
Refer to Exploded View and Parts List on pages 10 thru 14.
The lubricants used in and recommended for the ShopAir Hoist may contain hazardous materials that mandate specific handling and disposal procedures.
TO AVOID CONTACT AND CONTAMINATION:
Handle and dispose of lubricants only as directed in applicable material safety data sheets and in accordance with applicable local, state and federal regulations.
NNOOTTEE:: TToo aassssuurree eexxttrraa lloonngg lliiffee aanndd ttoopp ppeerrffoorrmmaannccee,, bbee ssuurree ttoo lluubbrriiccaattee tthhee vvaarriioouuss ppaarrttss ooff tthhee SShhooppAAiirr HHooiisstt uussiinngg tthhee lluubbrriiccaannttss ssppeecciiffiieedd bbeellooww.. IIff ddeessiirreedd,, tthheessee lluubbrriiccaannttss
6
ffoorr iinnffoorrmmaattiioonn oonn oorrddeerriinngg tthhee lluubbrriiccaannttss..
yy bbee ppuurrcchhaasseedd ffrroomm CCMM®®.. RReeffeerr ttoo ppaaggee 1111
mmaa
Bar and
Gears
The Protector™ (620-111) should operate for the normal life of the hoist without service. The device has been lubricated and calibrated by CM
®
and should not be adjusted.
CCAAUUTTIIOONN:: TThhee PPrrootteeccttoorr iiss ttoo bbee uusseedd wwiitthh CCeennttuurryy LLuubbrriiccaannttss HHBB--1111,, ##33 ggrreeaassee.. DDoo nnoott uussee aannyy ootthheerr ggrreeaassee oorr tthhee PPrrootteeccttoorr wwiillll nnoott ooppeerraattee pprrooppeerrllyy aanndd ppaarrttss ccoouulldd bbee ddaammaaggeedd..
Th
e gears and Protector™ are packed at assembly with
ease and should not need to be renewed unless the gears
gr have been removed from the housing and degreased.
CCAAUUTTIIOONN:: NNeevveerr ddeeggrreeaassee tthhee PPrrootteeccttoorr oorr aatttteemmpptt ttoo ddiissaasssseemmbbllee tthhiiss ddeevviiccee.. DDeeggrreeaassiinngg tthhee PPrrootteeccttoorr mmaayy ddaammaaggee ppaarrttss aanndd uussiinngg aa ddeevviiccee tthhaatt hhaass bbeeeenn ddeeggrreeaasseedd mmaayy ccaauussee eerrrraattiicc,, iinnccoonnssiisstteenntt ooppeerraattiioonn.. IIff tthhee PPrrootteeccttoorr hhaass
bbeeeenn ddeeggrreeaasseedd,, iitt mmuusstt bbee rreeppllaacceedd bbyy aa CCMM®®ccaalliibbrraatteedd
ddeevviiccee..
If
the gears are removed from the housing, wipe the excess
ease off the outside surfaces of the Protector™ with a soft
gr cloth and degrease the remaining gears and housings. Upon reassembly, add 2 oz. of the above grease to gears and housing. Also, coat the spline on the end of the first pinion and shaft (620-131) with a Molydisulphide lubricant such as Moly-Duolube 67 (Hercules Packing Co.).
Bearings
Needle bearings (620-109, 620-114, 620-115, 620-128 and 620-164) are packed at assembly with grease and should not need to be relubricated. However, if the housings (620­113 and 620-107), liftwheel (620-127) or sheave wheel (620-
162) have been degreased, these bearings should be greased using “Century Lubricants HB-11, #3” grease.
Seals
When reassembling the unit, wipe the inside surface of the seals with “Century Lubricants HB-11, #3” grease.
Service Air Line Lubricator
The air line filter and lubricator is the only source of lubrication for control valves and air motor. Fill lubricator with a good grade air hoist motor oil or low machine oil (viscosity of 180 SSU at 100
0
F.). Multi-viscosity, detergent type oil is not recommended. Feed one drop of oil for every 50 to 75 cubic feet of air going through the air motor.
Hook Block
If the hook blocks are disassembled for inspection purposes, wipe the grease from the hook knob and the hook knob cavities in the hook blocks. At reassembly, coat the underside of the hook knob and the knob bearing surfaces of cavities in the hook blocks with Molykote BR-2-S (Dow Corning Corp.) grease or equivalent.
Chain Guide, Liftwheel and Sheave Wheel
When the hoist is disassembled for inspection and/or repair, the chain guide, stripper, sheave wheel (on double chain unit) and liftwheel must be lubricated with Lubriplate
®
Bar and Chain Oil 10-R (Fiske Bros. Refining Co.) prior to reassembly. The lubricant must be applied in sufficient quantity to obtain natural runoff and full coverage of these parts.
LLooaadd CChhaaiinn
See above for lubrication of the load chain.
Exterior Finish
he exterior surface of the hoist has a durable, scratch
T resistant baked powder coating. Normally, the exterior surfaces can be cleaned by wiping with a cloth.
Page 12
BRAKE
The brake is non-adjustable with a nominal 0.004 inch (0.012 mm) air gap and the brake disc must be replaced when the gap reaches 0.012 inches (0.305 mm). The brake spacer should be no more than 0.012 inches (0.305 mm) thicker than the combined thickness of the brake disc and armature plate.
Failure to follow proper lockout/tagout procedures may present the danger of injury from the escape of high pressure air.
TO AVOID HEALTH INJURY:
Disconnect the hoist from the air supply and lockout/tagout the main air supply valve before removing the cover or servicing this hoist.
Figure 10.
(250, 300, 500 & 600 Pound (Double Reeved)
(113, 136, 226 & 272 Kg.)
Air Motor
Once a year, remove the air motor (see Item 9, Page 16) and check the condition of the bearings, rotor for possible rubbing on the body or end plates, free movement of the blades in rotor slots, seals and shims. Replace worn or damaged parts. If the motor appears to be in good condition, do not service other than lubricating well with light machine oil.
Pendant Throttle Control
Once a year, disassemble the pendant throttle control (see page 8) and check the condition of the springs, valves and levers. Replace worn or damaged parts. If the parts appear to be in good condition, do not service other than lubricating well with light machine oil.
FFiigguurree 99.. BBrraakkee
To inspect the air gap, disconnect the hoist from air supply. Remove the brake end cover (620-533) and brake end spacer (620-527) from the gear housing (620-113) to expose the brake. Disconnect the two air tubes from the air cylinder (620-524). Remove the air cyclinder cap (620-503) and brake spring (620-123). Remove the air cylinder (620-524) by removing the 4 screws (620-124). Remove the piston (620-
521), o-ring (620-536), coupling (620-523) and seal (620-535) by removing screw (620-575). Removing the air cyclinder assembly will expose the brake armature (620-118), brake disc (620-117), brake spacer (620-193) and brake base plate (620-116). Inspect these parts and replace if worn or damaged. Check o-ring (620-536) and seal (620-535) and replace these if worn or damaged. Make sure to install new seal with the opening towards the coupling. Apply grease to the outside of the lip seal and o-ring. Making sure that the o-ring (620-536) is on piston shaft, slide the piston (620-521) into the air cylinder (620-524). Install coupling (620-523) into air cyclinder (620-524) using screw (620-575).
Assemble the brake base plate (620-116), brake spacer (620-193), brake disc (620-117) and brake armature (620-
118). Install 4 screw (620-526) into the air cyclinder (620-
524). Install brake spring (620-123) and air cycliner cap (620-
503). Reconnect the two air tubes. Assemble the brake end spacer (620-527) and end cover (620-533) to gear housing (620-113) using the three screws (620-507).
Control Valve Assembly
Once a year, disassemble the control valve assembly (see Exploded View, Pages 13 & 14) and check the condition of the pistons, springs, spring seats, gasket, O-rings, valve bolts, air fittings and muffler. Replace worn or damaged parts. If the parts appear to be in good condition, do not service other than lubricating them with light machine oil.
PROTECTOR
The Protector™ should operate for the normal life of the hoist without service. The device has been lubricated and calibrated and it should not be adjusted. If the Protector™ is not operating properly (see testing on page 9), it must be replaced with a properly calibrated unit from the factory.
PREVENTIVE MAINTENANCE
A preventive maintenance program should be established to prolong the useful life of the hoist and maintain its reliability and continued safe use. The program should include the periodic and frequent inspections with particular attention being paid to the lubrication of the various components using the recommended lubricants (see page 11).
RECOMMENDED SPARE PARTS
To insure continued service of the ShopAir Hoist, the following is a list of parts that are recommended to be kept on hand at all times to replace parts that have worn or failed. Parts applicable to your hoist should be stocked.
KKeeyy NNoo.. PPaarrtt NNaammee QQttyy.. PPeerr
620-117 Brake Disc 1 620-536 Piston Shaft Seal 1 620-512 Piston Return Spring 2 620-540 O-Ring 4 620-514 Piston 2 620-562 Gasket 1 620-515 Valve Gasket 1 620-564 Vane 4 620-531 Pendant Throttle
Control 620-535 Piston Seal 1 620-571 Snap Ring 1 620-576 Motor Repair Kit 1
KKeeyy NNoo.. PPaarrtt NNaammee QQttyy.. PP eerr
HHooiisstt
1 620-570 Oil Seal 1
HHooiisstt
Refer to pages 9-14 for ordering instructions and the Parts List for part numbers.
7
Page 13
DISASSEMBLY-ASSEMBLY
When disassembling and assembling the ShopAir Hoist, refer to the exploded view and the parts list on pages 10 thru 14. These show the proper relationship of the parts, the names of the parts and the required quantities of the parts. In addition, please observe the following:
 ! WARNING
Components such as motors, valves, lines, filter/lubricators located after a closed shut­off valve can contain pressurized air. Disassembly in this state can cause injury.
Bleed the stored air by repeatedly depressing the pendant paddles.
1. Needle bearings are pressed into the gear housing (620-113), main frame (620-107), liftwheel (620-127) and lower sheave wheel (620-162). Unless they are to be replaced, do not attempt to remove these bearings.
2. A liftwheel seal (620-108) is pressed into the main frame (620-107) and a seal (620-130) is pressed into the end of the liftwheel shaft (620-148). Be careful that these seals are not cut or damaged during disassembly and reassembly.
3. Refer to page 7 for disassembly, inspection and reassembly of the brake.
4. Do not attempt to disassemble the Protector™ - refer to page 7.
5. Refer to page 6 for lubrication instructions.
6. See next section for load chain removal and installation.
7. Tighten the various screws as follows:
KEY-NO. PART NAME SEATING TORQUE
LB. IN. NM
620-126 Pin Retainer Plate Screw 25 2.8 620-154 Motor Cover Screw 25 2.8 620-134 Gear Housing Screw 25 2.8 620-133 Brake End Cover Screw 25 2.8 620-168 Dead End Plate Screw 125 14.1 620-140 Hook Retainer Screw 10 1.1 620-157 Hook Block Screw
500, 600 and 1000 lbs. (226, 272 and 453 Kg.) (Double Reeved) units 125 14.1 250, 300 and 500 lbs. (113, 136 and 226 Kg.) (Single Reeved) units 50 5.6
620-510 Motor Screws 25 2.8
620-517 Valve Block Screws 25 2.8
620-518 Supply Bolt 50 5.6
8. To remove the air motor (620-538), remove the motor end cover (620-502) and motor end spacer (620-528). Loose the valve bolts (620-518) enough to remove the valve block assembly from the bottom of the motor. Remove the two screws used to attach the motor to the main frame (620-107) and carefully slide the motor shaft out of the coupling (620-508). If necessary, refer to page 9 for instructions for disassembling the motor.
9. To install the air motor (620-538), slide the coupling (650-
508) onto the end of the motor shaft. Align splines on the first pinion and shaft (620-131) and coupling and then slide the motor into position. Secure the motor to the main frame (620-107) using two screws. Attach the valve assembly to the bottom of the motor using the two valve bolts (620-518), making sure the O-rings are on the valve bolts. Assemble the motor end spacer (620-528) and motor end cover (620-502) to the main frame using three screws.
10. Properly install the upper hook as shown in Figure 11A, then slide the hook retainer (620-139) into the cavity on top of the hoist and secure it using hook retainer screw (620-140). Tighten screw to a seating torque of 10 in. lbs. (1.1 NM).
Hook Opening Towards Loose End
Loose End
Sh opA ir
Hook Opening Away From Loose End
Loose End
Sh opA ir
FFiigguurree 1111.. HHooookk PPoossiittiioonn
11. After reassembly, test the unit per instructions on page 9.
LOAD CHAIN REMOVAL/INSTALLATION
1. If unit has a chain container, remove it from the chain guide.
2. Remove the chain stop (620-146), Depress “DOWN” () lever and run chain out of hoist.
3. Feed a short length of soft wire through the opening between the chain guide (620-141), and stripper (620-143) until it comes out of the hoist. Remove the wire and attach the chain stop as shown below. On units with chain container, place the chain stop and loose end of chain in chain container. Attach chain container to chain guide.
4. Jog the “UP” () lever while pulling on the free end of wire until the chain comes out of the hoist. Remove the wire and attach the chain stop as shown below. On units with chain container, place chain stop and loose end of chain
in chain container. Attach chain container to chain guide.
FFiigguurree 1122.. AAttttaacchhiinngg LLoooossee EEnndd ooff CChhaaiinn
8
Page 14
5. On the 250, 300 and 500# (Single Reeved) (113, 136 and 226 kg.) units, remove the hook block from the old chain and attach it to the new chain by reusing the chain pin (620-158).
On the 500, 600 and 1000# (226, 272 and 453 kg.) units:
Remove dead end plate (620-160) from hoist.
Remove dead end pin (620-161) from the last link
of chain and pull chain out of dead end plate.
Pull old chain out of hook block and disassemble
the hook block.
Make sure the new chain is not twisted and wrap
the chain around the sheave wheel (620-162) with welds down and towards the sheave wheel.
Reassemble hook block and pull the new chain
through the hook block.
Slide the dead end plate over the last link and
secure it using the dead end pin.
Making sure the chain is not twisted between the
hook block and hoist, attach the dead end plate to the stripper (620-143).
Retrace the new chain and check for twists. If
chain is twisted, start over.
IIMMPPOORRTTAANNTT:: DDoo nnoott uussee oolldd cchhaaiinn ffoorr ootthheerr ppuurrppoosseess ssuucchh aass lliiffttiinngg oorr ppuulllliinngg.. LLooaadd cchhaaiinn mmaayy bbrreeaakk ssuuddddeennllyy wwiitthhoouutt vviissuuaall ddeeffoorrmmaattiioonn.. FFoorr tthhiiss rreeaassoonn,, ccuutt tthhee oolldd cchhaaiinn iinnttoo sshhoorrtt lleennggtthhss ttoo pprreevveenntt uussee aafftteerr ddiissppoossaall..
CUTTING CHAIN
Hoistaloy
®
load chain is hardened and it is difficult to cut. The following methods are recommended when cutting a length of new chain from stock or cutting off worn chain. Always wear eye protection when cutting chain.
1. Use a grinder and nick
the link on both sides (see right), then secure the link in a vise and break off with a hammer.
2. Use a 7”(177 mm) minimum diameter by 1/8" (3.1 mm)
thick abrasive wheel (or type recommended by wheel supplier) that will clear adjacent links.
3. Use a bolt cutter (see
right) with special cutter jaws for cutting hardened chain. Jaws should be 1 inch (25.4 mm) long.
TESTING
Before using, all altered, repaired or used hoists that have not been operated for the previous 12 months must be tested by the user for proper operation. First, test the unit without a load and then with a light load of 50 pounds (23 kg) times the number of load supporting parts of load chain to be sure that the hoist operates properly and that the brake holds the load when control is released. Next test with a load of *125% of rated capacity. In addition hoists in which load sustaining parts have been replaced should be tested with *125% of rated capacity by or under the direction of an appointed person and a written report prepared for record purposes. After this test, check the Protector™ functions. If the Protector™ permits lifting a load in excess of 200% of rated load, it should be replaced.
*If the Protector™ prevents lifting of a load of 125% of rated capacity, reduce load to rated capacity.
NNOOTTEE:: FFoorr aaddddiittiioonnaall iinnffoorrmmaattiioonn oonn iinnssppeeccttiioonn aanndd tteessttiinngg,, rreeffeerr ttoo AASSMMEE BB3300..1166 OOvveerrhheeaadd HHooiissttss oobbttaaiinnaabbllee ffrroomm AASSMMEE OOrrddeerr DDeeppaarrttmmeenntt,, 2222 LLaaww DDrriivvee,, BBooxx 22330000,, FFaaiirrffiieelldd,, NNJJ 0077000077--22330000,, UU..SS..AA..
ORDERING INSTRUCTIONS
The following information must accompany all correspondence and orders for replacement parts:
1. Hoist rated load from identification plate.
2. Serial number of the hoist from identification plate.
3. Length of lift.
4. Key number of part from parts list.
5. Number of parts required.
6. Part name from parts list.
7. Part number from the parts list.
NOTE: When ordering replacement parts, it is recom­mended that consideration be given to the need for also ordering such items as gaskets, fasteners, seals, etc. These items may be damaged or lost during disassembly or just unfit for future use because of deterioration from age or service.
Cutting chain can produce flying particles.
• Wear eye protection.
TO AVOID HEALTH PROBLEMS:
• Place a shield over chain to prevent flying objects.
Using “commercial” or other manufacturer’s parts to repair the ShopAir Hoist may cause load loss.
TO AVOID INJURY:
Use only factory supplied replacement parts. Parts may look alike but factory original parts are made of specific materials or processed to achieve specific properties.
9
Page 15
SHOPAIR MECHANICAL PARTS EXPLODED VIEW
11
10
Page 16
SHOPAIR PARTS LIST
KKeeyy NNoo.. DDeessccrriippttiioonn QQttyy.. PPaarrtt NNoo.. 620-107 Main Frame 1 20352 620-108 Liftwheel Seal 1 20705 620-109 Protector Bearing, Main Frame Side 1 88636
620-111
Protector Assembly 500# (Single Reeved) & 1000# Units
20645
1
20665 620-112 Thrust Washer, Second Pinion 2 88640 620-113 Gear Housing 1 20350 620-114 Protector Bearing, Gear Housing 1 88636 620-115 First Pinion Bearing 1 88635 620-125 Pin Plate 1 20700 620-126 Pin Plate Screw 2 20743
620-127
Liftwheel and Gear Assembly 500# (Single Reeved) & 1000# Units
20664
1
20666 620-128 Liftwheel Bearing 2 88637 620-129 Thrust Washer, Liftwheel 2 88638 620-130 Liftwheel Shaft Seal 1 20704
First Pinion and Shaft
620-131
620-133 Spacer
10 Tooth 12 Tooth
2
1
Contact Factory
20964 620-134 Gear Housing Screw 2 20384 620-135 Gear Housing Screw (short) 2 920718 620-136 Dowel Pin 4 920720 620-137 Upper Hook 1 20650 620-138 Hook Latch Kit 2 595522 620-139 Hook Retainer 1 20712 620-140 Hook Retainer Screw 1 920725 620-141 Chain Guide 1 20304 620-142 Chain Guide Pin 4 20729 620-143 Chain Stripper 1 20305 620-144 Load Chain (Specify Length Req’d.) - 85988 620-145 Loose End Ring 1 20744 620-146 Chain Stop 2 20428 620-147 Chain Stop Screw 2 25848 620-147A Chain Stop Screw Nut 2 982472 620-148 Liftwheel Shaft 1 20313 620-149 Thrust Washer, First Pinion 2 88639 620-155 Caution Label 1 20758
620-156
620-157
Hook Block
500#, 600# and 1000# 2 20739 Hook Block Screw
500#, 600# and 1000# 2 920724
2 20995
2 920730
620-159 Hook (Includes 620-138) 1 23030
KKeeyy NNoo.. DDeessccrriippttiioonn QQttyy.. PPaarrtt NNoo..
620-160
620-161
620-162
620-163
620-164
620-165
620-168
Dead End Plate 500#, 600# and 1000#
Dead End Pin 500#, 600# and 1000# Sheave Wheel (Includes 620-164) 500#, 600# and 1000#
Sheave Wheel Shaft 500#, 600# and 1000# Sheave Wheel Bearing 500#, 600# and 1000#
Sheave Wheel Thrust Washer 500#, 600# and 1000#
Dead End Plate Screw 500#, 600# and 1000#
1 20714
1 920720
1 20652
1 20318
1 88641
2 88639
2 73715
620-174 Gasket 1 20755 620-196 Hook Block Lockwasher 2 940802
Part Number for Packaged
Lubricants
Used in the ShopAir
(Refer to Page 6 for Lubrication Instructions)
Lubricant
Usage
Hoist Gears Grease
Spline one end of
First Pinion and Shaft
Load Chain
Lower Hook Knob Grease
When ordering lubricants, specify the type of lubricant, part number and packaged quantity required.
Type
Lubricant
Century
Lubricants HB-11,#3
Oil-Graohite Mixture
Hercules Packing Co.
Moly-Duolube
Oil
Friske Bros.
Lubriplate®Bar and
Chain Oil #10R
Dow Corning
Molykote BR-2-S
Part Numbers and
Packaged Quantity
of Lubricants
28605 for 1/2 lb. Can
28615 for 1 lb. Can
28617 for 4 lb. Can.
40628 for 1 Pint Can
28608 for 1 Pint Can
28619 for 1 Gal. Can
28606 for 1/2 lb. Can
28618 for 1 lb. Can
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Page 17
SHOPAIR PARTS LIST
KKeeyy NNoo.. DDeessccrriippttiioonn QQttyy.. PPaarrtt NNoo.. 620-103 Rotor Bearing, Inboard 1 88486 620-116 Brake Base Plate 1 20419
620-117 Brake Disc 1
620-118 Armature Plate 1 20420 620-123 Brake Spring 1 20887 620-124 Brake Screw 4 920740
Capacity Plate 250#
300# 1 20737
620-169
620-183 Hole Plug 1 20780 620-184 Hole Plug 1 20781 620-193 Brake Spacer 1 20723 620-501 ShopAir Label 1 20943 620-502 Motor Cover, Orange 1 20415C 620-503 Cylinder Cap 1 20425 620-504 Motor Cover Screw (1.75” Lg.) 1 20947 620-505 Motor Cover Screw (3.50” Lg.) 1 20957 620-506 Motor Cover Screw (5.75” Lg.) 1 20945 620-507 Brake Cover Screw 3 20946 620-508 Motor Coupling 1 20391 620-509 Air Tubing (Specify Length Req’d.) 1 20948 620-510 Air Motor Screw 2 20958 620-511 Valve Body 1 20392 620-512 Piston Return Spring 2 20949 620-513 Spring Seat 2 20393 620-514 Piston 2 20394 620-515 Valve Gasket 1 20951 620-516 Supply Block 1 20395 620-517 Valve Body Screw 6 20959 620-518 Valve Bolt 2 20396 620-519 Swivel Elbow 4 20952 620-521 Brake Piston 1 20424 620-523 Brake Coupling 1 20426 620-524 Air Cylinder 1 20427 620-525 Brake Shuttle Valve 1 20955
620-526 620-527 Brake End Spacer, Orange 1 20413C 620-528 Motor End Spacer, Orange 1 20414C 620-529 Control Tube (Specify Length Req’d.) 1 83979 620-530 Set Screw 1 20960 620-531 Pendant Throttle Control 1 647521600 620-533 Brake Cover, Orange 1 20411C 620-534 Muffler 1 20963 620-535 Piston Seal 1 11388201 620-536 Piston Shaft Seal 1 20211 620-537 Coupling Pin 2 982315 620-538 Air Motor 1 20950 620-539 Air Motor Screw Lockwasher 2 957844 620-540 O-Ring 4 20991 620-541 Warning Tube 1 687J6 620-542 Coupling 1 20990
620-543
620-550 Lever Pin 2 647521606S 620-551 Lever 2 648888613S
500# 1 20763 600# 1 20738 1000# 1 20884
Swivel Fitting 1 20956
Control Tube and Pendant Throttle Control for 10 ft. (3m) Lift. For other Lifts, contact CM.
Contact Factory
1 20762
1 20686
KKeeyy NNoo.. DDeessccrriippttiioonn QQttyy.. PPaarrtt NNoo..
620-552 Throttle Valve 2 648885601S 620-553 Throttle Valve Seal 4 648885602S 620-554 Throttle Valve Spring 2 648885615S 620-555 Throttle Valve Cap 2 648885616S
620-556 Throttle Valve Cap Seal 2 648885617S
Order
620-557 Housing
620-558 Valve Housing -
620-559 Valve Housing Seal 2 648885611S
620-560 Valve O-Ring 1 648885603S 620-561 “S” Hook 1 10814701 620-573 Strain Line Sleeve 1 989873
O.D. Cap Red 2 20997
620-574
620-575 Brake Screw 1 970980
620-576 Motor Repair Kit
620-578 Strain Cable
620-579 Shrink Tubing 4 20992
620-580 Air Supply Label 1 20363
620-581 Air Supply Line Connector 6 20994
620-582 Hose Clamps 6 82175
O.D. Cap White 2 20998
O.D. Cap Blue 2 20999
Kit Includes: Shaft Seal, Drive End Bearing, Dead End Bearing, Vanes, Push Pins, Spring & End Cap Gasket.
(Specify Length Required)
Complete
­Station
Order
Complete
Station
1 21900
1 89102
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Page 18
SHOPAIR EXPLODED VIEW
620-556
620-554
620-553
620-557
620-559
620-552
620-558
620-555
620-551
620-550
AIR HOIST PARTS
*SEE PAGE 16 FOR EXPLODED VIEW OF MOTOR
PENDANT THROTTLE
CONTROL
620-543
620-543
SHOPAIR
AIR CHAIN HOIST
EXPLODED VIEW
13
14
Page 19
TROUBLESHOOTING
TTRROOUUBBLLEE PPRROOBBAABBLLEE CCAAUUSSEE RREEMMEEDDYY
1. Hoist does not operate. a. Insufficient air pressure at source.
2. Hoist will not hold load in suspension.
3. Hook will raise but will not
lower or hook will lower but not raise.
b. Insufficient air supply at hoist.
c. Clogged air intake or muffler.
d. Excessive overload.
e. Clogged valve block.
f. Clogged pendant throttle control. g. Motor failure.
h. Lack of lubrication. i. Brake not operating.
a. Brake not holding. b. Broken brake spring. c. Excessive overload.
a. Clogged pendant throttle control. b. Clogged valve block. c. Excessive load.
a. Check and adjust air pressure. b. Use correct size air supply hose (see
page 3).
c. Shut off air supply, disconnect air supply
hose and clean air filter and muffler.
d. Reduce load to the rated capacity of the
hoist.
e. Disassemble and check for free movement
of pistons. f. Disassemble and check parts (see page 8). g. Disassemble motor and check rotor vanes
(see page 16). h. Make sure there is oil in the lubricator. i. Make sure the air tubing to the brake are not
kinked or pinched. Disassemble brake and
check for proper piston operation (see page 7). Replace worn or damaged parts.
a. See item 1(i). b. Replace spring. c. See item 1(d).
a. See item 1(f). b. See item 1(e). c. See item 1(d).
MOTOR REBUILD:
1. Remove dead end screws (12) from dead end cap (11). Remove dead end cap (11) and dead end gasket (10) from dead end plate (9).
2. Remove dead end plate bolts (13) from dead end plate (9). (Use proper tool, do not use a screwdriver to remove dead end plate).
3. Remove the dowel pins from the body (8) and push back into end plate until flush or just below the machined surface of the dead end plate.
4. Remove rotor (4) using an arbor press.
5. Remove vanes (5), vanes springs (7) and spring pins (6).
6. Remove shaft seal (1) and bearing (2) from drive end plate (3) and bearing (2A) from dead end plate (9). (Use proper tools). Do not remove drive end plate bolts (14) or drive end plate (3).
7. Clean parts. Check for scoring on the dead end plate (9), drive end plate (3) and rotor assembly (4). If scoring exists, motor should be replaced.
8. Place vane springs (7) and push pins (6) into rotor (4).
9. Place the drive shaft of the rotor assembly (4) through the drive end plate (3). Press the drive end bearing (2) onto the rotor drive shaft. (Use Proper Tool.) Lightly tap on inner race of the drive end bearing (2) to snug up rotor (4) to drive end plate (3).
10. Install new vanes (5). The notch on the vane faces to center of the rotor (4).
11. Place end plate gasket (10) on the body of the dead end (9). Place the dead end plate (9) on the body (8). Install the dead end bearing (2A) and press into place. (Use Proper Tool).
12. Install the dowel pin and fully tighten the remaining bolts to 80-120 In-Lbs. Set end clearances as required. Lightly tap on the inner race of the dead end bearing (2A) to free up and center the rotor (4) in the body (8).
13. Apply a small amount of grease to bearing seal and install the drive end bearing seal by pressing flush. (Use Proper Tools.)
14. Reattach dead end cap (11) with dead end cap screws (12). Apply a few drops of 10W oil into ports and rotate shaft by hand for a few rotations.
4. Hoist looses power. a. Insufficient air pressure. b. Clogged valve block. c. Clogged muffler. d. Worn or broken rotor vanes.
5. Pendant throttle control
levers do not return to off position.
6. Cannot regulate speed
using the pendant throttle
control levers.
7. Lifting and lowering speeds
differ from rated speeds.
a. Foreign material, rust or corrosion in
pendant throttle control, levers bent or lever pivot pin bent.
a. Brake not operating properly. b. Pendant throttle control not
operating properly.
a. Incorrect air pressure or inadequate
air supply.
b. Loss of power.
15
a. See item 1(a). b. See item 1(e). c. Clean or replace muffler. d. Replace worn or damaged rotor vanes (see
page 9).
a. Clean pendant throttle control and replace
worn or damaged parts. (see page 8).
a. See item 1(i). b. See item 5.
a. Check air pressure at hoist when hoist is
operating. (see page 3).
b. See item 1(b).
PENDANT THROTTLE CONTROL (Refer to Exploded View on Pages 13 & 14)
A. Disconnect the hoist from the air supply system and depress the operating levers to exhaust the air from the hoist. B. Disconnect the three air hoses from the top of the pendant throttle control. C. Remove the strain line from the top of the control handle (620-557). D. Remove the two throttle valve caps (620-555) from the back side of the control handle . E. Remove the throttle valve spring (620-554) from under each cap. F. Thread a #10-24 screw into the threaded hole in the throttle valve (620-552) and pull the valve out of the control handle. G. Clean all parts thoroughly using a mild solvent and check them for wear and damage. Check levers (620-551) for free
movement. Replace all worn or damaged parts. H. Lightly lubricate all parts and re-assemble the pendant throttle in the reverse order. I. Re-attach the air tubes to the top of the control handle and reconnect the strain line. J. Reconnect the hoist to the air supply and test for proper operation.
16
Page 20
NOTES
17
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