EC Series, 680-4 - Coffing Hoists, Coffing Hoist Parts

Transcription

Americrane & Hoist Corp. 1-800-652-1932
ElufF-Ncr-tcrn
OPERATING& MAINTENANCE
INSTRUGTIONS
COFFING"
HOTSTS
WITH PARTS LISTS
PUBLICATION
PARTNO.EC.68O-4
ELECTRICCHAIN HOISTS
For ModelNos.
EC-0516 EC-2008
EC-0s32 EC-2012
EC-0564 EC-2016
EC-l009 EC-4006
EC-l016 EC-4008
EC-l032 EC-6005
-
IMPORTANT -
CAUTION
This manual contains important information for the correct installation,operation and maintenanceof the
equipmentdescribedherein.All persons involvedin such installation,operationand maintenanceshould be
thoroughly familiar with the contents. To safeguard against the possibility of personal injury or property
damage,follow the recommendationsand instructioni of this manuat anci feep it for furthei reference.
1
WARNING
The equipment shown in this manual is intended for industrial use only and should not be used to lift,
support, or otherwise transport people, or to suspend unattended toads over people.
>
1993
"TOUFF-NORTON
g|rlE L_q'!f_E,_NORTH
CAROL|NA, USA
ALL RIGHTS
RESERVED
Duft-Nonton
rABLEOF CONTENTS
PAGE
SECTIONI
t-l
1l
l_3
l-4
l-5
t_6
SECTION II
tl
2-t
2-4
2-5
2-6
a1
2-8
SECTIONIII
3-l
t-z
J-J
3-4
SECTION IV
+l
+2
+t
u
+5
+6
SECTIONV
5-l
5-2
5-3
5-4
5-5
5-6
INTRODUCTION
General Information
S a f e t y S r a n d a r d.s. . . . .
Hoist Construction and Features . . . . . .
Basic Hoist Data . .
Applicarion Information
Warranty.......
J
.4
..4
..4
..4
.4
4
+5
.6
6
6
6
7
INSPECTION
General
Frequent Inspection
Periodic Inspection
[.oad Brake Function Check .
Chain Inspecrion
Hook Throal Opening
...7
7
....7
9
9 -l 0
l0
MAINTENANCE AND REPAIR
General
...
Limit Switch Adjustment
Motor Brake Adjustment
Top Suspension Removal and Replacement . . . . .
Chain Replacement
Lubrication
SECTIONVII
7-l
WIRING
SECTION IX
J
OPERATION
General
Safety Notes
Handling The Load
Overload Limiting Prorection .
TROUBLESHOOTING
SECTION VIII
8-l
8-2
8-3
FIGURE 8-I
FIGURE 8.2
FIGURE 8.3A
RGURE 8-38
FICURE 8-4A
RGURE 84B
FIGURE 8.5
FIGURE 8-6
FIGURE 8-7A
FIGURE 8-7B
FIGURE 8-7C
FIGURE 8.7D
FIGURE 8-8A
FIGURE 8.88
FIGURE 8.9
FIGURE 8.IOA
FIGURE 8.IOB
RGURE 8-II
5
INSTALLATION
Safety Notes
Hanging the Hoist
Power Supply Connection
Vent Plug .. .
Chain Lubrication . . . ..
Testing .
Trolley lnstallation. . . .
C h a i n C o n t a i n e r l n s t a l l a t i o.n. . .
SECTIONVI
6-l
11
l*
3
General
Voltage Conversion
WiringDiagrams......
...t0
lG.ll
...11
ll
...12
t2-t3
3
l+15
l6
l6-18
ILLUSTRATEDPARTSLISTS
General
How to Use lhe Parls List. .
How to Order Replacement Parts . .
Basic Hoist
SuspensionAssembly Kits
Motor Parts (Three Phase) . . .
Motor Pans (Single Phase)
Controller Area (SinSle Speed)
Controllcr Area (Two Speed)
Transmission.....
ChainingParts...
Bottom Block (th & t/z-ton) . . .
B o t r o mB l o c k ( l - t o n ) . . . . . . . .
Bottom Block (Double Chain) .
Bottom Block (Triple Chain)
Standard Limit Switcb Pans.
Long Lift Limir Switch Parts . .
Motor Brake Parts . . .
Pushbutton (Single Speed Hoist)
Pushbutton (Two Speed Hoist).
Chain Container Parts. . . . . .
.19
.19
l9
.20
DO'S AND DO NOT'S
43
J1
.24
.25
26
.27
.28
.30
.32
32
.32
.32
.34
.35
.J6
.38
40
.42
*'
sEcfloN I
INTRODUCTION
U
1-1.GeneralInformation
1-5.ApplicationInformataon
This manual provides information for the safeoperation
and maintenance of Coffingo EC-l Series Hoists. All
personsoperatingor maintaining thesehoistsshould be
familiar with the information contained herein. Adherence to the precautions,procedures,and maintenance
practicesdescribed should ensure long reliable operation. Suggestionsfor improvements to this manual are
solicited.
This hoist is intended for general industrial use in the
lifting and transporting of freely suspended material
loads within its rated load. Prior to installation and
operation, the user should review his application for
abnormalenvironmentalor handlingconditionsand to
observethe applicablerecommendationsas follows:
1-2. Safety Standards
All personsconcernedwith the installation, operation,
inspectionand maintenanceof thesehoists are urgedto
read American National Standard(ANSI) B30.16.That
Standardcontains valuable guidelinesconcerningpractices designedto minimize hazardsassociatedwith the
useof overheadhoistingequipment.ANSI B30.16also
contains detailed procedures for establishing hoist
inspection and maintenance programs and can be of
significant assistancein maintaining compliance with
OSHA regulations.
1-3.HoistConstruction
and Features
Strong,lightweightaluminum alloy die castingsprovide
a compact,protectiveenclosurefor the mechanicaland
clcctricalcomponentsof Coffrng' EC-l SeriesHoists.
Heal treated alloy steel gearing operatesin an oil bath
1o provide the most reliable lubrication and eflective
heatdissipation.
EC-l Series Hoists incorporate the following
features:
a. Overloadlimiting clutch.
b. Completely independentmechanicaland electrical
brakes.
c. Adjustablelimit swilches.
d. Tough, nylon weatherproofpushbulton stations.
e. Steelstrain cableinside pushbuttoncord.
f. Transformer isolated, low-voltage pushbutton
controls.
g. Quick voltageconversionon dual-voltageunits.
TABLE1-1.BASICHOISTDATA
Model
No.
EC-0516
EC4532
8C4564
EC-1009
EC-1016
EC-1032
EC-2008
EC-2012
EC-2016
EC4006
EC4008
EC-6005
Rrted
Irad
0b)
500
500
500
r000
1000
1000
2000
2000
2000
4000
4000
60m
l,ift Speed
et Reted l-oed
(ft per min)
l6
64
9
l6
32
8
t2
l6
6
8
)
Motor
HP
Vt
Ut
I
Vt
y2
I
Vt
th
I
I
I
1-4.Basic Hoist Data
Thebasichoistmodelscoveredbv thismanualarelisted
in Tablel-1.
a. Adverse Environmental Conditions Do not use the
hoist in areascontaining flammable vapors, liquids,
gasesor any combustible dusts or fibers. Refer to
Article 500 of The National Electric Code. Do not
use this hoist in highly corrosive, abrasive or wet
environments.Do not use this hoist in applications
involving extended exposureto ambient temperaturesbelow -10"F or above 130"8
b. Lifting of HazardousLoads This hoist is not recommendedfor use in lifting or transportinghazardous
loads or materials which could cause wide-spread
damageif dropped.The lifting of loadswhich could
explodeor createchemicalor radioactivecontamination if dropped requiresfail-saferedundant supporting deviceswhicharenot incorporatedinto this hoist.
c. Lifting of Guided l-oads This hoist is not recommendedfor usein the lifting ofguided loads,including
dumbwaitersand non-ridingelevators.Suchapplications require additional proteclive deviceswhich are
not incorporated into this hoist. Refer to your stale
and local regulationsgoverning the requirementsfor
clevatorand dumbwaiter installations.
1-6. Warranty
Every hoist is thoroughlyinspectedand testedprior to
shipmentfrom thelactory.Shouldany problernsdevelop.
returnthe completehoist prepaidto your nearestDufl'NortonAuthorizedWarrantyRepairStation.lf inspection
revealsthatthe problemis causedby clefectiveworkntanshipor material, repairswill be madewithoutchargeand
the hoist will be returned,transportatic'rn
prepaid.
This warrantydoesnot apply where:( I ) deterioration
is
causedby normal wear, abuse,improperor inadequate
power supply,eccentricor side loading, overloading.
chernicalor abrasiveactions.improperrnaintenance
or
excessive
heat;(2) problemsresultedfrom repairs,modificationsor alterations
madeby personsotherthanfactory
or Duff-NortonAuthorizedWarrantyRepairStationpersonnel;(3) the hoist has been abusedor damagedas a
resultof an accident;(4) repairpartsor accessories
other
thanthosesuppliedby Duff-Nortonareusedon the hoist.
Equipmentandaccessories
not of the seller'smanufacture
arewarrantedonly to the extentthat they arewarrantedby
the manufacturer.EXCEPT AS S]'ATED HEREIN.
D U F F - N O R T O NM A K E S N O O T H E R W A R R A N TIES, EXPRESS OR IMPLIED, INCLUDING
WARRANTIES OF MERCHANTABILITY AND
FITNESSFOR A PARTICULARPURPOSE.
sEcroN il
INSTALLATION
2-1.SaletyNotes
a. Inspectthe hoist for any evidenceof shippingdamage
or loose parts.
b. The supporting structure and load attachingdevices
shouldhave a load rating at leastequalto that of the
hois1.
c. This hoist is not suitablefor usein uncoveredouldoor
locationsor areascontainingexplosivedust, vapors
or gases.
e. When installing a three-phasehoist, make only temporaryconnectionsat the powerline. Pushthe "UP"
button and observethe direction of the hook. If it
raises,the phasingis correct and permanent connections may be madeat the powerline. If the load block
lowerswhen the "UP" button is pushed,releasethe
button immediatelysincethe limit switcheswill not
operateto protect the hoist from over-travel. Reverse
the red and black wires at the power line connection
to correctthe hook direction.
d. The installation area must provide safe operating
conditionsfor the operator,includingsufficientroom
for the operator and other personnelto stand clear
of the load at all times.
CAUTION
Do not changeconnectionsin the hoist or the pushbutton
assembly.
e. In areaswhere slack chain hanging from the hoist
may createa hazard,usea chaincontainer(seeFigure
2-2).
2-4. Vent Plug
This hoist has an oil-bath transmission.For shipping
purposes,a non-vented fill plug (24, Figure 8-l) was
installedat the factory.A vented plug is locatedin an
envelopetied to one of the hoist cnd coversand must
be installed in place of the non-ventedshipping plug
beforeoperatingthe hoist.
2-2. Hanging the Hoist
Hook mounted hoists can be used with a variety of
trollcysor stationaryhangers.It is recommendedthat a
hand-gearedor motorized trollcy be used when the
pulling effort required to move thc hoist exceeds100
poundsor when the applicationrcquiresfrequentmovemcnt of the hoist.
a. Makc sure thal thc-hook latch closesafter hanging
thc hoist.
b. The standardtop hook is restrainedfrom rotationby
a plate and two screws.Thc hook can be madc lo
swivel freclyby removingthe plate,or can be rotated
90" and fixed in that position.
c. Sce Figure 2-l for instructions on adjusting lugmounted plain trolleys.
d. Refer to Coffrng Motorized Trolley Operatingand
MaintenanceInstructionsmanualfor motorizedtrollcy installationinstructions.
2-3. Power Supply Connection
a. Disconnectpower beforemaking connections.
b. Voltagesuppliedto the hoist should be within plus
or minus 100/o
of the voltagespecifiedfor the hoist.
Hoisls are laggedat the factory with a tag indicating
the vohage for which the hoist is wired. Standard
singlephasehoistsare convertiblefrom ll5 to 230
volts. Standard single speed.three phase hoists are
convertible from 460 volts to 230 volts. See the
Wiring section(paragraph7-l) for voltageconversion
instructions.
c. National ElectricalCode(ANSI Cl) and localelectrical codesshouldbe consultedand properdisconnects,
branch circuit protectors,and wiring provided.
d. Power cablesfurnished with the hoist have a green
colored ground wire which must be securely connected to the electricalsystemground.
2-5. Chain Lubrication
Thc hoist chain should bc liberallyoiled beforeplacing
thc hoist inlo operation.For lubricationinstructions,
scc paragraph5-6.a.
2-6. Testing
a. Bcfore placing the hoist into operation, check for
properlimit switchoperation.Pushthe "UP" butlon
and verify that the hook block stopsat least2 inches
from the botlom of the hoist. Run the hoist down to
ils lowerlimit. At leastl2links ofchainshouldremain
on the slackend. If eitherswitchis not correcl,adjusl
accordingto the procedureoutlinedin paragraph5-2.
NOTE
The upperand lower limit switchesare factorysetto
provide the maximum allowablehook travel. This
travel adjustmentshould not be increased.Howcver,
the switchesmay be adjustedto stop the hook sooner
at either end of its travel.
b. Attach a light load to the hook and check the hoist
for proper operation.The load should slop without
noticeable drift when the pushbutton is released.
Increasethe load to nearratedload.The hoist should
still lifl the load without hesitationand stop with no
more than one inch drift.
2-7. Trolley Installation
Cofling'CT Seriestrolleyscanbe mounledon American
StandardI Beamsfrom 6 to l8 incheshigh. Adjustment
for di{Ierentbeamdimensionsis accomplishedwith thft:proper placementof spacerwashersas describedbelow
in paragraph2-7.a.
a.
"I"-Beam Adjustment.Adjustment for "I" beam sizes
and tolerancesis accomplishedby locatingthe spacer
washersas shown in Figure 2-1. Normal placement
of washersis given in Table 2-2. Refer to Table 2-l
for identification of part names and numbers.
BEAM MANUFACTURING TOLERANCES
ALLOW WIDE VARIATIONS FROM HANDBOOK FLANGE WIDTHS, AND SLIGHT
CHANGES TO RECOMMENDED WASHER DISTRIBUTION MAY BE NECESSARY TO SUIT
SPECIFIC INSTALLATIONS.
The particular beam on which your hoist is to be
installedshould be measuredand trolley spacerwashers adjustedas required to achievea clearanceof ln"
to t/s".
b. Periodic Inspection.The trolley should be inspected
periodically for evidenceof excesswear or overload.
Parts should be replacedas required.
c. Lubrication. Trolley wheelsare equippedwith sealed,
lifetime lubricated, precision ball bearings which
should not require lubrication for the normal service
of the trolley.
DETAIL
3-TON CT TROLLEY
WHEEL ASSEiIBLY
t1
I
I
f
1a
\
FIGURE 2-I. COFFING CT TROLLEY
TABLE2-1. PARTSLIST FOR CT TROLLEY
INDEX
NO.
t
z
3
4
5
6
7
PART NUMBERS
% TO 2-TON 3-TON
t03Kt
Load Pin
r03Kl
Washer(7r" Thick)
H-42t1
H-42t1
Washer(.135"Thick) H-4209
H-4209
Washer(.075' Thick) H-42r0
H-4210
Nut
H-3945
H-3945
5Kl
5K2
Side Plate
Wheel
45Kl
45K2
PART
NAME
INDEX
NO.
8
9
0
I
2
3
4
PART
NAME
Axle
RetainingRing
Bearing
Retaining Ring
Nut (Axle)
Washer
Spacer
PART NUMBERS
% TO 2-TON 3-TON
t02K2
l02Kl
H-5530
Not Req.
500K5
500K4
H-5528
H-5529
H-3945
H-3946
H-42t1
H-42t2
200Kr
Not Req.
TABLE2-2. TROLLEYI-BEAMADJUSTMENTDATA
l-Beam'
Si"r &
Weight
6"-t2.5#
6-t7.25#
8"- I 8.4
8"-23.0
0'-25.4 #
0'-35.0 #
2',-31.8#
2"-35.0#
5'42.9 #
5',-50.0 #
8',-54.7 #
8"-70.0 #
tAmenan
Foint B
Weshers Between
Sideplete & Nut
Foint A
Wsshers Between
Susp. Lug & Sleeve
F-lange
width
.135 Thicli
.075 Thick
.135Thick
.075 Thick
I
0
0
8
7
5
5
I
2
6
6
4
6
7
0
0
z
5.000
5.078
5
7
4
I
J.500
5.640
6.000
6.250
9
9
0
I
2
0
0
8
9
5
I
0
1.330
3.565
4.000
4 . t 7|
4.660
4.944
2
Srandard I-B€am
NOTE: All dimensions are in inchx
unl6s otheryiF
smificd.
J
J
5
5
I
4
5
4
0
0
Acturl
Sprcing
Susp.Lug
to Sleeve
.135
.2"1o
.480
.555
.8t0
.945
.965
1.021
t.215
1.290
1.460
l.590
hintC
Cleennce
Wheel to
Berm
l5
J)
25
l5
25
l8
l0
26
l0
l5
-tQ7
.lil
2-8. Ghain Container Installation
a. Operate hoist in "down" direction until it is stopped
by the limit switch. Disconnect the slack end of the
chain from the hoist by using a small screwdriverto
slide the spring-loadedpin to the left. At least8 inches
of chain should hang from the hoist. If less than 8
inches of slack chain is present,readjust lower limit
switch usingthe proceduresdetailedin paragraph5-2.
b. Slide the spring-loadedpin asideand slip the mounting arm into the slot until the pin fits through the
hole in the plate (seeFigure 2-2). Be sure pin passes
completely through plate and into the opposite
housing.
c. Use the two hex washer head screws provided to
fasten the two remaining hanger chains into the
notcheson the lower edgei of tne hoist housings.
I
e
d. Be sure the end of the chain is started into the
container.Run hoist up until the hook block is even
with the bottom of the chain container.
e. Resetupper limit switch at this position (seeprocedure, paragraph 5-2) to prevent the possibility of
raising a load into the chain container.
SLOT FOR
SMALL SCREWDRIVER
CHAIN
CoNTAINER--\
CAUTION
\
Short edgeof chain container\
bodv must be mounted
$
\
\
HEX HEAO
toward hoist (as shown).
FIGURE 2-2. CHAIN CONTAINER INSTALLATION
sEcTtoNill
OPERATION
3-1. General
This sectionpresentsinformation concerningthe proper
operationof the Cofling'Electric Chain Hoist. It is not
intended to serveas a handbook on rigging.Rigging,the
processof moving heavy loads using mechanical
devices,requiresspecialknowledgeand equipment. For
information on the safeuseof slingsand similar riggrng
gear, usersare urged to consult a textbook on rigging.
3-2.SafetyNotes
a. Inspect the hoist for any sign of loose, broken, or
malfunctioningparts(seeSectionIV). Any malfunctioning hoist should be taggedas "out oforder" and
removed from serviceuntil the defect is corrected.
b. Before starting the hoist, the operator should be
certain that all personnelare clear.
c. Do not lift more than the rated load of the hoist.
d. Do not lift people or loads over people.
e. Avoid joggrng controls or quick reversalsof suspended loads.
f
Do not leave a suspendedload unattended.
g. The operator should have a clear view of the load
anytime it is moving and should be sure that the
load does not contact any obstructions.
h. Read ANSI 830.16 SafetyStandardfor Overhead
Hoists.
3-3. Handling The Load
a. Align hoist directly over load. Avoid side pull.
b. The hoist chain should not be wrappedaround the
load. Use proper slings.
c. Be sure there are no twists in the load chain as it
entersthe hoist.
CAUTION
This conditionshould be constantlycheckedon double or triple chain hoists becauseit is possible for
the load block to be "capsized" or flipped over one
or more times, putting twist in the chain. The presenceof twist may not be obviouswhen the hook block
is in the lowered position but can causeserious chain
binding when the hook block is in its fully raised
position.
d. Bring the hook into engagementwith the load and
make sure it is well seatedbefore proceedingto lift
b"
{y
the load. On multiple reevedhoists,be surethat the
load is equalizedon all supporting chains.
e. Lift the load just clear of its supports and stop the
hoist to check for proper brake operation.
f.
Avoid letting the hook or load swing excessively
while moving a trolley suspendedhoist.
3-4.OverloadLimitingProtection
This hoist is equippedwith a factory-calibratedoverload
limiting clutch, which will permit the lifting of loads
within its load rating, but will prevent the lifting of
damaging overloads while the hoist is being operated.
If the load being lifted exceedsthe lifting capability of
the overload clutch, the hoist motor will continue to
run, causing overheating of both the clutch and the
motor. This condition should be avoided by immediately releasingthe "[JP" button and reducing the load
to within the hoist load rating.
CAUTION
The overloadlimiting clutch is an emergencyprotective
deviceand should not be usedto measurethe maximum
load to be lifted, or to sensethe overloadimposed by a
constrainedload. Manufacturing tolerancesrequire that
the clutch be set somewhatabovethe load rating of the
hoist. The fact that the hoist will pick up loads in excess
of its load rating does not in any way sanction the use
of the hoist in an overloadedcondition.
sEcTroN
rv
INSPECTION
4
lD
4-1. General
A scheduledinspection routine should be established
for this hoist basedupon severityof use and environmental conditions.Some inspectionsshould be made
frequently (daily to monthly) and others periodically
(monthly to yearly). It is suggested
that an Inspection
and MaintenanceCheckList and an Inspector'sReport
similar to those shown in Figures4-l and 4-2 be used
and filed for reference.All inspectionsshould be made
by a designatedinspector.Specialinspectionsshould be
madeafterany significantrepairsor any situationcausing suspicionthal the hoist may have been damaged.
Any hoist which has been removed from servicefor an
extendedtime should receivean inspectionasdescribed
under PeriodicInspections.ANSI B30.16,SafetyStandard for OverheadHoists,providesguidelinesfor hoist
operationand inspection.
CAUTION
Any unsafecondition disclosedby any inspectionmust
be corrected before operation of the hoist is resumed.
4-2.FrequentInspection
a. Checkpushbuttonstation,brake,and limit switches
for properoperation.
b. Check hooks for deformation, chemical damage,or
cracks.Bent hooks or hooks damagedfrom chemicals,deformation,cracks,or having excessivethroat
opening (see paragraph 4-6) should be replaced.
Visible deformation of any hook may be evidence
of hoist abuseand overloadingand indicatesthat a
thorough inspectionof the completehoist shouldbe
made.
c. Checkthat bottom hook swivelsfreely.
d. Checkfor missing,bent or otherwisedamagedhook
latches.
V
e. Check pushbutton and power cord for cuts or other
damage.
4-3.PeriodicInspection
The exact period for the following inspections will
dependon the anticipatedseverityofhoist use.Determination of this period should be based on the user's
experience.It is recommendedthat the user begin with
a monthly inspection and extend the periods to quarterly, semi-annually,or annually,basedon his monthly
inspection experience.
a. Clean hoist of any dirt or foreign material. Inspect
bottom block for accumulationof debns.
b. Perform all frequent inspectionslisted above.
c. Check for loose bolts, screwsand nuts.
d. Checkhousings,load block, and other partsfor wear,
corrosion,cracksor distortion. Check for abnormal
openingsbetweenhousingsections.
e. Checkmotorbrakeforworn discs,oil contamination
or excessiveclearance(seeparagraph5-3).
f.
Check mechanicalload brake function (see Figure
4_3).
g. Inspect the entire length ofchain for gouges,nicks,
weld spatter, corrosion, distortion and wear. See
CHAIN INSPECTION, paragraph4-5.
h. Inspect hooks and suspensionparts for cracks,distortion or extreme wear.
i.
Inspecthooksfor cracksusing magneticparticle,dye
penetrantor other crack detectingmethods.
j.
Check limit switch set points and resel if necessary
(seeparagraph5-2).
k. Inspectall wiring for defectiveinsulation, and check
to be sureall electricalconnectionsare tight. Check
motor reversing contactor or relay for burned
contacts.
l.
Inspect for oil leaks.Check oil level.
m. Inspect for missing or illegible capacity or warning
labels.
n. Inspect the supporting structure for continued ability to support the hoist rated load.
I N S P E C T I O&NM A I N T E N A N CCEH E C KL I S T
POWERED
ELECTRIC
OVERHEAD
CHAINHOIST
u
C a p a c r t y( T o n s ;
n ate
O r g r n a l l n s t a l l a t r oO
M a n u fa c t u r e rs S e r a l N o
T y p eo l H o r s l
Localron
l v l a n uaf c t ur e r
Item
O p e r a t r n gC o n t r o l s
L r m rS
t wrtches
F r e q u e n c vo l l n s D e c l r o n
Frequent
Periodrc
Darlv MonthlV 1 1 2 M o
a
a
o
a
a
o
a
D r s c ( M o t o r )B r a k e
o
a
Load Brake
{Mechanrcal)
Hooks
a
a
o
a
a
a
a
S u s p e n s r oLnu g
( r fu s e d )
a
a
Charn
o
o
a
P o s s r b l eD e l r c r e n o e s
ff
Actron
Requ red
A n y d e fr c r e n c yc a u s r n qr m p r o p e ro p e r a t r o ' l
A n y d e fr c r e n c yc a u s r n g r m p r o p e ro p e r a t r o n
Pitlinqor delerloralton
S l i p p a g e o r e x c e s s i v ew e a r
G l a z i n o .c o n t a m r n a t r oonr e x c e s s i v ew e a r
F a r l u r et o s u p p o r t l o a d w r t h d r s c b r a k e o p e n
( s e e p a r a g r a p h4 - 3 f )
E x c e s s r v et h r o a t o p e n r n g , b e n t o r t w r s t e d. n o r e t h a n
1 Od e g r e e s ,d a m a g e d h o o k l a t c h .w e a r .c h e m r c a l
damage, worn hook bearrng
. a g n e t r cp a n r o l eo r
C r a c k s( u s e d y e p e n e t r a n t m
o t h e r s u r t a b l ed e t e c t r o nm e t h o d )
C r a c k s , e x c e s s r v ew e a r o r o t h e r d a m a g e w h r c h m a y
r m p a r rt h e s t r e n g t ho f t h e l u g
, a g n e l r cp a r l r c l eo r
C r a c k s( u s e d y e p e n e t r a n t m
o t h e r s u r t a b l ed e t e c t i o nm e t h o d )
I n a d e q u a t eI u b f l c a t i o n ,e x c e s s r v ew e a r o r s t r e l c h
c r a c k e d ,d a m a g e d o r t w l s t e d l r n k s ,c o r r o s r o no r
f o r e r q ns u b s t a n c e
C r a c k s ,b e n d r n g ,s t r p p e d l h r e a d s l o o s e m o u n t r n g
screws
E x c e s s r v ew e a r .c o r r o s o n c r a c k s d i s t o r t r o n
Hook and Suspensron
Luo Connections
a
Pins,Bearings.
Eushings.Shatts
C o u p l i n g sC,h a r n
Guides
o
N u t s . B o l t s .R r v e l s
a
Sheaves
a
Housings,Load
Elock
a
Wrrrnoand Termrnals
a
ContactBlock,
MagnelrcHorst
C o n l r o l S w r t c h ,O t h e f
E l e c t r r c aA
l oparatus
o
Structure
Supporting
(if used)
and TrolleV
a
N a m e p l a t e s ,D e c a l s ,
Warninq Labels
a
D a m a g e o r w e a r w h l c h r e s t i l c t sa b l l r t yt o s u p p o r t
r m p o s e dl o a d s
M i s s r n gd
, a m a g e do r r l l e g i b l e
Transmissron
Lubricant
a
L o w L e v e l ,R e q u r r e sC h a n g i n g
L o o s e n e s s .s l i l p p e d a n d d a m a g e d l h r e a d s
corrosron
D r s t o r t r o nc, r a c k s , a n d e x c e s s r v ew e a r
B u i l d u o o f f o r e r o ns u b s t a n c e s
C r a c k s d r s t o r t r o ne x c e s s i v ew e a r
I n t e r n a lb u i l d u o o f f o r e i q n s u b s l a n c e s
F r a v r n o .d e l e c l r v eI n s u l a t r o n
L o o s e c o n n e c l r o n s ,b u r n e d o r p t t t e d c o n t a c t s
N O T E : R e l e r t o M a r n t e n a n c ea n d I n s p e c t r o nS e c l r o n so f l h e H o r s t M a r n t e n a n c eM a n u a l l o r f u r t h e r d e t a r l s
F R E O U E N C Y O F I N S P E C T I O N:
I n d r c a l e sr t e m s r e q u r r r n gr n s p e c l r o n sd a r l y t o m o n t h l y D a r l y I n s p e c l r o n sm a y b e p e r l o r m e d b y t n e o p e r a l o r r l
F r e q u e n tp r o p e r l yd e s r g n a t e d
P e r r o d r cI n d i c a t e si t e m s r e q u r r r n gI n s p e c t r o nm o n t h l y t o y e a r l y I n s p e c t r o n st o b e p e r f o r m e d b y o r u n d e r l h e d r r e c t r o no f a
p r o p e r l yd e s r g n a t e dp e r s o n T h e e x a c t p e n o d o f I n s p e c t r o nw r l l d e p e n d o n f r e q u e n c y a n d t y p e o f u s a g e . D e t e r m r n a t i o n o f t h i s p e r i o d w i l l b e b a s e d o n t h e u s e r ' s e x p e n e n c e .l t r s r e c o m m e n d e d t h a t t h e u s e r b e g r n w a t ha m o n t h l y
i n s p e c t i o na n d e x t e n d t h e p e r i o d s t o q u a r t e r l y ,s e m i - a n n u a l l yo r a n n u a l l y b a s e d o n h r s m o n t h l y e x p e r t e n c e .
FIGURE 4-I. RECOMMENDED INSPECTION AND MAINTENANCE CHECK LIST
8
INSPECTOR'S
REPORT
ITEM
REMARKS(L|STDEFTCTENC|ES
AND RECOMMENDED
ACTION)
!
INSPECTOR'S
SIGNATURE
DATE
INSPECTED
APPROVEOBY
DATE
FIGURE4-2.RECOMMENDEDINSPECTOR'SREPORT.
4-4. Load Brake Function Check
To checkthe functioningof the mechanicalload brake,
proceedas follows:
a. Attacha lightloadto the hoistand lift it severalinches.
SCREWORIVER
NO.1
TRANSMISSIONCOVER
b. DISCONNECT HOIST FROM POWER SUPPLY
and remove short end brake cover (seeFigure 8-1,
Index No. l).
c. Refemng to Figure 4-3 (below) and Figure 8-9, place
screwdriversNo. I and No. 2 behind the plate and
arrnature assembly and prepare to pry against the
transmissioncover.
NOTE
Do not allow either screwdriverto contactbrake disc
(seeFigure8-9, Index No. 7).
d. Carefully pry open motor brake (closesolenoidgap)
and observeaction of load. If the load descends.the
mechanicalload brake is malfunctioningand must
be repaired.
>rl+-
4-5.ChainInspection
U
Chain inspectionand lubrication are the most important
aspectsofhoist maintenance.Removal ofthe chain from
the hoisr usually is not necessary,but the chain should
be run through the hoist enoughthat every link is made
visible for inspection.
a. Checkeachlink forgouges,nicks,weld spatter,corrosion and distortion.
SCREWORIVER
NO.2
FIGURE 4-3. LOAD BRAKE FUNCTION CHECK
b. Inspecteachlink for wearto thediameterof thelink
chain is worn lessthan l7:0/0,
checkit at severalmore
placesalong its length. If any section is worn more
than I t/zo/0,
the chain should be replaced.
(seeFigure4-4).The nominallink diameteris 0.250
inch for chainon modelsup to EC-2008and 0.281
inch for modelsEC-2012and above.If the diameter
of anylink of 0.250chainis wornto lessthan0.200,
or thediameterof anylink of 0.281chainis wornto
lessthan0.225,theentirechainmustbe replaced.
d. The chain used in this hoist is accuratelycalibrated
to operateover the load sprocketand is very carefully
heat treated for maximum wear life and streneth.
t
WARNING
l. Do not weld or join hoist load chain.
2. Do not substituteanother manufacturer'schain in
this hoist.
3. Damageor wear, beyondthe stated limits, to any
portion of the chain requiresthat the entire length
be replaced.
WEAR IN
THESEAREAS
4-6.HookThroatOpening
Use Table4-l (below)to checkhook throat opening.
FIGURE 4-4. TYPICAL WEAR ON LINKS
l.) Check the chain for overall wear or stretchby
selectingan unworn, unstretchedlengthof chain (at
the slackend, for example).Let the chain hangverticallywith a light load(about20lbs.)on rhe chainro
pull it taut. Use a largecaliper10measurethe outside
length of a convenientnumber of links (about 12
inches). Measurethe same number of links in a
used sectionof chain and calculatethe percentage
increasein lengthof the worn chain.
TABLE4-1. MAXIMUMALLOWABLEHOOK
THROATOPENING
Hoist I-oad
Reting
(ton)
t/q, t/t and
2.) If the lengthof the worn chain is more than l7z0lo
longerthan the unusedchain(.015"per inch of chain
measured),then the chain should be replaced.If thc
Top
Hook'
(in)
Bottom
Hoohr
(in)
l'/tt
l'/rt
lr%:
l'/rt
5/,0
I
ttln
I
I
2
3
rFigu.es gru.n
arc for hok
wirh latch. Add
r/ro'
if mcasured withoui h@k latch
sEcTtoN
v
MAINTENANCE
AND REPAIR
5-1. General
This sectionprovidesinstructionsfor the most common
routinemaintenanceand adjustments.Major repairsare
not within the scope of this manual and should be
referredto qualified servicefacilities.
SAFETY NOTE
Always remove load and disconnecthoist from power
suppll' before removing end coversor making repairs.
5-2.LimitSwitchAdjustment
Limit switches are provided to protect the hoist
againstdamageresultingfrom overtravel.For easyidentification the upper (No. 2, Figure 5-l) and lower (No.
3, Figure5-l) limit switchadjustingnuts arecoloredred
and green respectively.Each limit switch nut has ten
slots for adjustment,and the incrementof adjustment
FIGURE 5-I. LIMIT SWITCH ADJUSTMENT
10
u
iyr
is such that one slot is equivalentto one link of chain
travel. Care should be exercisedwhen adjusting either
limit of travel. When a geared type limit switch is
furnished (long lift hoists) each adjustment is equal to
3 links of chain, or 30 links per revolution.
Adjustto
give.015"-.,
oaD
a. Adjusting Upper Limit (Red Nut).
l.) Carefullyraisethe load block to a point whereits
top is 2" or more from the hoist housing.
t
T-
2.) DISCONNECT POWER from the hoist and
remove the short end cover.
pry the springguideplate(No.
3.) With a screwdriver,
l, Figure 5-l) out of the slots in the colored limit
switch nuts (Nos. 2 and 3).
FIGURE 5-2. MOTOR BRAKE ADJUSTMENT
4.) Turn the slotted red nut (No. 2) toward its limit
switch until the switch clicks.
a. Remove any load and DISCONNECT POWER
liom hoist.
5.) Releasethe springguideplateand be sureit snaps
back into the slots in both nuts. Do not disturb the
other slotted nut if is has beenpreviouslyset.
b. Remove the short end cover.
Rcferringto Figure4-2,checkthe gapbetweenarrnature (A) and frame (B). The correctgap is .015".
d. Adjust the gapby turning the threelock nuts (F) and
check with a feelergaugeto be sure the gap is the
sameon both ends of the solenoid.
c.
6.) Replacethe short end coverand reconnectpower
to the hoist.
7.) Carefully raise the load block to its upper limit
and observe10 see if it stops automaticallyat the
desiredpoint. Do not allow the load block to run into
the hoist housing.The stoppingpoint should be at
least2" below the hoist housing.
O
CAUTION
Be sure the bottom of the armature does not touch
the splined adapter (H). As wear occurs,the original clearancewill be reduced.When this clearance
is gone, THE BRAKE DISCS MUST BE REPLACED.
b. Adjusting l,ower Limit (Green Nut)
l.) Carefullylowerthe load block 1oa poinl whereat
leastl2 links of slackchain hanedown from the hoist
housing.
e. Replaceshort end cover and reconnectpower. Ifthe
brake still chattersor is hesitantto release.refer to
SectionVI, Troubleshooting.
2.) DISCONNECT POWER from the hoist and
removethe short end cover.
5-4.TopSuspension
Removaland Replacement
3.) Adjust the green limit switch nut in the same
manner descnbedabovefor the red nut.
A number of diflerent top suspensionassembliesare
availableto accommodatedifferentmethodsof hanging
to changetop suspenthe hoist.Ifit shouldbe necessary
sions,proceedas follows:
4.) Replacethe short end coverand reconnectpower
to the hoist.
5.) Carefullylower the load block to its lower limit
and observeif it stopsautomaticallyat the desired
level.Do no1run chain out of hoist or allow the slack
end loop to becometaut againstthe hoist housing.
At least12 links of slackchain should hanefrom the
hoist.
a. DISCONNECT POWER from hoist and move the
hoist to a safe working area. If necessary,remove
trolley and/or rotate suspensionlug to gain access
to the socketheadcap screwsbolting the top suspension yoke to the frame of the hoist.
NOTE
b. Remove socket head screws(1|rc"hex) and lift out
the suspensionassembly.
If upper and lower limits are not operatingsatisfactorily, repeatadjustment.
c. Install new suspensionassemblyand tighten socket
head screwsto 75 ft-lbs torque.
5-3.MotorBrakeAdiustment
NOTE
Due to the off-centerhook or lug hole,the suspension
yoke can be installed in the hoist in two different
ways. With the hoist level, the hook or lug must
always be directly over the bottom hook. Refer to
Figure5-4for the proper yoke orientationsfor single,
double and triple chain hoists.
When properly adjusted,the multiple disc motor brake
should release promptly, operate without noticeable
chatter,and stop the load with no more than one inch
of drift. If the hoist hesitatesto lift the load promptly
when the pushbutton is depressed,the brake should be
adjustedper the following procedure.
11
5-5. Chain Replacement (Old chain still in hoist)
Refer to Figure 5-4,Chaining and SuspensionDiagrams
and proceedas follows:
accomplishedby depressingthe pin againstthe slack
end spring (29) with a small screwdriver.Remove
the soft split link (23) from the old chain and attach
the link to the new chain. Depressthe slack end pin
and install the split link observingproperorientation
of the slack end of the chain when secured.Avoid
twists in the chain.
k. Adjust the lower limit switch per paragraph5-2.b.
a. Run the load block up to its top limit.
b. DISCONNECT POWER from the hoist and remove
the short end cover.
c. With a screwdriver,push the springguideplate (No.
l, Figure 5-l) out of the slots in the plastic limit
switch nuts. Turn the red slotted nut (2) back to
about the center of the threaded screw. DO NOT
DISCONNECT THE WIRES FROM THE LIMIT
SWITCHES.
L
d. Removethe load hook assemblyfrom the old chain.
t
Attach the bottom hook on single-chainedhoists to
the looseend ofthe chain. On double-chainedhoists,
feed the loose end of the chain through the load
block (welds of the upstanding links will be in
towardsthe sheave)and fasten the end ofthe chain
to the dead end lug (No. 18,Figure 8-6).
NOTE
On triple chainhoists,feedthe looseend ofthe chain
through the load block (welds away from sheave),
around the idler sheavein the hoist. and to the center
of the load block.
m. Adjust the upper limit switch per paragraph5-2.a.
n. Lubricate the new chain per paragraph 5-6.a and
perform an operation test ofthe hoist.
5-6. Lubrication
Proper lubrication is necessaryfor long, trouble-free
hoist operation. Refer to the following and to Table 5-1,
Recommended Lubrication Schedule, for lubrication
points, type of lubricant,and frequencyof lubrication. 'lr.)
a. Load Chain Cleanthe load chain with a non-acid and
non-causticsolvent and coat with SAE 90 gear oil.
Wipe excessoil to prevent dripping. If the hoist is
usedin an atmospherecontainingabrasivedust, the
chain should be cleanedand oiled more frequently.
Never apply greaseto the chain.
FIGURE 5-3. CHAINING HOIST
Make a "C"-shaped chain link by grinding through
one side of the end link of either the old or new
chain. SeeFigure 5-3.
b. GearingThe gearcaseof the hoist is filled at assembly
with 46 oz. of a gear oil containing special frictionreducing additives.
Hook the special"C" link to the end link of both
chainsthusjoining them. BE SURE the weldsof the
upstandinglinks of the new chain are out away from
the load sheave.and that proper orientation is
observed for attachment of the slack end in paragraph j. below.
WARNING
The use of gear oils other than that recommendedin
Table 5-l can causebrake chatter or can render the load
brake incapableof holding a load. A 46 oz.container of
this oil ls availablefrom the Duff-Norton Co. (Part No.
l4Jl).
NOTE
On triple chain hoistsbe sure all weldsare aligned
like the welds on the old chain. It may be necessary
to cut a link from one or both ends of the chain to
accomplishthis.
a. To check the oil level, remove the 7e"pipe plug from
the side of the hoist. With the hoist hanging level,
transmissionoil should be even with the edgeof the
tapped plug hole.
With the end cover o{I, connect the hoist to power
supply. Be sure the gteen glound wire is properly
grounded.
b. Thelengthof timebetweennecessary
will
oil changes
dependon the severityof usethe hoist receives.In
general,the oil shouldbe changedevery 12monlhs
r
of normal operation,or every 200 hours of actual 1,..1
Y
hoist on-time.Very heavyuseor operationin high
(over 105'F)will requirethat
ambienttemperatures
oil be changedmoreoften.An indicationof the need
h . Carefully jog the "lJP" button and run the joined
piecesof chain into the hoist until about 12 inches
of the new chain comes out the other side.
DISCONNECT POWER from the hoist.
Remove both the "C" link and the old chain from
the slack end pin (No. 28, Figure 8-6). This can be
L
12
POWER
CABLE
NOTEPOSITION
OF SUSPENSION
ASSEMBLY.
POWERCAELE
OOUBLE
CHAIN
ENDVIEW
A S V I E W E OF R O M
E N DW I T HS H O R T
COVER
FIGUR-E5-4. CHAINING AND SUSPENSION DIAGRAMS
greasethrough the greasefitting in the bottom block
shaft.Avoid pumping an excessive
amount of grease
into the bottom block. On triple chain hoists,use a
greasegun to lubncatethe idler sheavein the hoist
until freshgreasepumps from the end of the sheave
bearing.
for oil replacementis load brake noise. If an erratic
tapping sound is made when lowering a load, the oil
should be changed.
c. Limit Switch Shaft To preventrust, the threadedlimit
switch shaft should be given a light coat of greaseor
sprayedwith a generalpurposelubricant.
e. Hook BearingApply a fewdropsof SAE 30 oil around
the edgeofthe beanng.
d. Idler SheaveBearing(doubleand triple chain models
only) Use a greasegun to put about a teaspoon of
TABLE5-1.RECOMMENDED
LUBRICATION
MODELEC ELECTRICCHAINHOIST
SCHEDULEFigure And
Index No.
I
Component
Type of Service And
Frequency of Lubrication
Type of Lubricanl
Frgure 8-6, No. 7
Ilad Chain
SAE90 GearOil
Figure 8-5
ueanng
F i g u r e8 - 8 A , N o . 9 ;
Figure 8-8B, No. 7
-imit Switch Shaft
C o f f r n gN o . H - 7 8 1 3t r a n s mission oil (Kit No. l4J I
contains quantity of oil
suflicient for one oil change).
'WD-40"
or general purpose
spray lubricant.
Figure 8-6, No. &No.-
-oad Hook Beanng
Figure8-2,
Nos.t.3.4&5
Figure 8-7C, No. I I
F i g u r e8 - 7 D , N o . I I
Heavy
Normal
Infrequenl
Daily
Weekly
Monthly
At periodic inspection (see Figure {1, paragraph 5-6-2\.
Monthly
Yearly
Yearly
SAE30 Gearor Motor Oil
WeekJy
Monthly
Yearly
lop Hook or Susrnsion Lug Bearing
iurfaces
SAE 30 Gear or Motor Oil
Monthly
Yearly
Yearly
Idler Sheave
Bearing (Bushing)
NLGI #2 multi-purpose
lithium basegrease
(Coffrne No. H-7610)
I
I
l
Alt
ercpt
dust. etc., should be lubri€ted
rdlcr
At periodic inspection(seeFigure 4-l).
b€ann8s
more freeucntly.
13
VI
SECTION
TROUBLESHOOTING
6-1. General
Use the followingtableas an aid to troubleshootyour
hoist.If you do not have an experienced
machinist-
electricianto do your repairwork, we recommendthat
you sendyour hoist to an approvedservicecenterfor
repairs.
TROUBLE
I
REMEDY
Hook Fails To Stop At End Ol Travel.
I . Limit switchesnot operating.
2. Plastic limit switch nuts no1 moving on shaft.
3. Magnetic reversingswitch malfunction.
| 1. Check adjustment.Seeparagraph5-2. Check connectionsagainst
wiring diagram. Tighten loose connectionsor replace.
| 2. Check for stnpped threadsor bent nut guide.
| 3. Remove electricalcover and check reversingswitch
Hoist Does Not Respond To Pushbutton.
l. Power failure in supply lines.
I l. Check circuit breakers,switchesand connectionsin power
2. Wrongvoltageor frequency.
I supplylines.
I 2. Checkvoltageand frequencyof powersupplyagainstthe ratingon
3. Improper connectionsin hoist or pushbutton
station.
4. Motor brake does not release.
5. Faulty magnetichoist conlrol switch.
| 3.
I
I
| 4.
I
| 5.
the nameplateof the hoist.
Checkall connectionsat line conneclorsand on terminal block.
Check terminal block on dual-voltagehoists for prop€r
voltageconnections.
Check connectionsto the solenoid coil. Check for open or short
circuit. Check for proper adjustment.Seeparagraph5-3.
Checkcoils for open or short circuit. Checkall connectionsln
control circuit. Check for burned contacts.Replaceas needed.
,rl
Hook Does Not Stop Promptly.
l. Hoist overloaded.
2. Brake not holding.
I L Reduceload to within rated capacity of hoist.
| 2. Check motor brake adjustment (seeparagraph5-3) and load brake
(figure4-3).
I
l-
Three-phasereversal.
2 . Improper connections.
l. Reverse
any two wires(exceptthegreengroundwire)at the power
source(seeparagraph2-3).
2. Checkall connections
againstWiring Diagram.
Hoist HesitatesTo Lift When Energized.
l.
2.
3.
4.
Hoist overloaded.
Motor brake requiresadjustmenl.
Worn overloadlimiting clutch.
Low voltage.
I l.
I 2.
| 3.
| 4.
Reduceload within rated capacity of hoist.
Check motor brake adjustment, seeFigure 5-3.
Replaceclutch.
Check voltageat hoist power cord with hoist slarting. Voltage
should be no lessthan 90% of volhge specifiedon hoist.
5. FaultySINPAC startingswitchor startcapacitor 15. Replacet-aultycomponent.
( s i n g l ep h a s eh o i s t so n l y ) .
HookRaisesButWillNot Lower.(Motornotrunning)
l. "Down" circuit open.
2. Broken conductor in pushbutton cable.
3. Faulty magnetichoist control switch.
I l. Checkcircuit for looseconnections.Check "Down" limit switch
for malfunction.
2.
Check eachconductor in the cable.Ifone is broken, replace
|
entire cable.
| 3. Check coils for open or short circuit. Check all connectionsrn
control circuit. Check for burned contacts.Replaceas needed.
14
i
( .1
v
TROUBLE
REMEDY
HookRaisesBut Will Not LowerWhenMotorls Operating.
Consult Factory Or Authorized Duff-Norton Warranty Repair Station.
HookLowersBut Will Not Raise.
L Hoist overloaded.
2. Low voltage.
3. "UP" circuit open.
4. Broken conductor in pushbutton cable.
5. Faulty magnetic hoist control switch.
6. Faulty capacitor (single-phasehoists only).
7. Worn overloadlimiting clutch.
l. Hoisl overloaded.
2. Motor brake is dragging.
3. Low voltage.
4. Overloadlimiting clutch intermittentlyslipping.
0
I l. Reduceload to within rated capacity.
| 2. Determine causeof low voltageand bring up to at least l0% of the
voltagespecifiedon hoist. Line voltageshould be measuredwhile
holding or lifting load.
| 3. Checkcircuit for looseconnections.Check"UP" limit switch for
malfunction.
| 4. Check eachconductor in the cable. lf one is broken, replace
I
entire cable.
| 5. Check coils for open or short circuit. Check all connectionsin
control circuit.
Check for burned contacts.Replaceas needed.
6.
Check starting capacitor in motor. Replaceif necessary.
|
| 7. Replaceclutch.
l. Reduceload to within rated capacity of hoist.
2. Checkfor properbrakeadjustmentor other defects.Seeparagraph5-3.
3. Bring up voltageto plus or minus l0% of voltage specifiedon
hoist. Line voltageshould be measuredwhile hoist is lifting load.
4. Replaceclutch.
Brake "Noise". (Erratic
Need transmissionoil changeor
improper lubncant has beenused.
Load brake malfunctionrns.
l. Changetransmissionoil. SeeTable 5-1.
Note: Hoist Warranty is void if unapproved oil is used.
2. Check load brake operation. SeeFigure 4-3
Motor Brake Noise Or Chatter.(Whilestartinghoist)
l. Brakeneedsadjustment
2. Low voltage.
l. Adjust as per parag.raph5-3.
2. Check voltageat hoist power cord with hoisr starting. Voltage
should be no lessthan 90% of the voltagespecified. I l5 volt hoists
are particularly subjectto voltagedrop problems due to their high
curent draw. Conversion to 230 volt operation is suggestedin
extreme cases.
Motor Brake "Buzz". (Anytimehoist is
l. Brakeneedsadjustment.
2. Brokenshadinecoil on brakeframc.
l. Adjust as per paragraph5-3.
2. Replaceshadingcoil or completebrake frame assembl
15
sEcfloN vll
WIRING
c . T H R E E P H A S EH O I S T S :T r a n s f e rl e a d sT . 1 .T 5 . T 6 . T 7 .
T U . T 9 . H 2 . H 3 . S l . a n d S 2 p e r t h e a p p r o p r i a ttee r m i n a l
b l o c ks c h e m a t i c .
SafetyNotes
Disconnectpowerfrom hoist beforeremovingendcovers.
t
CAUTION
Do not moveany wiresor makeany changesto the
7-1. Voltage Conversion
StandardsingJephaseunits are convertible from I l5 to
230 volts and standardsinglespeedthree phaseunits
are convertiblefrom 460 to 230 volts. Conversionto
the alternatevoltagecan be accomplishedwith the following procedure.
wiring exceptat the terminalblock.
d. After converting voltage,checkfor proper phasingof
three phaseunits and check for proper limit switch
operation.
a. Be sure power is disconnectedfrom hoist. Remove
long end cover.
7-2.Wring Diagrams
The wiring diagrams for standard hoist models are
) :r a n s - reproducedon the following pages.In addition, every
b . S I N G L IP
TH A S EH O I S T S
r w i t hS I N P A Cs' w i t c h T
f'crleads2, Hl. H3. T2. SI. andT3 pcr thc appropriatc hoist should have a wiring diagram locatedinside the
lone end cover.
tcrrrrinul
hlockschentatrc.
L1 (wxre)
telrcx) L2
T5'
1
T4
c2
c5
c4
c1
T1
H 1 ,C l
2,H2 Hl, C1
H4, C2
H3
H4,C2
2, s1
c4
T2,51
c4
c5
T3,52
c5
c1s
S2
230V
MOTOR
DN
L.S.
tp+-
GREEN
NUT
BRAKE
S1
E+
S2
c21
c20
t
TO CONVERTVOLTAGE,RECONNECT
WIRESTO TERMINALBLOCKAS SHOWN
r-l
NI
andT8.
H2, H3
115V
c14
T2, T3
r
H4
f3>L*
H3
H2
H1
XFMR
SINPACSWITCH
FIGURE7-I. WIRING DIAGRAM
ll5/230V,I Phase,SingleSpeedHoistwith SINPAC! switch
981EC 50
I
NOTE:
Diagramshownfor
6 to 32 FPM chain
hoists.For EC-0564
modelswap locations
of motorleadsT5
16
REVERSING STITCH
L]L2L3
I1
c5
TA
c6
T9
cl
A2
c2
ts3
c6
c2
c5
. INO]C
TES SPLICE CONNECTION
fIRING
HARNESS
c6
cl
c
c2
N2
r5
cr4
cza
s2
T6.
LFI
R€O
I
NUT
OOIN L. S
GREI:N NUT
NOTE.
D U A L V O L T A G EO P E R A T I O N .
SHOTN 'IRED FOR 46OV
T O C O N V E R TV O L T A G E .
XFXER
f'-"i
I
I
R E C O N N € C T O L € ^ O S M ^ R K E OT 4 , T 5 . T 6 . T 7 . I 8
T9.82,HJ,S
, & 5 2 P E R ^ P P R O P R l A T EO I A G R ^ M
xx?
FIGURE 7-2. WIRING DIAGRAM
2301460V,3Phase, Single Speed Hoist
9E3 EC 44C
REVERS]NG SWITCH
II
L2
L3
c14 C20
C15
tl
l"ql
tat
UPLS
RED
NUT
s]
Ir.lI
!l
/
I
C2t
tl
tk4
DNLS
GRE€N
NUT
s2
q"\.P
)<'
tl
BRAKE
SOLENOID
MOTOR \
208v
l
\J7
GR
--r?-Ellu"
al
oru
c,'{l!
PUSH
EUTTON
STATION
FIGURE 7.3. WIRING DIAGRAM
208V,3 Phase,SingleSpeedHoist
983 EC 48
17
'.
wrRrN.rHARNESS
/-
ll1
TI.-l
cr4 c20
cl5
. REO
NUT
GBEEN
NUT
_
,
sl
H]
!",!.f
H2
l**r
1
s2
a
I
c?,
r mf -f : '{ 1 1 i
E
*l
iFii
l
G8
aru-re
soLENoD
].t
XFMER
xt 6----?'
x2 -l
ro
ii;;
I
I
"', ffIlor
PUSts
BUffON
STATION
FIGURE7-4.WIRING DIAGRAM
575V,3 Phase,SingleSpeedHoist
983 EC 45
SPEEOCOIJIROT
I
trt"
t EADS
L
..i!
;lI
iJ{
t
,'
"" i- ;1
--)
r..,r
]
(uo,
I . o *j
ll
l'11
I,
-l
d-j
j
I
"i
i, -f
1
I
(.r5
|14 i1t
.+|-|
'r-r
, -a
I[].\.'r
r_
.- a
_ r. -as - '-oorruurrssup
uPrS
NEO
NIjT
GREEN
NUI
,:,
A
r NL r N E
sPLrcE
II
rf f ll1'l lI
J r ' ' | " ,). ': 'ii
I
I
I
I
f].l
fl.'
fr4
t*J
/.Yr'f\
XMFR
18
-a
tl
li r
lir
i
ta\
5l
i ^.J
Tll
j1,.'
1ay
(
MOTOF
It
,'
L"l
j
L__:
,,'
i'"
ll
IL
lrl
i--t
FIGURE 7-5.WIRING DIAGRAM
230,460,575& 208V,3 Phase,TwoSpeedHoist
983EC 14r
L
lLt
TT TT1
h
u?l ?
lt
-t
?
f
l--I
n" , ].a
-L.ll.,
:t
lr
it
L+
,{
sEcTloNvill
PARTSLIST
ILLUSTRATED
4) If more than one part number is listed with the
sameusagecode,the information under "part name"
will determine the correct part number. This is also
the caseif no usagecode is listed and more than one
part number is listed for the index number.
8-1. General
The following exploded drawingsprovide a complete
list of partsusedin the standardEC hoistmodels(shown
in Table l-1, page3). Sinceseveraldiflerent modelsof
hoists are coveredby this manual, diflerencesmay be
noted betweenthe appearanceof your hoist part and
the referenceillustration.Ifthis is the case,the partslist
will show severaldiflerent part numberswith sufficient
information to allow the selectionof the correct part
number.
EXAMPLE
B
INDEX USAGE PART
PART NAME
NO.
NO.
CODE
4
B
JF-82l -3 Transformer(Pri. 208,230/
460V Sec2a V 50/60Cy)
B
JF-82r-9 Transformer(Pri. 575V Sec
2a v 50/60Cy)
8-2.HowTo UseThe PartsList
a. The parts list consistsof four columnsas follows:
I ) lndex Number
2) UsageCode-This column may contain a code
relating to the model numbers of, or other dala
relatingto the hoist in which the part is used.Usage
codesare as follows:
A- SinglePhaseHoists (SingleSpeed)
B- Three PhaseHoists (SingJeSpeed)
C- Three PhaseHoists (Two Speed)
D- Hoists with r/,rin. Load Chain (ModelsEC-0516.
EC-1016,
EC-0532,EC-0s64,EC-1008,EC-1009.
EC-1032and EC-2008)
E- Hoistswith e/r in. Load Chain (ModelsEC-2012.
EC-2016,EC-4006.EC-4008and EC-6005)
F- SingleChain Hoisls (Models EC-0516,EC-0532.
EC-1032)
EC-0564,EC-1009,EC-1016,
G- Double Chain Hoists (Models EC-2008,
EC-4006,EC-4008)
H- Single Chain Hoists (Models EC-2012,
EC_2016)
J- Triple Chain Hoists (Model EC-6005)
Parts
8-3.HowToOrderReplacement
When ordenngpartsor requestinginformationconcerning your EC hoist,alwaysincludethe hoist model number and serialnumber. Both numbersare permanently
stampedon the transmissionhousingcastingnear the
chain entrancearea. See index No. 6. Fieure 8-l and
illustrationbelow.
3) Part Number
4) In additionto basicpartname,thiscolumn contains
descriptionswhich are essentialfor choosingthe correcl part number when more than one is listed.
b. How to determine proper part number:
l) Locate the index number in the corresponding
figure of the parts list.
2) If only one part number is listed for the index
number, that part number should be ordered.
3) If more than one usagecode and part number is
listed for that index number,choosethe correctusage
code by comparing the model number or electrical
characteristicsof your hoist with the usage codes
above.
;t
When ordering motor parts, please provide complete
motor nameplatedata, including motor "ref." number or
model number.
EXAMPLE A
INDEX USAGE PART
PART NAME
NO.
NO.
CODE
TransmissionHousing
E
35Jl
6
TransmissionHousing
D
35J2
NOTE
Repair partsareavailableonly from Coffing distributors
or authorized repair facilities. It is recommended that
repair part orders be directed to the authorized repair
facilitv nearestvou.
19
{
{
I
FIGURE8-I. BASIC HOIST
20
PARTSLIST FOR BASICHOIST
INDEX USAGE PART
PART NAME
NO. CODE
NO.
Brake Cover
I
36Jr
ElectricalCover
2
36J2
Gasket, Brake &
J
560J4
4
A&C 33Jl
B
33JI
B
33Jl-r
A,B,C 33J2
A.B.C 33J2-r
J
33J19
34JGI
5
34JIK
6
1
8
a
r0
E
D
INDEX USAGT PART
PART NAME
NO. CODE
NO.
l0
6 7 5 J 3 8 Decal,Capacity(l Ton)
(cont.)
675J48 Decal,Capacity(2 Ton)
6 7 5 JI r
Decal,Capacity(3 Ton)
H-4002-PFlat Washer
ll
Decal,Coffing
6 1 1t l
t2
H - 2 9 8 1 Screw
l3
Gasket,Transmission
560Js
t4
616J28 Decal. Duff Norton
l5
A
679J1
Decal, Power
l6
Electncal Covers
SheaveHousing
(Models EC-2012,
EC-2016,EC-4006
& EC-4008)
SheaveHousing
(ModelsEC-2016
& EC-4008)
SheaveHousing
(ModelsEC-2012
& EC-4006)
SheaveHousing
(Models EC-0564
& EC-I032)
SheaveHousing
(ModelsEC-0516,
EC-O532.
EC-1008.
EC-1016,
EC-2008&
EC-1009)
SheaveHousing
(Model 6005)
TransmissionCover
(includes2 oil seals)
TransmissionCover
(older hoistsonly,
has fill plug
insidecover)
Requirements
(llsl230v)
B
A,B,C 67913
Decal, Power
Requirements
B&C 679J4
Decal, Power
Requirements
B&C 619J5
Decal, Power
Requirements
( 230v)
(460v)
( 575v)
TransmissionHousing
TransmissionHousing
Power Cable
Power Cable
Wiring Harness
Wiring Harness
Screw (slotted
hex head)
H-2980-P Screw(older hoists
only, Phillips head)
675J28
Decal, Power
Requirements
(2301460
v)
35JGI
35JG2
A
9 5 l Jl
B
9 5 3 Jl
A&B 940JI
940Jl -36
C
H-2923-P
6 7 5 JI B
67912
t7
l8
l9
20
619J9
679JI 0
679Jtl
2l
24
25
Screw(Includedin all
Suspension
AssemblyKits)
H-4086-P Lock Washer
(Includedin all
Suspension
AssemblyKrts)
PushbuttonCable
(Ref. Figure 8-l0A
& 8-l0B)
H - 6 2 5 8 Fill Plug
H-2910 Screw
)6
s-25-l 3
22
:J
Decal,Capacity
(% Ton)
Decal,Capacity
(7r Ton)
{
21
Decal. Right
Decal, trft
Decal,Bottom
SuspensionAssembly
K i t ( R e f .# 1 . 3 , 4
& 5, Figure 8-2)
703Jl
lrvel Plug
,d
N
'/ ./''n
fr"
FIGURE 8-2.SUSPENSIONASSEMBLY KITS
22
'. -J/
ASSEMBLYKITS
PARTSLIST FOR SUSPENSION
INDEX
PART NAME
NO.
Hook AssemblyKit,
F,G,H r4125
Swivel
Hook AssemblyKit,
F,G'H t4126
Risid
Rigid Hook Assembly
3JG23
J
F,G,H H-7540 Iatch Kit
H-7544 Latch Kit
J
.:
F,G,H 50JG22 Multi-purposeLugi'fi,
Assembly
TrolleyLug Assembly
F,G,H t4J3
Kit, PlainTrolley,
ParallelMount
INDEX JSAGE PART
PART NAME
NO.
NO. CODE
5OJG53 Trolley Lug Assembly
4
J
(cont.)
Kit, Plain Trolley
Trolley Lug Assembly
F'G,H l4J4
5
J
Kit, Motorized
Trolley, Cross
Mount
50JG54 Trolley Lug Assembly
Kit, MotorizedTrollel
MotorizedTrolle
(J
.J
23
PARTSLIST FORTHREEPHASE.SINGLEAND TWO SPEEDMOTOR
INDEX USAGE PART
TNDEX.]SAGT PART
PART NAME
NO. CODE NO.
NO. CODE
NO.
I
B
863J201 Motor(% HP, 208V
873J20
l
I
C
(cont.)
60 Hz)
B
863J208Motor(% HP, 208V
873J202
C
60 Hz)
B
863J209Motor(% HP. 208V
873Jr 03
60 Hz)
B
863J109 Motor(l HP, 208V,
C
873Jl 04
60 Hz)
873J204
8 7 3 J 2 t l Motor(.25l.08HP,
C
208V, 60 Hz)
C
873J205
7P.
C
873J209M o t o r( . 5 0 / . 1H
208V. 60 Hz)
8 7 3 J1 0 7
8 7 3 Jl16 M o t o r( . 7 5 1 . 2H5P ,
C
208V, 60 Hz)
cl 873Jl 08
8 7 3 J l l 5 Motor(l/.33 HP.
C
208V, 60 Hz)
873J207
l Motor(rAHP,
B
863J20
230/460v, 60 Hz)
873J208
B
863J202 Motor(r/:HP,
V, 60 Hz)
2301460
C ] 8 7 3 Jl1I
B
863J203Motor(% HP,
v, 60 Hz)
2301460
8 7 3 IJl 2
B
863Jl 04 Motor(l HP,
v, 60 Hz)
2301460
Contact fa( 1ory with length
B
863J204Motor(r/.r
HP, 575V
req urred.
60 Hz)
Contacl fa<tory.
J
B
863J205Motor(h HP, 575V
+
N o t a v a i l a lrle separately
60 Hz)
I500K3
5
B
863J206Motor (r/.rHP, 575V
Contact fa<tory with complete
6
eplare data for
60 Hz)
B
8 6 3 Jr 0 8 M o t o r( l H P . 5 7 5V ,
7
H-4082-P
60 Hz)
Ci
CI
CI
cl
Ci
CI
a
A
Hff,,lli
FIGURE 8-3A.MOTOR PARTS
(THREE PHASE)
I
PART NAME
Motor(.25l.08HP
230V, 60 Hz)
7P
M o t o r( . 5 0 / . 1 H
230V, 60 Hz)
Motor(.75/.25HP
230V, 60 Hz)
M o t o r( 1 / . 3 3H P ,
230V, 60 Hz)
Motor(.25l.08HP
460 V, 60 Hz)
7P
M o t o r( . 5 0 / . 1H
460V, 60 Hz)
Motor(.751.25
HP
460V, 60 Hz)
M o t o r( l / . 3 3H P ,
460 V, 60 Hz)
Motor(.25l.08HP
575V, 60 Hz)
7P
M o t o r( . 5 0 / . 1H
575V, 60 Hz)
Motor(.751.25
HP
575V, 60 Hz)
M o t o r( l / . 3 3H P ,
575V, 60 Hz)
Thru Bolt
End Shield
Stator
Bearing
Rotor Shaft
Lock Washer
.{
PARTSLIST FOR SINGLEPHASEHOISTMOTOR(INTERNALSWITCH)
rJ
Index
No.
Motor, Completc:
t/a HP. I l-5/230Vrlt
th HP, I l5/230 Volt
t/c HP, I I5/230 Volt
I HP. I 15/230Volt
I
2
3
I
I
I
Part
No.
Part Name
4
6
1
li
9
tt6lJ20l
tt6IJ202
86lJl0l
I t 6 l J1 0 , 1
tnd Shicld
Switch, Stationary:
Docrr,7a& I HP
Dtrcrr, 7a & t/: HP. All l,ccson
S c r e w( f o r a l u m i n u mc n d s h i c l d )
Washer,Shim
RctainingRing
Bcaring
t()
lt
tl
tl
JFA-1t447
h,c0027750 |
s-31-tt4
JFA ]24
JF-5| (X)-66
5(X)Kl
,\i
Part Name
Switch. Rrrlating
Rotor & Shaft
Parl
No.
JFA-11647-02
('()nlrct Fa!lor\
qrlh L()ntplctc
lor rrarlabrltty
I rctorl
tl
Nrr rratlrblc
icfrrfutcl)
Stator
'fhru
Eolt
Lock Washcr
Washcr
Scrcw
*rth hnfth rrqurrcd
H-.1082P
s--l ll
H-2118I
W
11
6/
II
rJ
Index
No.
7
13
\
v/ t n
PARTSLIST FOR SINGLE PHASE HOISTMOTOR(SINPAC"SWITCH)
Index
No.
I
I
L
7
9
Part Name
Motor. Complctc.
t/t HP, I t 5/230 Volt
t/z HP, I l5/2-30Volt
% HP, I l5/230 Volt
I HP, ll5/230 Volt
End Shicld
Bearing
Rotor & Shaft
Index
No.
Part
No.
I t f , l J l lI
136lJ22l
tt6tJI 2-l
86lJl24
Part Namc
t0
Stator
il
Thru Bolt
(-r)ntaLl Frrlor\ wrlh
Rcqurrcd
I.n[rh
l2
Lockwasher
H-4082-P
-s00K3
( 0nt.r(l I r(l0r\ qrth
(,rn\Plcla nJrIlaPlJlc
,hlr
lor a\rrlrhrlir!
FIGURE 8-28. HOIST MOTOR PARTS (I PHASE)
25
Part
No.
N({ r!rrlJble
\cfJrdrr r\
2 -----+
\
o
Capacitor(lndex No. 8)
and SINPACeswitch
(lndex No. 13) are used
on slnglephase
units only.
\
'8
't4'-''
Index
No.
I
2
2A
28
3
A
Part Name
Control Panel
ReversingContactor:
E s s e x ,2 4 V C o i l
E s s c x ,1 2 0V C o i l
SquarcD. 24 V Coil
S q u a r cD . 1 2 0V C o i l
Coil:
Essex,24 V
E s s c x ,1 2 0V
SquareD, 24 V
S q u a r eD , 1 2 0 V
Replacement
ContactKit:
Esscx
Squarc D
TerminalBlock.
20 position
l0 position
6 position
Transformer:
I 1 5 / 2 3 0V - 2 4 V
208, 230/460V - 24 V
575V-24V
I 1 5 / 2 3 0V - 1 2 0 V
208, 230/460V - 120 V
575V-120V
Part
No.
lndex
No.
l - 5 7 Jl A
5
6
1
1320J
I
rJ20J2
It20Kl
lJ20K.r
l7
IJ
u20J.r0I
1320J
302
lJ20K30|
tt20K.r0l
820Jl(X)
tt20K3(x)
909JC2
909JG4
909JI
Part Name
Scrcw
l-ock Washcr
H v el c t ( - l P h a s eU n i t s )
S c r c w( l P h a s cU n i t s )
C a p a c i t o rl . l 6 l - 5 9 r n l d . .
I I 7 r o[ ) i a .
Capacitor,4(X)-4tt0mld..
l r T r oD i a .
C a p a c i t o r2. 3 0 n r f d . .
I I 7rr Dia.
C a p a c i t o r1. 7 5 m t d . .
2r,uro
l)ia.
C a p a c i t o r5.3 4 n r l d . .
2 1 / t tD i a .
Capacitor.,155nrfd..
2t/to l)ia.
JF-tt2I -4
J F - 82 l - 3
J F - 8 2l - 9
J F - l t 2 ll-9
JF - 8 2l
J F - 8 2l - 2
l0*
ll
l2
ll
l4
Capacitur Bracket:
I rTrr Dia.
2t/to Dia.
Splicc Conncctor
Grommct
Scrcw
S I N P A C T {S w i t c h
Cablc Tic
x Not illustrated
FIGURE8-3A.CONTROLLERAREA (SINGLESPEEDHOIST)
26
Parl
No.
H-2751
H-415lt
H,4912
H-2152
JL ul0-3
J L - t it 0 - 4
J L - t il 0 - 3
8l0K3
810K4
8l LlK5
ullJl
8ilJ2
H-5157
H-7906
H-2981-P
839J2
H-9ff)6
J
CoNTROLLERAREA PARTSLIST (TWOSPEED)
INDEX USAGT PART
PART NAME
NO. CODE
NO.
I
2 5 7J tA l ControlPanel
2
820Jr
ReversingContactor
(Essex,
24 V Coil)
Reversing
Contactor
82012
(Essex,120V Coil)
ReversingContactor
820K2
(Square
D, 24 V Coil)
Reversing
Contactor
820K317
(Square
D, 120V Coil)
2A
24 V)
820J301 Coil (Essex,
120V)
8201302 Coil (Essex,
D,24 Y)
820K301Coil (Square
D, 120V)
820K302 Coil (Square
2B
Contact
820J300 Replacement
Kit (Essex)
Contact
820K300Replacement
Kit (Square
D)
INDEX USAGT PART
PART NAME
NO. CODE
NO.
J
C
JF-82r- l 5 Transformer(208,
230/460V - 24v)
Transformer
C
JF-82l-l6
( 5 7 5v - 2 4 v )
C
J F - 8 2 1I 7- Transformer(208.
2301460
V - l20v)
C
J F - 8 2 1 - 2Transformer
0
a
( s 7 s v- l 2 0 v )
4
5
6
7
C
C
C
8
9
r0
H-2"751
H-4158
H -1 8 5 3
820J3
SpeedControl Relay
(24 V Coil)
820J4 SpeedControl Relay
( 1 2 0V C o i l )
H-5157 SpliceConnector
H-7906 Grommet
H-2981-P
Screw
J
,1
FIGURE 8-48. CONTROLLER AREA
(TWO SPEED)
Screw
Lock Washer
Screw
r
'l
Y**<Fi"
l".L!r& x
S/$*
FIGURE8-5.TRANSMISSION
28
>
J
PARTSLIST FORTRANSMISSION
INDEX USAGE PART
PART NAME
NO. CODE
NO.
I
TransmissionCover
34JGI
2
56rK2
Seal
a
MA-562 Seal
J
4
404J1
Output Pinion
401JG25 OutputGearAssembly
5
580J8
BrakeDisc (all models
6
INDEX USAGT PART
NO. CODE
NO.
/.J
59lJG3
(cont.)
591JG4
59lJG5
exceptEC-0564)
1 Jt 4
H-2255
H - 4 1 3 3 Lock Washer
H - 5 3 8 2 Dowel Pin
H-2978-PScrew
H-5503 RetainingRing
H-6258 Fill Plug,Vented
s-25-l 3
Level Plug
560J5
Gasket(Ref.#14,
u
t2
l3
t4
l5
l6
l7
r8
20
2l
E
D
H-6268
35JGI
35JG2
500K7
400JI
400J2
400J3
400J4
400J9
22
59lJG7
exceDt0-564)
Spacer'(8C0564
only)
Screw
l0
l9
59rJG6
-5J6
PressurePlate
r30J3
Nut
7 J G l 5 - r Ratchet(all models
7
8
9
40lJl
40tJ2
40rJ3
59lJG20
24
402J2
Figure7-l)
Drain Plug
TransmissionHousing
TransmissionHousine
Beanng
402J3
25
Input Pinion (Models
EC-2012,
EC-2016,
EC-4006.EC-4008
& EC-6005)
EC-O516,
EC-1008,
EC-1016& EC-2008)
EC-0532& EC-I032)
Input Pinion
(Model EC-O564)
Input Pinion
(Model EC-1009)
401J9
ZJ
59lJGl
59tJG2
H-5549
H-5553
H-5530
26
Input Gear (Models
EC-2012& EC-4006)
Input Gear (Models
EC-0516,EC-1008,
EC-1016& EC-2008)
Input Gear (Models
2tt
t 4 Jl
Slip ClutchAssembly
(ModelEC-0564)
Slip ClutchAssembly
(ModelsEC-1016
& EC-2008)
SlipClutchAssembly
(ModelEC-1032)
SlipClutchAssembly
(ModelsEC-2012
& EC-4006)
SlipClutchAssembly
(ModelsEC-2016,
EC-4008& EC-6005)
SlipClutchAssembly
(ModelEC-1009)
Intermediate
Pinion
(ModelsEC-2012,
EC-4006& EC-1009)
Intermediate
Pinion
(ModelsEC-0516.
EC-1008,
EC-1016,
EC-2008,
EC-2016,
EC-4008
& EC-6005)
Intermediate
Pinion
(ModelsEC-0532
& EC-1032)
RetainingRing
(ModelsEC-0516,
EC-1008,
EC-10r6.
EC-2008.
EC-2016.
EC-4008& EC-600s)
RetainingRing
(ModelsEC-2012,
EC-4006
& EC-1009)
RetainingRing
(ModelsEC-0532
& EC-1032)
Transmission
Oil
Replacement
Kit,
IncludesOil
Requiredfor One
Oil Change
D
t 3 2 J G 2 2 SheaveShaft
tl
r 3 2 J G 2 l SheaveShaf't
Assembly
EC-0s32
& EC-1032)
4 0l J 5
402J1
PART NAME
Input Gear(Models
EC-2016,
EC-4008
& EC-6005)
Input Gear
(ModelEC-1009)
SlipClutchAssembly
(ModelsEC-0516
& EC-1008)
SlipClutchAssembly
(ModelEC-0532)
29
30
3r
500K29
H-5539
H-5493
32
t4J2
-l -)
at
J+
35
29
340t7
25J2
t 4 l Jl 4
Assembly
Bearing
Retaining Ring
Dowel Pin,
Ratchet Ring
Seal Kit, Includes
Three 561K2 Seals,
One MA-562 Seal
and One 560J5
Gasket
Spring
Pawl
Spacer
I
<s
<x'
V,I
\-
-)^',--/1 8
e-< \
\\v
1s \J/
1Y
/ rr)
22
lS
n)
7*U1
fM
w
,{
44
q5
'
'{-t"
:
.\iriJ
z fr.ii
hi
U
\I'
J\'
.^\'
'2
1
/
a//\'
\2
t"
'
lr' -/ >
t( ,
tl,
3.TON MODEL
FIGURE 8-6.CHAINING PARTS
30
,/
\"
^{"
\.,
J
CHAININGPARTSLIST
INDEX USAGE PART
NO. CODE
NO.
D
s00K28
6
E
500K5
7
D
JLI98
l8
19
20
2l
22
23
24
25
26
27
28
29
E
JLl9-r
G
G
E
413
l 8 Jl
272J1
D
272J2
PART NAME
Bearing
Bearing
Load Chain
('A in. Chain)
Load Chain
(eln in. Chain)
Dead End Lug
Dead End Pin
Chain Guide Plate
(%zin. Chain)
Chain Guide Plate
(% in. Chain)
t27Jl
Spacer,Chain Guide
Plate
H-5025-PCotter Pin
G
H-7596 Split Chain Link
E,G,H H-2978-PScrew
H-2232
J
Screw
H-2976-P Screw
Transmission
Housing(Ref.#6,
Figure8-l )
SheaveHousing (Ref.
#4, Figure8-l)
H-5490-P Pin, SlackEnd
23J2
Spring, Slack End
INDEX USAGE PART
NO. CODE
NO.
PART NAME
500K29 Bearing (Ref. #29,
30
Figure 8-5)
H- 5539 Retaining Ring (Ref.
31
JZ
34
35
D
E
D
E
36
EG,H l 0 7 J l
Drive Coupling
t07IG1-4 Drive Coupling
RetainerBlock
EG,H l 7 0 J r
H-5382 Dowel Pin
H
l 8J8
Dead End Pin
r22JGt6 Idler Shaft
J
t7014
J
RetainerBlock
Washer
2 5 5 K 3r
J
J
5 3 0 J 3 s SleeveBearing
281t2
Idler Sheave
J
H-52t9 Grooved Pin
J
J
H - 7 8 1 8 GreaseFitting
J
37
38
39
43
44
45
46
47
48
49
#30, Figure 8-5)
SheaveShaft
t612
Sheave(th in. Chain)
l 6 JI
Sheave(%zin. Chain)
JF-250-3 Chain Guide
(% in. Chain)
IF-254-3 Chain Guide
(%r in. Chain)
23
25
z\-
-
\\a
26
FIGURE 8-7A.BOTTOM BLOCK
% & %-TONHOISTS
FIGURE 8-7B.BOTTOM BLOCK
ONE-TON HOISTS
FIGURE 8-7C.BOTTOM BLOCK
DOUBLE CHAIN HOISTS
FIGURE 8.7D. BOTTOM BLOCK
TRIPLE CHAIN HOISTS
rs'o-.
//
17/
16
32
I
PARTSLIST FOR BOTTOMBLOCKASSEMBLIES
INDEX USAGE PART
PART NAME
NO. CODE
NO.
I
F,H 3JG2OS Hook and latch
Assembly
l^atch Kit
Load Block Frame
Load Block Frame
Screw
2
3
4
5
6
F,H
F
F
F
F
H-7540
JF-20-2
JF-20-3
JF-700
9I3JG4ASBottom Block
8
G
9r4JG2
G
9t4IG4
Bottom Block
Assembly(Models
EC-4006& EC-4008)
G
3KGI
Hook and latch
Assembly(Models
EC-4006& EC-4008)
Hook and latch
Assembly(Model
Assembly
Bottom Block
Assembly(Model
EC-2008)
9
l0
ll
G
3KG6
G
G
H-7540
I6JG7
*l$'trflr'df1oJ
Sheaveand Bearing
Assembly(Model
EC-2008)
INDEX USAGT PART
NO. CODE
NO.
ll
G,J I6JG6
(cont.)
t2
G
3012
G
30J4
l3
l4
l5
l6
l7
G,J
G,J
G,J
G,J
G,J
l8
l9
J
J
20
2l
22
J
J
J
PART NAME
Sheaveand Bearing
Assembly(Models
EC-4006,EC-4008
& EC-6005)
Frame (Model
EC-2008)
Frame (Models
EC-4006& EC-4008)
t22IG3 Shaft Assembly
255t<2 Washer
H-2403-P Screw
H-4085-PLock Washer
H-3473-PHex Nut
30J20 Frame
3JGI45 Hook and latch
Assembly
H-7544 Latch Kit
l8Jl5
Dead End Pin
9t4JG23 Bottom Block
Assembly
23
24
25
26
27
H
H
H
H
H
Frame
30J14
l 8J8
Dead End Pin
s-49-77 Screw
9 I 3 J G 3 A SBottom Block
Assembly
PARTSLIST FOR STANDARDLIMIT SWITCH
INDEX PART
PART NAME
NO.
NO.
I
9 1 8 J G 4 Limit Switch and Shaft
A
JF900-3
5
6
JF-53r -4
8l5Jr
INDEX
NO.
1
8
9
l0
Assembly(Consistsof
Index Nos. 4 thru l2)
Limit Switch BracketAssembly
(IncludesIndex No. 5)
Limit Switch Bushing
Microswitch,Limit
ll
t2
l3
I4
PART
NO.
PART NAME
H-1402-P Screw
H-3944
Nut
JF-l I 7-3 Limit Switch Shaft
JF-75r-3-GLimit Switch Nut (Green)
JF-75r-3-RLimit Switch Nut (Red)
H-5520 RetainingRing
JF-343-3 Spring
H - 2 9 8 1 - PScrew
{
h\
u"/'
.)'
'.1
'*-4
7
FIGURE 8-8A.STANDARD LIMIT SWITCH PARTS
34
PARTSLIST FOR LONG LIFT LIMITSWITCH
INDEX PART
PART NAME
NO.
NO.
I
9441G6 Long Lift Limit Switch
Assembly(all itemsexcepl
No. l9)
2 t29Jl
MountingPlate
a
J
2 5 5 K 1 6 Thrust Washer
4
PB-287 Spring
5
JF-75I -3R RedNut
6
1 - 3 GGreenNut
JF-75
7
I I 7 J G 2 Shaftand GearAssemblv
8
J F - 5 3 1 - 4 Bushing
9
258J8
End Plate
l0
INDEX
NO.
ll
l2
l3
t4
l5
l6
t'l
l8
19
20
2l
PART
PART NAME
NO.
H-2741-P Screw
8l5Jl
Switch
H-3944
Locknut
427J1
Drive Pinion
258JG7 Frame and Guide Assembly
H-1402-PScrew
854823 Screw
H-5520 Retaining Ring
H - 2 9 8 1 - PMounting Screw
H - 1 2 1 0 Flat Head Screw
I l 0 J1 4
Post
,t6
t-
+\r
z\l
M--..
i
'Dtv
-.i,
13
i ?/'$
.lo
-"
j
FIGURE 8-8B.LONG LIFT LIMIT SWITCH PARTS
35
Il
ii
di\ - l \
-4
7l\
!
tr/
llf'x /
)o
7
(32&lHPMODELS)
13
(Vt &Vz HP MODELS)
FIGURE 8-9.MOTOR BRAKE PARTS
36
MOTORBRAKE PARTSLIST
INDEX USAGE PART
PART NAME
NO. CODE
NO.
A
854JG6 Disc BrakeAssembly
(Ve
&thHP,
Il5/230 V Hoists)
A
8 5 4 J G l Disc BrakeAssembly
( 3 / e & lH P , l l 5 1 2 3 0 V
Hoists)
B
( t h& t h H P ,
230/460V Hoists)
B
(3/e
& | HP, 230/460V
Hoists)
C
(Vq& VtHP. 230 V
Hoists)
C
854JG2 DiscBrakeAssembly
(3/e
& | HP, 230V
Hoists)
c 854JG8 Disc BrakeAssembly
INDEX USAGE PART
NO. CODE
NO.
4
859JG
l
5
6
7
8
9
l0
(t/q& t/z HP, 460 V
Hoists)
C
B,C
B,C
o
B,C
B,C
2
J
J
854JG3 Disc Brake Assembly
(3/c& | HP. 460 V
Hoists)
(th & VzHP, 575 V
Hoists)
(3/4& I HP. 575 V
Hoists)
854JGl 0 Disc Brake Assembly
(t/n& VzHP, 208 V
Hoists)
(3/e& | HP, 208 V
Hoists)
8 5 7 J G l Plate and Frame
858JG
l
Assembly
Plate and Armature
Assembly
ll
t2
13
t4
l5
r6
t1
l8
t9
PART NAME
Plateand Stud
Assembly
29tJl
BrakePlate
JF-344 Spring
5 8 l J l A BrakeDisc
JF-7l0
Retainer
H-3978 LockingNut
A
JF-853l Coil (l l5 V, 60 Hz,
For Brake854JG6,
8s4JGl)
B&C JF-853-2 Coil (230V, 60 Hz,
For Brake854JG7,
854JG2)
C
JF-853-3 Coil (460V, 60 Hz,
For Brake854JG8,
854JG3)
B&C JF-853-4 Coil (575V, 60 Hz,
For Brake854JG9,
854JG4)
B&C JF-853-5 Coil (208V, 60 Hz,
For Brake854JG10.
854JGs)
t4tJ2
Spacer(Va& VzHP
modelsonly)
H-2982-P Screw
t42Jl
BrakeAdapter
H - 5 5 0 1 RetainingRing
34JGI
Transmission
Cover
(Ref.#5, Figure8-l)
JF-860 ShadingCoil Element
(Must be attachedto
framewith H-7812
Adhesive)
(l Oz.
H-78r2 Adhesive
Tube)
616J1
Decal,Load Equalizer
H-4t34
Lock Washer
,#
.--w
fi
\-j
"L
FIGURE 8-IOA.PUSHBUTTON
(SINGLE SPEEDHOISTS)
38
\
I
U
PARTS IST FOR PI SHBUTTON (S'N
INDEX PART
PART NAME
NO.
NO.
T
I
2
J
4
5
6
PART NAME
Pushbutton & Cable
Assembly(Consistsof
Index Nos. 2 thru 25)
PB-299-68 6 ft. cable length
P B - 2 9 9 -llB I I ft. cable length
PB-299-l6B l6 ft. cablelength
PBS-299*-BSpecialDrop (*Equal to
P.B. Drop)
JF-761
9
l0
ll
t2
l3
t4
l5
l6
tl
l8
l9
20
2l
22
23
24
25
Rubber Grommet
Pushbutton Cable
Assembly:
PB-299-ll
I I ft. cable length
PB-299-16 l6 ft. cablelength
PBS-299*- SpecialDrop (*Equal to
P.B. Drop)
534K978
PB-282-4
PB-298
PushbuttonAssembly
(Consistsof Index Nos.
5 thru 25)
Enclosure
Cover
o
J
39
PB-284-2
PB-285
PB-286
PB-287
PB-288
PB-289
PB-290
PB-291
PB-301
PB-293
PB-294-I
PB-295
x-6477-l
H-7851
H-2991
H-2992
H-2993
PB-296
H-4160
Pushbutton
Interlock (Single speed,Red)
Boot
Spring, Compression
Spring, Conical
Contact Plate
Contact Plate, Common
Washer,Contact
Screw
Washer, Boot
Grommet
Cap, Enclosure
"O" Ring
Rubber Seal
Screw
Screw
Screw
Warning Tag
Lock Washer
tb
?
.h,r(
\
FIGURE 8-IOB.PUSHBUTTON (TWO SPEED HOIST).
40
Hoists)
PARTS ST FOR PUSHBUTTON
INDEX
NO.
I
2
3
4
5
6
l
8
PART
NO.
INDEX
PART
NO.
NO.
9
PB-286
PB-287
l0
ll
PB-288
t2
PB-289
l3
PB-290
l4
PB-29r
H -1 8 5 2 - P
l5
PB-293
t6
t7
PB-294-l
PB-29-5
l8
l9
x-6471-l
20 H - 7 8 5 1
zl
H-2925
H-2992
22
H-2993
23
24
PB-296
25 H-4160
26 PB-308
2 1 7 5 5 Jl
2 8 344J5
29 2 0 r Jl
30 200Jr 6
IF-940-42
3l
PART NAME
Pushbutton& Cable
Assembly(Consistsof
Index Nos. 2 thru 30)
534JG4-6 6 ft. cable length
l I I ft. cable length
534JG4-l
5 3 4 J G 4 - 1 6l6 ft. cablelength
534JG4-* SpecialDrop (*Equalto
P.B.Drop)
JF-76I
Rubber Grommet
PushbuttonCable
Assembly:
PB-300-l
l I I ft. cable length
PB-300r 6 l6 ft. cablelength
PBS-300-* SpecialDrop (*Equalto
P.B.Drop)
534JG4
PushbuttonAssembly
(Consistsof Index Nos.
5 thru 3l )
PB-282-4 Enclosure
PB-29tt
C'over
PB-284-22Pushbutton
PB-2tt5I
Interlock (Two-speed.Black)
;4'
41
PART NAME
Boot
Spring, Compression
Spring,Conical
Contact Plate
Contact Plate,Common
Washer,Contact
Screw
Washer,Boot
Grommet
Cap, Enclosure
"O" Ring
Rubber Seal
Screw(Enclosure)
Screw(Cap)
Screw(Plates)
Warning Tag
Lock Washer
2-SpeedAdapter
InsulatingBushing
Spring. Lower
Contact Button
Bushing
JumperWire
CHAINCONTAINERPARTSLIST
INDEX PART
PART NAME
NO.
NO.
I
9 2 7 J G t 1Chain Container Kit (20 feet
INDEX PART
NO.
NO.
2
927Jt7
927Jt8
927J19
927120
J
26tJ3
^
.+
53J4
H-7929
5
6
H-2349
chain max.)
921JGt8Chain ContainerKit (25 feet
chain max.)
9 2 t I G t 9 Chain ContainerKit (35 feet
chain max.)
927JG20Chain ContainerKit (50 feet
chain max.)
, ---___-
1!
'Xi',!l
-
il \q\
\| i
I
PART NAME
Container(20 feet chain max.)
Mounting Arm
Chain Section
Split Link
Screw
\--\-
':r-'l
"
I
,;. 1.
I
lr
FIGURE 8-TI.CHAIN CONTAINER PARTS
42
h
SECTIONIX
DO'S AND DO NOT'S
Electricand Air PoweredHoists
18. DO apply lubricantto the wire rope or load chain
as recommendedby the hoist manufacturer.
rhe following warnings and operating practices have
\.
u6ssn
taken from American National (Safety)Standard
ANSI 830.16and are intendedto avoid unsafehoisting
practiceswhich might leadto personalinjury or property
damage.
Theserecommendationsapply to all electncand air
poweredhoistsfor vertical lifting serviceinvolving material handlingof freelysuspendedunguidedloads.
19. DO NOT lift more than rated load.
20. DO NOT use the hoist load limitine device to
measurethe load.
21. DO NOT use damagedhoist or hoist that is not
working correctly.
22. DO NOT usethe hoist with twisted,kinked, damagedor worn wire rope or chain.
WARNING: TO AVOID INJURY
23. DO NOT lift a load unlesswire rope is properly
seatedin its groove(s)or unless chain is properly
seatedin chain wheel(s)or sprocket(s).
I . DO readANSI B30.l6 SafetyStandardfor Overhead
Hoists and Hoist Manufacturer'sOperating and
MaintenanceInstructions.
24. DO NOT use load rope or load chain as a sling or
wrap rope or chain around the load.
2. DO be familiar with hoist operatingcontrols,procedurcs and warnings.
25. DO NOT lift a load if any binding preventsequal
loadingon all supportingropesor chains.
3. DO make sure hook travel is in the samedirection
as shown on controls.
26. DO NOT apply the load to the tip of the hook.
4. DO make sure hoist limit switches function
properly.
21. DO NOT operate unless load is centeredunder
hoist.
5. DO maintain firm footing when operatinghoist.
28. DO NOT allow your attention to be diverted from
operatingthe hoist.
6. DO make sure that load slingsor other approved
sling attachmentsare properly sizedand seatedin
the hook saddle.
29. DO NOT operatethe hoist beyond limits of load
rope or load chain travel.
7. DO makesurethat the hook latch,if used,is closed
and not supportingany part ofthe load.
30. DO NOT use limit switchesas routine operating
stops unless recommended.They are emergency
devicesonly.
8. DO make sure that load is free to move and will
clearall obstructions.
31. DO NOT use hoist to lift, support or transport
people.
9. DO take up slackcarefully,checkload balance,lift
a few inchesand check load holding action before
contlnulng.
32. DO NOT lift loadsover people.
33. DO NOT leavea suspendedload unattendedunless
specificprecautionshave been taken.
10. DO avoid swingingof load or load hook.
I l. DO make sure that all personsstay clear of the
suspendedload.
34. DO NOT allow sharp contact between two hoists
or betweenhoist and obstructions.
12. DO warn personnelof an approachingload.
35. DO NOT allow the rope, chain or hook to be used
as a ground for welding.
13. DO protect wire rope and load chain from weld
spatteror other damagingcontaminants.
36. DO NOT allow the rope,chain or hook to be touched
by a live welding electrode.
14. DO promptly report any malfunction,unusualperformance,or damageof the hoist.
37. DO NOT remove or obscurethe warningson the
hoist.
I 5. DO inspecthoist regularly,replacedamagedor worn
parts, and keep appropriate records of maintenance.
38. DO NOT adjust or repair a hoist unlessqualified
to perform hoist maintenance.
16. DO use the hoist manufacturer'srecommended
parts when repairinga hoist.
39. DO NOT attemptto lengthenthe load ropeorchain
or repair damagedload rope or chain.
17. DO use hook latcheswhereverpossible.
43
I
DUFF.NORTON
HAS ALL YOUNEEDTO
HANDLEA VARIETYOF TOUGHINDUSTRIAL,
MAINTENANCE
AND CONSTRUCTION t'
LIFTINGJOBS.
is America'sfirstnamein quality,
Coffing(-'
industrialhoistingequipment.Nowhereelsecan you
find sucha broadrangeof hoistswith suchconsistent
high-quality
construction
and durability.
A detarled
CoffingroElectric Chain
Hoists
Load ratingsfrom % to 5
lons. More standard
featuresthan any
comparablehoist-Twospeed optionsavailable;47
modelsto choose.
Colf ing''r Electric Wire
Rope Hoists.
Lowheadroomunitswith
load ratingsfrom % to 3
tons.Choiceof rigidhookor
plusplain.
lug suspensions,
gearedor motorizedtrolleys
Singleor two speedoptions
and varietyof standard[fts.
35 models.
productcatalogis availablefrom your localCoffing
hoistdistributor,Duff-NortonDistrictSalesManaqer,
or by writingdirectlyto Duff-Norton.
Ask for
Catalog201,it includes:
Coffing'' Hand Chain
Hoists.
Designedfor lightweight
a n d l o n gl i f ew i t hm i n i m u m
mainlenance.
Ootronal
capacitylimiteravailablein
somemodels.99 modelsin
ratedfoadstrom:/z lo 25
tons.
Coffingr"'Lever Hoists.
A varietyof mechanisms
and rated loads from % to
15tons;in 36 modelslor
bothconventional
and
specialpurpose
applicalions.
The hoistingequipmentdescribedin this manualis intendedfor industrialuse only
WARNING:
and should noi be used to lift, support, or otherwise transport people,or lift loads over people.
AVAILABLE
FROMYOURLOCAL
DUFFNORTON
COFFING@/DUFF
LYNX@
HOISTDISTRIBUTOR:
Duff-Nonton
P . O .B o x 7 0 1 0
Charlotte,
NC 28241-7010
CustomerService(800)477-5003
PartsService(800) 477-5004
FAX (704)588-8466
Duff-NortonManufactures:
Duff-NortonActuatorsi!'. MechanicalJacks . RotaryUnions . Coffing'ur
Hoists . Duff Lynxo Hoists
Yale.oHoists,Shop King Hoists . LittleMulec'Productsand AmericanLifts
EC 680-4
Printedln USA
500 10/93

EC Series, 680-4 - Coffing Hoists, Coffing Hoist Parts

Transcription

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