ELCMT Series, JLMT 680-1 - Coffing Hoists, Coffing Hoist Parts

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853Figure 1 - Specifications and Dimensions*NOTE: Headroom, dimension A, is basedon S6 x 12.5 beam.Table 1 — Hoist SpecificationsCapacity Lifting Dimensions Dimension “E”**Capacity Speed Hoist 1-Speed 2-SpeedModel (lbs) (fpm) HP** A B C D 1-Phase 3-Phase 3-PhaseELCMT0232 250 32 ¼ 19¼ 4 1 1 1 /16 9 1 /8 8 1 /8 10 1 /8ELCMT0516 500 16 ¼ 19¼ 4 1 1 1 /16 9 1 /8 8 1 /8 10 1 /8ELCMT0532 500 32 ½ 19¼ 4 1 1 1 /16 9 1 /8 8 1 /8 10 5 /8ELCMT1016 1000 16 ½ 19¼ 4 1 1 1 /16 9 1 /8 8 1 /8 10 5 /8ELCMT1032 1000 32 1 19¼ 4 1 1 1 /16 10 1 /8 8 5 /8 11 1 /8ELCMT2016 2000 16 1 19¼ 4 1 1 1 /16 10 1 /8 8 5 /8 11 1 /8ELCMT4008 4000 8 1 23 3 1 /8 1 1 /8 1 1 /4 10 1 /8 8 5 /8 11 1 /8Table 2 — Motorized Trolley SpecificationsDimension “F”**1-Speed2-SpeedModel Trolley HP** 1-Phase 3-Phase 3-PhaseAll Models (except below) 1/4 10 3 /8 9 3 /8 11 3 /8ELCMT4008 with 100or 150 fpm Trolley1/2 10 3 /8 9 3 /8 11 7 /8Standard Trolley Speed: 35 fpm; Optional Speeds: 18, 24, 50, 75, 100 or 150 fpm (The slow speed for 2-speed trolleys is 1/3 of thetop speed; i.e., 75 fpm trolley has a slow speed of 25 fpm).Beam Width Adjustment Range: 3.33 to 6 inches standard, up to 9 inches optional (As an option, trolleys are also available to workwith patented track).**Note: Hoist and trolley horsepower can vary from what is listed, which can also affect dimensions “E” and “F”. Refer to the motornameplates on the hoist and trolley for specific information on the supplied motors.4

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853SAFETY INFORMATIONFor safe use of the electric chain hoist and motorized trolley,adherence to the following precautions is imperative. Allpersons concerned with the installation, operation, inspectionand maintenance of the hoist and trolley are urged to read theAmerican Society of Mechanical Engineers (ASME) SafetyCode B30.16, “Overhead Hoists (Underhung).”1. Follow all local electrical and safety codes, as well as theNational Electrical Code (NEC) and the OccupationalSafety and Health Act (OSHA) in the United States.2. Before installing the hoist and trolley unit, be sure that thebeam and the supporting structure have adequate strengthfor the capacity of the hoist. If in doubt, consult a qualifiedstructural engineer.3. Open-ended beams must have end stops to prevent thetrolley from running off the beam. In the event of a collision,the stops should only contact the side plate bumpers.4. The hoist and trolley must be adequately grounded. Thepower and ground connections are made at the trolleymotor junction box (green wire is ground), or if supplied, thetrolley control box.5. Make certain that the power source conforms to therequirements of your equipment.6. Three-phase power connections must be made such thatthe hoist runs in the correct direction when pushing the“UP” or “DOWN” buttons (See ELECTRICALCONNECTIONS, page 6).7. Power must be supplied to the unit in a manner that willensure that power cables, if used, do not develop kinks orcome in harms way. Do not allow cables to come in contactwith oil, grease, hot surfaces or chemicals.8. The hoist and trolley are designed for vertical lifting only.Loads should be located directly under the hoist. Sideloading can damage the unit as well as endanger lifeand limb.9. Do not lift loads in excess of the rated capacity.10. Do not use the hoist and trolley to lift and transport peopleor to move loads over people. Stand clear when lifting aload and be sure that all personnel are clear and awarebefore moving a load in their area.11. The operator should have a clear view of the load anytimeit is moving and should be sure that the load does notcontact any obstructions. Never leave a suspended loadunattended.12. Always allow the trolley to coast to a stop in the direction oftravel before reversing its direction. Reversing or “plugging”to stop the trolley causes overheating of the trolley motorand causes the load to sway.13. Inspect the unit daily before operating the hoist.14. Cluttered areas and benches invite accidents.15. The operator should not engage in any practice which willdivert his attention while operating the hoist.16. Do not attempt to operate hoist beyond normal maximumlift range.17. Do not operate hoist with twisted or damaged chain.18. Do not operate a damaged or malfunctioning hoist untilnecessary adjustments or repairs have been made.19. Always remove load before making repairs.20. Do not remove or obscure capacity or warning decals.Always disconnect power source before working onor near a hoist or its connected load. If the powerdisconnect point is out of sight, lock it in the openposition and tag to prevent unexpected applicationof power.INSTALLATION1. Before installing the hoist and trolley, review and adhere tothe following precautions.a. Be sure that the beam and the supporting structure haveadequate strength for the capacity of the hoist. If in doubt,consult a qualified structural engineer.b. Provide proper branch circuit protection for the hoist asrecommended in the National Electrical Code.c. The power supply voltage should be within plus or minus10% of the voltage for which the unit is wired. Refer to thehoist and trolley motor nameplates for information onthe full load amperage. It is critical to use adequatesized power cables, especially with 1-phase hoists (SeeTable 4, page 14). Be sure dual voltage hoists areconnected or wired to correspond with your power supply(See ELECTRICAL CONNECTIONS, page 6).d. The installation area must provide operating conditions forthe operator including sufficient room for the operator andother personnel to stand clear of the load at all times.e. For installations where the slack chain hanging from theunit may be objectionable or hazardous, the use of achain container is recommended. See CHAINCONTAINER, pages 6 & 7.INITIAL LUBRICATIONLubricate the trolley wheel gears with NLGI-2 or heaviergrease. Hoists are shipped with the load chain prelubricated.If necessary, apply SAE 90 gear oil.TROLLEY MOUNTING TO BEAMRefer to Figure 11.1. Coffing ELCMT models are designed to fit beam flangewidths in the range of 3.00 to 6" as a standard. Wider beamsup to 9" and patented track beams can be fit with optionalload pins and/or wheels. Be sure that the flange width of therunway beam is within the adjustment range.The unit is shipped assembled with the trolley set for aflange width of 3.33" unless otherwise specified whenordering. If adjustment is required, place the hoist and trolleyunit onto a worktable and follow the steps below. Be surethat power is not connected to the unit.a. Adjusting to a particular beam size is accomplished bylocating the thick (.135”) and thin (.075”) washers asshown (See Figure 11, page 16). Begin by removing theload pin nuts on the plain side of the trolley (1 1 /16" wrench5

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853or socket required). If necessary a pry bar can be usedbetween the load pins to prevent the pins from turningwith the nuts. Slide the washers off the load pins, keepingthe washers for each load pin stacked separately. Slidethe side plate off of the load pins. Remove the remainingwashers on the plain side of the trolley and stack themseparately for each load pin.b. Carefully pull the trolley transmission with the attachedside plate assembly away from the suspension lug. Becareful not to pull on the tie cable. Remove the exposedwashers on the two load pins and stack them separatelyfor each load pin. Lay the assembly upside down to wherethe load pin nuts can be accessed. Remove the twoelastic stop nuts with a 1 1 /16" wrench and a vise grip to holdthe pins.c. From Figure 11 determine how many spacer washers ofeach thickness are required on the outside of the side plates(Locations B) and on the inside of the side plates (LocationsA) for each load pin. The chart is an approximate guide.Flange widths will vary, so it is important to measure thebeam flange to be sure of its width. Slight changes to therecommended washer distribution may be required. Whenthe trolley is set correctly, the distance between the wheelflanges will exceed the beam flange width by 1/4" to 7/16"(See Figure 11).d. Reassemble with the correct placement of spacerwashers. Be sure to put the load pins, washers and nutson the transmission side plate first. At this point, do nottighten the load pin nuts on the plain side plate. Be surethat all four “Locations A” have an equal number of thickand thin washers (See Figure 11). Once together, thewidth adjustment must be double-checked beforetightening the nuts completely in the following steps.2. For mounting to a beam that is not open ended, leave offthe outside washers on the plain side plate and turn the twonuts onto the load pins just enough to prevent the side platefrom falling off. Slide the plain side plate out enough to allowthe wheels to clear the beam flange. Carefully position thehoist and trolley unit to where the wheels are over the flangeand pull the side plates together. Ensure that the plates donot separate as you remove the load pin nuts on the plainside plate, replace the outside spacer washers, and reinstallthe nuts. Tighten the load pin nuts to 100 ft-lbs. A pry barmay be used between the load pins to prevent them fromturning as the nuts are tightened.3. For mounting to an open-ended beam with rail stops,first tighten the load pin nuts to 100 ft-lbs. If necessary, use apry bar between the load pins to prevent the pins fromrotating as the nuts are tightened. With the rail stop removedat the end of the beam, position the hoist and trolley so thatthe trolley can slide onto the beam. Reinstall the rail stop onthe end of the beam.ELECTRICAL CONNECTIONSRefer to Figures 11 & 12A-12F.1. Disconnect and lock out power before making connections.2. Ensure that the hoist and trolley are built and wired for theintended voltage. Single-phase units have dual-voltagemotors and components designed for use on 115V or 230Vwhen wired correctly. Similarly, 1-speed hoist/1-speed trolleyunits made for 230/460V must be wired for intended voltage.Refer to the wiring diagram that is supplied with the unit.Figures 12A - 12F are diagrams for standard units.3. Single-phase units (115/230V) are shipped wired for 115Vunless otherwise specified. Dual voltage 230/460V units arewired for 460V as a standard. Units that have a 2-speedhoist and/or 2-speed trolley are for one voltage only, as canbe found on the nameplate of the 2-speed motor. Makevoltage conversions on 115/230V or 230/460V models asfollows:a. Remove the electrical cover on the hoist. Rewire per the“Motor and Brake Connections” on the wiring diagram.b. Connect the transformer lead, “H2” or “H4”, to the trolleycontactor according to the voltage. Be sure to insulate theterminal on the spare transformer lead.c. Access the trolley motor connections by removing thesplice plate (See Figure 11). Disconnect the existingsplice connections and rewire per the splice connectionchart on the wiring diagram.4. The power connection is made at the trolley motor junctionbox, or, if provided, a trolley control box. If connecting to thejunction box, remove and discard the plug to allow the powercord to enter, and remove the splice plate to make the powerconnections. Be sure to make the ground connection.5. Turn on the power. On 3-phase models, push the “UP”button and observe the direction of travel of the load block. Ifit raises, the phasing is correct and permanent connectionsmay be made at the power source. If the load block lowerswhen the “UP” button is pushed, release the buttonimmediately since the limit switches will not operate toprotect the hoist from over-travel. Reverse any two wires(except the green ground wire) at the power source tocorrect the load hook direction (phasing). Do not changeconnections in the hoist or pushbutton assembly.6. Before placing the hoist into operation, check the limit switchadjustment. See LIMIT SWITCH ADJUSTMENT, page 10.CHAIN CONTAINER (Optional Accessary)Refer to Table 3.For installations where the slack chain hanging from the hoistmay be objectionable or hazardous, the use of a chaincontainer is recommended.Always disconnect power source before working onor near a hoist or its connected load. If the powerdisconnect point is out of sight, lock it in the openposition and tag to prevent unexpected applicationof power.Do not attempt to store more chain in chaincontainer than that specified in the table below orserious damage to hoist may result and hazardousconditions may be created.6

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853Available chain containers include the standard metalcontainers designed for lifts of up to 50 ft on single-chainedhoists and 25 ft on double-chained hoists. For longer lifts, theJL927-5 metal container is available. For applications where afabric bag is preferred, the JL927-20F, JL927-40F and theJL927-70F are all options.Installation of Standard Metal ChainContainers (JL927-1, JL927-3 and JL927-4)Refer to Figure 2.1. Remove dead end screw and washers and let chain hang free.2. Place chain container bracket flush against housing.Replace washers and screw. Tighten securely.OPERATIONOVERLOAD LIMITING PROTECTIONThis hoist is equipped with a factory-calibrated overloadlimiting clutch that will permit the lifting of loads within its ratedcapacity, but will prevent the lifting of damaging overloads whilethe hoist is being operated. If the load being lifted exceeds thelifting capability of the overload clutch, the hoist motor willcontinue to run, causing overheating of both the clutch andhoist motor. This condition should be avoided by immediatelyreleasing the “UP” button and reducing the load to within therated capacity of the hoist. See GEARING, page 12, foradditional instructions on this device.Dead-end ScrewFigure 2 — Installing Chain Container Assembly3. Attach chain container to bracket with two open links andthen close the links.4. Run load hook down to its lowest position. Place the slackend of chain in chain container. Feed the remainder of chaininto container by operating hoist in the “UP” direction to thetop limit. This will allow the chain to pile freely withoutkinking, which occurs when you place the chain in thecontainer by hand.Do not allow load to come in contact with the chaincontainer. If this situation exists reset the “UP” limitswitch so that the hook block stops below the chaincontainer (See LIMIT SWITCH ADJUSTMENT, page 10).The overload limiting clutch is an emergencyprotective device and should not be used to measurethe maximum load to be lifted, or to sense theoverload imposed by a constrained load. While theoverload limiting clutch will protect the hoist fromdamaging overloads, it will not ensure that a load iswithin the rated capacity of the hoist.SAFE OPERATIONThis hoist and trolley unit is designed for safe operation within thelimits of its rated capacity. Using the control station, the operatorhas full control in one hand – positioning the hoist with the “LEFT”and “RIGHT” trolley buttons and lifting or lowering a load with the“UP” and “DOWN” hoist buttons. To ensure safe operation, thefollowing guidelines must be observed.1. Above all, always use common sense when operating thehoist and trolley. Refer to all of the safety guidelines listed inthe General Safety Information section of this manual andto ASME B30.16 Safety Code for Overhead Hoists.2. Use the “LEFT” and “RIGHT” buttons to position the unitover the load. The load should be directly under the hoistbefore attaching the load hook. The hoist and trolley aredesigned for vertical lifting only. Never lift a load that is offcenter with the hoist.Table 3 - Optional Chain ContainersChainRecommended for Use With:Container Hoist Maximum Container Dimensions in InchesModel Capacity Lift (ft) Material Width Length DepthJL927-1 1 Ton & Under 20 Steel (.036" thick) 3 6½ 11½2 Ton 10JL927-3 1 Ton & Under 35 Steel (.036" thick) 3 6½ 18½2 Ton 17JL927-4 1 Ton & Under 50 Steel (.036" thick) 3 6½ 272 Ton 25JL927-5 1 Ton & Under 143 Steel (.06" thick) 6 8 342 Ton 71JL927-20F 1 Ton & Under 20 Open Weave Vinyl 7½ 7½ 102 Ton 10 Coated PolyesterJL927-40F 1 Ton & Under 40 Open Weave Vinyl 7½ 7½ 162 Ton 20 Coated PolyesterJL927-70F 1 Ton & Under 70 Open Weave Vinyl 7½ 7½ 202 Ton 35 Coated Polyester7

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-68533. Before raising a load, always check to see that it is heldsecurely in the saddle of the hook. Never allow a load to beapplied at the tip of the hook. Raise the load only until theload chain is taut and then double check the rigging beforecontinuing to raise the load.4. Stand clear of the load at all times. Before moving the loadalong the runway beam, ensure that all personnel are clearof the runway path and are aware of your intentions.5. With the load suspended, push the “LEFT” or “RIGHT”button to move the load in the desired direction. Avoidletting the load swing excessively while moving the trolley.Always allow the trolley to coast to a stop before reversingits direction. Sudden reversal of the trolley motor causes itto overheat and the load will begin to sway.6. The operator should have a clear view of the load anytimeit is moving and should be sure that the load does notcontact any obstructions. Never leave a suspended loadunattended.7. Do not run the trolley into beam end stops or other trolleyson the beam.8. Never use the hoist and trolley to transport people or tomove loads over people.9. Do not overload the hoist.10. Do not make side pulls with the hoist.11. Do not “sling” the load hook and chain around the load. Usean approved sling.12. Be sure there are no twists in the load chain as it travels intothe hoist housing.This condition should be constantly checkedon double-chained hoists because it is possible for the loadblock to be “capsized” or turned over one or more times.13. Do not operate if direction of hook travel is not the same asindicated on button being pushed.14. Do not operate unless hook travel limit devices function.Test without load each shift.15. Do not operate if chain is not seated properly in sprocketsor sheave grooves.16. Do not operate a damaged or malfunctioning hoist or trolley.Do not use hoist to lift, support or otherwisetransport people.MAINTENANCEINSPECTIONSA planned inspection routine should be established for thishoist based upon frequency of use, severity of use, andenvironmental conditions (Reference ASME Standard B30.16).Some inspections should be made frequently (daily to monthly)and others periodically (monthly to yearly). It is stronglyrecommended that an Inspection and Maintenance Check Listand an Inspector’s Report, similar to those shown in Figures13A and 13B, be used and filed for reference. All inspectionsshould be performed or overseen by a designated inspector.Special inspections should be made following any significantrepairs or any operating occurrence leading one to suspectthat the hoist’s capability may have been impaired.LOWERING WITHOUT POWERIf the power fails with a load suspended, the hoist willautomatically stop. In an emergency the load can be loweredwithout power as follows:1. DISCONNECT HOIST FROM POWER SUPPLY ANDREMOVE ELECTRICAL COVER.Do not allow screw driver blades to touch rotatingfriction disc “C”.Do not allow the load to descend rapidly. This causesthe motor to race and serious damage may result.2. Refer to Figure 7. Open disc brake manually by using twoscrewdriver blades, one on each side of the brake at a pointclose to the brake spring posts. Apply pressure to theunderside of the armature plate (points “X”) to close thesolenoid and release the brake.3. Use several quick releases instead of holding brake opencontinuously. Do not exceed normal lowering speed.HOOKSRefer to Figure 3.1. Inspect the load hook once daily for cracking, extreme wear orspreading. Replace the hook if it is showing any of thesesigns. If the throat opening is spread wider than the maximumpermissible 15% increase listed here, the hook has beenoverstressed and must be replaced. Any hook that is bent ortwisted more than 10 degrees from the plane of an unbenthook must also be replaced. Material wear in the saddle of thehook should not exceed 10% of the original thickness.2. Inspect to see that the hook latch performs the function ofclosing off the hook throat opening in a secure manner whena load is attached. Also, inspect the hook’s threadedconnections for stripping or other damage. The retaining pinshould be intact.3. Load hooks should be inspected for cracks by the magneticparticle, dye penetrant or other suitable crack testinginspection method. This should be done at least once a year.“T” Dimension “X” Dimension*Hoist Minimum BottomCapacity Thickness Hook1 Ton & Under 31/32" 1 7 /32"2 Ton 1 5 /32" 1 11 /32"(*) Maximum permissible throat opening of hook.Figure 3 — HookInspection8

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853CHAINChain is to be kept clean and lubricated (See LUBRICATION,page 11). Visually check chain every time hoist is used. Hoistmust not be operated when chain is twisted or kinked. Animportant part of hoist maintenance is chain inspection. Checkindividual links and check for chain elongation.1. Check the chain for overall wear or stretch by selecting anunworn, unstretched length of chain (at the slack end forexample). Let the chain hang vertically with a light load(about 20 pounds) on the chain to pull it taut. Use a largecaliper to measure the outside length of a convenientnumber of links (about 12 inches). Measure the samenumber of links in a used section of chain and calculate thepercentage increase in length of the worn chain.The chain used on this hoist has very carefullycontrolled dimensions and has been heat treated. Donot attempt to substitute other manufacturer’s chain.2. If the length of the worn chain is more than 1½% longerthan the unused chain (0.015" per inch of chain measured),then the chain should be replaced. If the chain is worn lessthan 1½%, check it at several more places along its length.If any section is worn more than 1½%, the chain should bereplaced.CHAIN REPLACEMENT WITH CHAIN INHOISTRefer to Figure 4 & 5.1. Run hook up to its top limit.2. DISCONNECT HOIST FROM POWER SUPPLY andremove the electrical cover.Always disconnect power source before working onor near a hoist or its connected load. If the powerdisconnect point is out of sight, lock it in the openposition and tag to prevent unexpected applicationof power.3. Using a screwdriver, pry the spring guide plate out of theslots in the limit switch nuts (See Figure 4). Turn the goldnut back to about the center of the threaded screw. Do notdisconnect the wires from the limit switches.Gold Nut(Up)Silver Nut(Down)Figure 4 — Limit Switch Adjustmentfor Chain ReplacementSpring GuidePlateLoad EndDead-EndScrewChainSupportSlack EndSingle-chainedHoistDouble-chainedHoistFigure 5 — Chain Replacement DiagramNote lugposition4. Remove the load block assembly from the old chain. Ondouble-chained hoists detach the chain from the chainsupport and pull it through the load block assembly.5. Make a “C” shaped chain link by grinding through the endlink on the load end of the old chain.6. Using the “C” link, attach the new chain to the load end ofthe old chain. Be sure that the welds of the upstanding linksof the new chain will face outward from the load sheave.The end links must be oriented for attachment to the deadendscrew and the chain support (double-chained only)without any twist in the chain.7. With the electrical cover off, connect the hoist to the powersupply. Be sure that the green ground wire is properlygrounded, (See ELECTRICAL CONNECTIONS, page 6).8. Carefully jog the “UP” button and run the joined pieces ofchain into the hoist until about 15" of the new chain comesout the other side.9. DISCONNECT HOIST FROM POWER SUPPLY.10. Remove the “C” link and the old chain. Remove the chainstop from the old chain by prying off its retaining ring with aflathead screwdriver. If attached, remove the old chain fromthe side of the hoist by removing the dead-end screw andwashers (note placement of washers).11. Attach the chain stop to the slack end of the new chain bycapturing the 12th link with the two stop halves positionedwith their tapered ends pointing towards the hoist. Slide thesleeve over the halves and attach the retaining ring. If youare not using a chain container, attach the slack end of thenew chain to the side of the hoist using the dead-end screwand washers. With factory supplied hardware there shouldbe six washers between the hoist and chain link and twowashers between the chain link and screw head. DO NOTallow twists in the chain.12. Adjust the lower limit switch (See ADJUSTING LOWERLIMIT, page 10).13. Attach the bottom block on single-chained hoists using anew load block pin (See Figure 28). On double-chainedhoists, feed the chain through the load block (welds of theupstanding links will be in towards the sheave) and fastenthe end of the chain to the chain support using a new chainsupport pin (See Figure 28). Be sure there are no twistsin the chain.14. Adjust the upper limit switch (See ADJUSTING UPPERLIMIT, page 10).9

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853CHAIN REPLACEMENT WITH NO CHAIN INHOISTRefer to Figures 5 and 6.1. DISCONNECT HOIST FROM POWER SUPPLY. Removethe hoist and trolley from the beam (follow reverse ofINSTALLATION, page 5). Do not remove the electrical cover.2. Remove the trolley from the suspension lug and lay thehoist on its side. Remove the four screws from the motorend of the hoist housing.3. Carefully pull the motor and housing assembly off thehoist. The two sections come apart where the chain entersthe hoist.1Figure 6 — Chain Replacement with No Chain in Hoist4. Turn the two hoist sections at right angles and remove thechain guide screws on the nearest chain guide (Ref. No. 1,Figure 6).5. Remove the two chain guide plate screws (Ref. No. 2) andthe nearest chain guide plate. Be careful not to lose the twospacers that are between the chain guide plates.NOTE: Inspect chain guides and load sheave for wear, replaceas needed.There are wires running through the hoist. Carefullyease the hoist sections apart. Do not jerk them apart.6. Lay the new chain over the load sheave. Allow about 15" ofchain below the hoist on the slack end (See Figure 5). Besure the welds of the upstanding links are out away fromthe load sheave and that proper orientation is observed forattachment of the dead end. Also be sure the load hookassembly (if already attached to the chain) is toward thecenter of the hoist or to your right as you face the loadsheave.7. Replace the chain guide plate and the chain guide. Greasethe splined shafts that project from both the housing andthe motor.8. Place the motor coupling on the splined shaft and carefullyfit the two hoist sections together. Be sure the dead-endnut, the suspension lug, and the support screw (doublechainedhoists only) are all in place. On single-chainedhoists, the lug goes in the center hole; on double-chainedhoists, it goes in the off-center hole (See Figure 5). Becareful not to pinch any of the wiring. Turn the hoist on itsside and replace the four screws and tighten securely.Reassemble the hoist and trolley.29. Follow steps 11 through 14 in the previous section, CHAINREPLACEMENT WITH CHAIN IN HOIST, to complete thechain replacement procedure. Reinstall the unit asdescribed in INSTALLATION, page 5.LIMIT SWITCH ADJUSTMENTIMPORTANT: Before placing hoist in operation, check the limitswitch adjustment. Limit switches are provided to protect thehoist against damage resulting from overtravel or to allow settingthe hook travel within the factory-set limits of travel. The standardlimit switch is designed for lifts of 50 ft or less on single-chainedhoists and 25 ft or less on the 2 ton, double-chained models. Thelong lift limit switch allows for the maximum amount of lift, whichis 134 ft on 1/2 ton and under models, 143 ft on the 1 tonmodels, and 71 ft on the 2 ton models.The upper and lower limit switch adjusting nuts are color-codedgold and silver respectively. Each limit nut has 10 slots for fineadjustment, and the increment of adjustment is such that oneslot is equivalent to approximately one link of chain travel withthe standard limit switch (about 3 links with the long lift limitswitch). Movement of the limit switch nuts toward or away fromeach other increases or decreases the hook travel respectively.ADJUSTING UPPER LIMIT (GOLD NUT)Refer to Figure 4.1. Suspend the hoist. For single chain models raise the loadblock until there is a minimum clearance of 2" from the hoisthousing and the top of the block. Double chain modelsrequire a minimum clearance of 1" from the chain support tothe top of the load block.2. DISCONNECT HOIST FROM POWER SUPPLY andremove the electrical cover.3. With a screwdriver, pry the spring guide plate out of the slotsin the limit switch nuts.4. Turn the slotted gold nut toward its limit switch until theswitch “clicks” then turn two slots farther. Release the springguide plate and be sure it slips back into the slots in bothlimit switch nuts. Do not disturb the silver slotted nut if it hasbeen set previously.ADJUSTING LOWER LIMIT (SILVER NUT)Refer to Figure 4.1. Suspend the hoist. Carefully lower the load block to a pointwhere the slack-end loop of the chain hangs down 6" ormore from the hoist housing (or the limit desired in anyparticular application allowing the minimum 6"). Thereshould be a minimum clearance of 1½" between the chainstop and the bottom of the hoist.2. DISCONNECT HOIST FROM POWER SUPPLY andremove the electrical cover.3. With a screwdriver, pry the spring guide plate out of the slotsin the limit switch nuts.4. Turn the slotted silver nut toward its limit switch until theswitch “clicks,” then turn two slots farther. Release the springguide plate and be sure it slips back in the slots in both limitswitch nuts. Do not disturb the gold slotted nut if it has beenset previously.10

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853CHECK BOTH UPPER AND LOWER LIMITS1. Connect the hoist to the power supply. Be sure the greenground wire is properly grounded (See ELECTRICALCONNECTIONS, page 6).2. Check load hook direction (See ELECTRICALCONNECTIONS 4, page 6).3. Carefully raise load block to upper limit and observe if itstops automatically at desired level. Do not allow load blockto run into hoist housing — this will damage the hoist.Maintain a minimum clearance of 2" from the hoist housingand the top of the load block on single-chained models and1" from the chain support to the top of the load block ondouble-chained models.4. Carefully lower load block to lower limit and observe if itstops automatically at the desired level. Do not allow slackchain, if attached to the dead-end screw, to become tautagainst hoist housing. This will damage the hoist. Thereshould be a minimum clearance of 1½" between the chainstop and the bottom of the hoist.5. If upper and lower limits operate satisfactorily, hoist is readyfor use. If they are not as desired, repeat adjustment.If the wires running to the limit switches are everdisconnected for any purpose, be sure to replacewires in accordance with the correct wiring diagram(See Figures 12A - 12F).HOIST BRAKEProperly adjusted, this brake will release promptly whenenergized. It is capable of both smoothly stopping and securelyholding the rated capacity of the hoist. If the hoist developseither undesirable over-travel after the pushbutton is released(this condition is most noticeable in the lowering direction) orhesitates to lift the load promptly when the pushbutton isdepressed (this condition is most noticeable in the hoistingdirection), the brake should be adjusted.BEGapAXDFigure 7 — Brake AssemblyFGXCAlways disconnect power source before working onor near a hoist or its connected load. If the powerdisconnect point is out of sight, lock it in the openposition and tag to prevent unexpected applicationof power.HBRAKE ADJUSTMENTRefer to Figure 7.1. DISCONNECT HOIST FROM POWER SUPPLY andremove the electrical cover.2. With reference to Figure 7, the gap between the brakearmature “A” and the field “B” should be checked. Thecorrect gap is 0.015". Adjustment should not be necessaryuntil gap reaches 0.040".Be sure the bottom of the armature does not bearagainst the splined adapter “H”. As adjustments aremade, the built-in clearance will be reduced. Whenthis clearance is gone REPLACE BRAKE DISCS.Minimum allowable disc thickness is .162".3. Adjust gap by adjusting the 3 locknuts “F” and checking witha feeler gauge to be sure gap is the same on both ends ofthe solenoid.4. Adjustment is now complete and the brake properly set.Replace the electrical cover, reconnect the power supply,and check hoist brake action.LUBRICATIONRefer to Figure 14.Proper lubrication is necessary for a long and relatively troublefreehoist operation. Refer to the following and Figure 14 forlubrication points, type of lubricant, and frequency oflubrication.Load ChainClean the load chain with acid-free solvent and coat with SAE90 gear oil. Wipe excess oil to prevent dripping. Never applygrease to the chain.GearingThe gear case of this hoist is filled at assembly withapproximately 1½ pints of SAE 90 EP gear oil. Check oil levelby removing the oil level check plug from the side of the hoist.With the hoist hanging level, gear oil should be even with thehole. Change oil periodically depending on the severity of theapplication and the environmental conditions (at least every200 hours of run time).BearingsAll bearings except hook and idler sheave bearings arelubricated at the factory and should not require additionallubrication. Noisy or worn bearings should be replaced.Limit Switch ShaftRemove any dirt accumulation and spray with a generalpurpose lubricant.Hook BearingApply a few drops of SAE 30 gear oil around the edge of thebearing.Idler Sheave Bearing (Bushing) - 2 Ton ModelsDisassemble load block and apply a light coat of NLGI #2grease, or equivalent, inside of bearing.11

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853HOIST REPAIRS1. For major repairs or when the hoist is to be sectioned in thesuspension area, it will be necessary to move the hoist to aworkbench or table.2. For repairs which can be done by removing the electricalcover only, the hoist need not be moved. Lowering the hoistto a convenient working level is desirable.NOTE: If you do not have an experienced mechanic/electricianto do your repair work, we recommend that you send your hoistto an approved service center for repairs. Use authorizedrepair parts only. The following repair instructions will help youin understanding repair procedures, when related to the RepairParts List starting on page 26. For clarity these are brokendown into areas.Terminal BlocksRemove byprying up feetReversingContactorEnd ClampApply pressure at baseand pivot contactor up toremove.Remove load and disconnect hoist from power supplybefore starting to do any repairs or to take anysections apart.ELECTRICAL PARTS AND BRAKE1. Refer to the correct wiring diagram for your hoist. Standardwiring for units without extra electrical options are shown inFigures 12A - 12F. In the case of standard units with a1-speed hoist and 1-speed trolley, all the controls arelocated inside the hoist cover. Any hoist/trolley combinationswith a two-speed motor require a control box on the trolley tohouse the trolley controls.The contactors, terminal blocks and end clamps aremounted on DIN rail (See Figure 9). Remove the blocks andclamps by prying their “feet” with a small screwdriver. DONOT SLIDE THE END CLAMPS. Reversing contactors canbe slid off the rail, but they are attached to the rail bysnapping. Where the contactor fits the rail, one side hassprings or pads that apply pressure against one edge of therail. By pressing against that side at the base of thecontactor, you can snap the part on or pull it off using arotating action (the contactor pivots about the other edge ofthe rail). Some components, such as a two-speed relay, mayattach using a spring loaded retaining clip at their base.When replacing contactors, orient them so that the numberingon the screw clamps corresponds with the wiring diagram.Reversing contactors consist of an “UP” contactor and a“DOWN” contactor. Note that single-phase contactors have asmall jumper joining the 3 and 5 screw clamps on the“DOWN” contactor (See Figure 12A). Always be sure that allthe clamps are tightened. Loose clamps will limit the powerflow to the hoist.Figure 9 - Hoist Electrical Panel2. Remove the electrical panel by removing the stand-offscrews (See Figures 19 & 20). The limit switch and brake arenow accessible as shown in Figure 8.3. Remove the transformer bolted to the back of the panel plateif it requires replacement.4. Refer to Figure 18 to disassemble the brake. See BRAKEADJUSTMENT on page 11 to properly set the brake.5. Refer to Figures 25 and 26 to disassemble the limit switch.See LIMIT SWITCH ADJUSTMENT on page 10 to properlyset the upper and lower limits of travel.6. Refer to Figures 22 - 24 for repairs on the pushbuttonstation. Also refer to the wiring diagram inside the electricalcover or Figures 12A - 12F, pages 18-21 for wiring instructions.HOIST MOTORRefer to Figures 15 - 17.The hoist motor is located on the opposite end to that of theelectrical parts, but the two are tied together with electricalleads running through the housing.1. If it is necessary to replace or repair the motor,DISCONNECT THE HOIST FROM THE POWER SUPPLYand remove the electrical cover.2. Loosen the screw clamps on the terminal blocks andreversing contactor to disconnect the motor leads(See Figures 19 and 20).3. Remove the four motor mounting bolts attaching the motorto the housing. It will come loose at the motor coupling.4. Inspect the motor coupling, motor shaft and all the bearings.Replace as necessary.5. Install new or repaired motor according to the wiring diagramlocated inside the electrical cover or Figures 12A - 12F.GEARINGRefer to Figures 15 and 27.Figure 8 - Electrical Panel RemovedDISCONNECT HOIST FROM POWER SUPPLY. Remove thehoist and trolley from the beam (follow reverse ofINSTALLATION, page 5). Disassemble the trolley from the hoist.1. Remove electrical cover.2. Remove electrical panel.3. Remove brake assembly and limit switch assembly.12

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853Do not disassemble or readjust the clutch, or replaceit with a clutch assembly from another hoist. Doing sowill void the warranty and may create an unsafecondition. If replacement is needed due to wear orloss of adjustment, always use a new clutch assembly.4. Drain oil from transmission.5. Remove four screws attaching gear box cover to gearhousing and remove gear box cover. Limit switch drive shaftwill come along with the cover.6. Inspect gears for broken or severely worn teeth and inspectall bearings. Replace as necessary. The overload slip clutchis factory calibrated and must not be disassembled orreadjusted.Figure 10 - Assembled Gearing7. Reassemble in reverse order of disassembly making suregasket is in place and in good condition. Coat gasket withPermatex ® or other gasket cement. Extreme care should betaken to avoid damage to oil seals.8. Check all wire terminals to be sure they are properly seatedand in accordance with wiring diagram. Check brakeadjustment and limit switch settings. Follow INSTALLATION,page 5 to reinstall the unit.SUSPENSIONRefer to Figures 15, 28 and 29.The sheave housing and the gear housing must be separatedto remove the lug suspension, chain guides and plates, andchain support (2-ton models); and to inspect the load sheave.1. DISCONNECT HOIST FROM POWER SUPPLY.Disassemble the trolley from the suspension lug.2. Lay the hoist on its side and remove the four screws holdingthe sheave and gear housings together. Refer to CHAINREPLACEMENT WITH NO CHAIN IN HOIST for moreinformation on working on this section of the hoist. Carefullypull the motor and sheave housing assembly from the hoist.Turn the two hoist sections at right angles. Be careful not todamage any motor leads, which run from the motor to theother side of the hoist.3. The lug assembly is easily removed once the housings arepulled apart. It should be inspected for any deficiencies inthe lug, lug nut or retaining pin. The load sheave, chainguides and plates, chain support (2-ton models) and bearingshould be inspected at this point. Replacement of the loadsheave requires disassembly of the gearbox (seeGEARING, page 12).4. Replace parts as necessary, including any associatedhardware. Refer to CHAIN REPLACEMENT WITH NOCHAIN IN HOIST, page 10 for reassembly. Whenreassembled, check that the travel limit switches are setcorrectly (see LIMIT SWITCH ADJUSTMENT, page 10).TROLLEY MAINTENANCENo routine maintenance of the trolley is required other thanwheel gear lubrication. The trolley should be inspected fordamage, loose parts, and excessive wheel wear at the sametime as the hoist inspections.Any deficiencies are to be corrected before the hoistand trolley is returned to service. Also, the externalconditions may show the need for disassembly topermit a more detailed inspection, which, in turn, mayrequire the use of nondestructive type testing.TROLLEY LUBRICATIONTROLLEY WHEEL GEARSLubricate the trolley wheel gears at the periodic inspectionswith an NLGI #2 or heavier grease.TROLLEY TRANSMISSIONPeriodic lubrication is not necessary. If the gearbox is openedfor repair, repack with an NLGI #1 grease.TROLLEY WHEEL BEARINGSTrolley wheel bearings are prelubricated and sealed. Bearingsmust be replaced if problems are indicated.OPTIONAL TROLLEY BRAKERefer to Figure 31.Units that are supplied with an optional trolley brake utilize atrolley transmission that allows the brake assembly to bemounted opposite the trolley motor. The brake must bemaintained similarly to the hoist brake (see HOIST BRAKE,page 11). The gap between the brake armature and the field isfactory set to 0.015". Do not allow the gap to exceed 0.040".TROLLEY INSPECTIONAt regularly scheduled hoist inspections, ensure that thefollowing conditions, as well as any other unsafe conditions, donot exist.1. Loose fasteners, such as the load pin and wheel nuts.2. Damaged electrical cables or wires.3. Loose or corroded terminals and other electricalconnections.4. Excessive wear of wheel tread and flange.5. Excessive wear of wheel gears and output pinion.6. Cracks, excessive wear or other damage that may decreasethe strength of the suspension lug.13

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853TROLLEY REPAIRSIf you do not have an experienced mechanic/electrician to doyour repair work, we recommend that you sendyour hoist to an approved service center for repairs. Useauthorized repair parts only. The following are instructions forminor repairs that may not require a service center.ELECTRICAL PARTSThe trolley motor controls include a reversing contactor, and, inthe case of 2-speed motors, a speed control relay. Thesecomponents are located under the hoist electrical cover or in aseparate trolley control box (See Figures 19 and 21). SeeELECTRICAL PARTS AND BRAKE, page 12, for moreinformation on replacing electrical parts.TROLLEY MOTOR1. If it is necessary to replace or repair the motor,DISCONNECT THE UNIT FROM THE POWER SUPPLY,and remove the splice plate on the trolley junction box.2. Disconnect the motor leads from the tie cable. Be sure thatall the wires retain their markings.3. Remove the four motor mounting bolts and pull the motoraway from the trolley transmission.4. Inspect the motor shaft and all the bearings, replace asnecessary.5. Install the new or repaired motor according to the wiringdiagram intended for your unit (See Figures 12A - 12F forstandard diagrams).TROLLEY WHEELSWorn wheels should be replaced with new assemblies.Remove the locknut from the wheel shaft and remove theassembly. Replace with a new assembly, which includes a newlocknut. Be sure to replace the washers and tighten nuts to 100ft-lbs.Remove load and disconnect hoist from power supplybefore starting to do any repairs or to take anysections apart.POWER CORD PRECAUTIONS WITH 1-PHASE HOISTSElectric hoists require a sufficient power supply. It is especially important with single-phase voltage to ensure that theconductors running to the hoist from the power source are adequate in size to handle the power requirements of the hoist.Inadequate power cables and branch circuits will cause low voltage, high amperage, damage to the hoist, and potential firehazards. Such problems can be minimized by using 230V power on 115/230V hoists. The following are recommendations for theconductor gage size depending on the length, horsepower, and voltage.Table 4 - Recommended Conductor Sizes for 1-Phase HoistsMaximum Length of Power Cord in FeetVoltageHP (1-Phase) 14 AWG 12 AWG 10 AWG 8 AWG1/4 115V 75 120 190 300230V 350 560 9001/2 115V 40 60 100 150230V 200 330 520 8101 115V 0 30 50 75230V 120 190 310 49014

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853Spacer Washer LocationFigure 11 — Spacer Washer LocationTable 5 — American Standard I-Beam (Tapered Flange)Standard Locations A Locations BBeam Flange H4209 H4210 H4209 H4210Size & Weight Width (Thick) (Thin) (Thick) (Thin)6" x 12.5# 3.332 9 4 11 16" x 17.3# 3.565 11 2 9 37" x 15.3# 3.662 12 1 8 47" x 20.0# 3.860 12 2 8 38" x 18.4# 4.001 12 3 8 28" x 23.0# 4.171 12 4 8 110" x 25.4# 4.661 14 4 6 110" x 35.0# 4.944 15 4 5 112" x 31.8# 5.000 15 4 5 112" x 35.0# 5.078 15 5 5 012" x 40.8# 5.252 16 4 4 112" x 50.0# 5.477 17 4 3 115" x 42.9# 5.501 17 4 3 115" x 50.0# 5.640 17 5 3 018" x 54.7# 6.001 19 4 1 116

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853Table 6 — Wide Flange Beam (Flat Flange)Wide Flange Locations A Locations BBeam Flange H4209 H4210 H4209 H4210Size & Weight Width (Thick) (Thin) (Thick) (Thin)4" x 13.0# 4.060 13 1 7 45" x 16.0# 5.000 16 2 4 35" x 19.0# 5.030 15 4 5 16" x 9.0# 3.940 12 2 8 36" x 12.0# 4.000 11 4 9 16" x 15.0# 5.990 18 5 2 06" x 16.0# 4.030 13 1 7 46" x 20.0# 6.020 18 5 2 06" x 25.0# 6.080 20 2 0 38" x 10.0# 3.940 12 2 8 38" x 13.0# 4.000 11 4 9 18" x 15.0# 4.015 13 1 7 48" x 18.0# 5.250 18 0 2 58" x 21.0# 5.270 17 2 3 310" x 12.0# 3.960 11 4 9 110" x 15.0# 4.000 11 4 9 110" x 17.0# 4.010 13 1 7 410" x 19.0# 4.020 13 1 7 410" x 22.0# 5.750 17 5 3 010" x 26.0# 5.770 20 0 0 510" x 30.0# 5.810 19 2 1 312" x 14.0# 3.970 11 4 9 112" x 16.0# 3.990 11 4 9 112" x 19.0# 4.005 13 1 7 412" x 22.0# 4.030 13 1 7 414" x 22.0# 5.000 16 2 4 314" x 26.0# 5.025 15 4 5 116" x 26.0# 5.500 19 0 1 516" x 31.0# 5.525 19 0 1 518" x 35.0# 6.000 18 5 2 018" x 40.0# 6.015 18 5 2 018" x 46.0# 6.060 20 2 0 517

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853WIRING DIAGRAMSThe following are standard wiring diagrams. Units that have special electrical features will have different diagrams. Specificdiagrams are included with each hoist. If necessary, note the model and serial number stamped into the sheave housing of thehoist and consult the factory for the correct diagram.Figure 12A — Wiring Diagram for 1-Speed, 115/230V - 1 Phase Models18

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853Figure 12B — Wiring Diagram for 1-Speed, 230/460V - 3 Phase - 60HZ Models19

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853Figure 12C — Wiring Diagram for 1-Speed Hoist, 1-Speed Trolley, 3 Phase Models* Factory supplied wiring diagrams will have numbers beginning with 985 for 575V, 987 for 208Vand 988 for 380V.Figure 12D — Wiring Diagram for 2-Speed Hoist, 1-Speed Trolley, 3 Phase Models* Factory supplied wiring diagrams will have numbers beginning with 983 for 230 or 460V, 985 for575V, 987 for 208V and 988 for 380V.20

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853Figure 12E — Wiring Diagram for 2-Speed Hoist, 2-Speed Trolley Models* Factory supplied wiring diagrams will have numbers beginning with 983 for 230 or 460V, 985 for575V, 987 for 208V and 988 for 380V.Figure 12F — Wiring Diagram for 1-Speed Hoist, 2-Speed Trolley Models* Factory supplied wiring diagrams will have numbers beginning with 983 for 230 or 460V, 985 for575V, 987 for 208V and 988 for 380V.21

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853HOIST TROUBLE SHOOTINGAlways disconnect unit from the power supply system beforeremoving hoist covers or the back cover of control station.Failure to follow proper lockout/tagout procedures maypresent the danger of electrical shock.TO AVOID INJURY:Disconnect power and lockout/tagout disconnectingmeans before removing cover or servicing thisequipment.––– Probable Cause ––– ––– Remedy–––Hook fails to stop at end of travel1. Limit switch not operating 1. Check adjustment (See LIMIT SWITCH ADJUSTMENT, page 10). Check connections against wiring diagram.Tighten loose connections or replace.2. Brass limit switch nuts not moving on shaft 2. Check for stripped threads or bent nut guide.3. Hoist reversing contactor malfunctioning 3. Remove electrical cover and check reversing contactor.Hoist does not respond to pushbutton1. Power failure in supply lines 1. Check circuit breakers, switches and connections in power supply lines.2. Wrong voltage or frequency 2. Check voltage and frequency of power supply against the rating on the nameplate of the motor.3. Improper connections in hoist or pushbutton 3. Check all connections at line connectors and on terminal block. Check terminal block on dual voltage hoists forstationproper voltage connections.4. Brake does not release 4. Check connections to the solenoid coil. Check for open or short circuit. Check for proper adjustment (See BRAKEADJUSTMENT, page 11).5. Faulty hoist reversing contactor 5. Check coils for open or short circuit. Check all connections in control circuit. Check for burned contacts.Replace as needed.Hook does not stop promptly1. Hoist overloaded 1. Reduce load to within rated capacity of hoist.2. Brake not holding 2. Check brake adjustment (See BRAKE ADJUSTMENT, page 11). It may be necessary to replace discs.Hook moves in wrong direction1. Three phase reversal 1. Reverse any two wires (except the ground wire) at the power source (See ELECTRICAL CONNECTIONS, page 6).2. Improper connections 2. Check all connections against wiring diagram.Hoist hesitates to lift when energized1. Hoist overloaded 1. Reduce load within rated capacity of hoist.2. Motor brake requires adjustment 2. Check motor brake adjustment (See BRAKE ADJUSTMENT, page 11).3. Worn overload limiting clutch 3. Replace clutch.4. Low voltage 4. Determine cause of low voltage and bring up to within plus or minus 10% of the voltage specified on the motor.Measure voltage at the hoist reversing contactor while lifting a load.5. Faulty SINPAC ® starting switch or start capacitor 5. Replace faulty component.(single phase hoists only)Hook raises but will not lower1. “DOWN” circuit open 1. Check circuit for loose connections. Check “DOWN” limit switch for malfunction.2. Broken conductor in pushbutton cable 2. Check each conductor in the cable. If one is broken, replace entire cable.3. Faulty hoist reversing contactor 3. Check coils for open or short circuit. Check all connections in control circuit. Check for burned contacts.Replace as needed.4. Loose screw clamps 4. Ensure that screw clamps are tightened on the terminal blocks and reversing contactor.Hook lowers but will not raise1. Hoist overloaded 1. Reduce load to within rated capacity of hoist.2. Low voltage 2. Determine cause of low voltage and bring up to within plus or minus 10% of the voltage specified on the motor.Measure voltage at the hoist reversing contactor while lifting a load.3. “UP” circuit open 3. Check circuit for loose connections. Check “UP” limit switch for malfunction.4. Broken conductor in pushbutton cable 4. Check each conductor in the cable. If one is broken, replace entire cable.5. Faulty hoist reversing contactor 5. Check coils for open or short circuit, check all connections in control circuit. Check for burned contacts.Replace as needed.6. Faulty capacitor (single phase hoist only) 6. Check starting capacitor on motor. Replace if necessary.7. Worn overload limiting clutch 7. Replace overload clutch assembly.8. Loose screw clamps 8. Ensure that screw clamps are tightened on the terminal blocks and reversing contactor.Motor overheats1. Excessive load 1. Reduce load to within rated capacity of hoist.2. Low voltage 2. Determine cause of low voltage and bring up to within plus or minus 10% of the voltage specified on the motor.Measure voltage at the hoist reversing contactor while lifting a load.3. Extreme external heating 3. As the ambient temperature rises towards the 130°F limitation of the unit, frequency of the hoist operation must belimited to avoid overheating of the motor. See ADVERSE ENVIRONMENTAL CONDITIONS, page 3.4. Frequent starting or reversing 4. Excessive inching, jogging or reversing should be avoided since this type of operation will drastically shorten the lifeof motor, contactor and brake.5. Brake dragging 5. Check brake adjustment (See BRAKE ADJUSTMENT, page 11).22

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853HOIST TROUBLE SHOOTING CONTINUEDAlways disconnect unit from the power supply system before removing hoist covers or the back cover of control station.––– Probable Cause ––– ––– Remedy–––Lack of proper lifting speed1. Hoist overloaded 1. Reduce load to within rated capacity of hoist.2. Brake dragging 2. Check for proper brake adjustment or other defects.3 Low voltage 3. Ensure that the voltage at the reversing contactor is within ±10% of the nominal voltage while lifting a load.4. Overload limiting clutch intermittently slipping 4. Replace overload clutch assembly.Motor brake noise or chatter (while starting hoist)1. Brake needs adjustment 1. See BRAKE ADJUSTMENT, page 11.2. Low voltage 2. Ensure that the voltage at the reversing contactor is within ±10% of the nominal voltage while lifting a load.Motor brake “buzz” (anytime hoist is running)1. Brake needs adjustment 1. See BRAKE ADJUSTMENT, page 11.2. Broken shading coil on brake frame 2. Replace shading coil or complete brake frame assembly.Trolley does not operate1. No voltage at trolley 1. Mainline or branch circuit switch open; branch line fuse blown or circuit breaker tipped. Close, replace orre-set. Check for grounded or open connections in supply lines or current collectors.2. Open control circuit 2. Open or shorted windings in transformer or reversing contactor; control station switch contacts not making contact;loose connection or broken wire circuit. Check continuity and repair or replace defective parts.3. Wrong voltage or frequency 3. Check voltage and frequency of power supply against the rating on the nameplate of the motor.4. Low voltage 4. Ensure that the voltage at the trolley contactor does not drop below 10% of the nominal voltage.5. Excessive load 5. Reduce load to within rated capacity of unit.6. Faulty SINPAC ® starting switch or start capacitor 6. Replace faulty component.(single phase trolleys only)Trolley operates in one direction only1. Open control circuit 1. Open or shorted windings in transformer or reversing contactor; control station switch contacts not making contact;loose connection or broken wire in circuit. Check continuity and repair or replace defective parts.Trolley operates sluggishly1. Excessive load 1. Reduce load to within rated capacity of hoist.2. Low voltage 2. Ensure that the voltage at the trolley contactor does not drop below 10% of the nominal voltage.3. Worn or dirty rails 3. Clean rails, inspect for worn spots.Motor overheatsTROLLEY TROUBLE SHOOTING––– Probable Cause ––– ––– Remedy–––1. Excessive load 1. Reduce load to within rated capacity of hoist.2. Low voltage 2. Ensure that the voltage at the trolley contactor does not drop below 10% of the nominal voltage.3. Extreme external heating 3. As the ambient temperature rises towards the 130°F limitation of the unit, frequency of trolley operation must belimited to avoid overheating of motor. See ADVERSE ENVIRONMENTAL CONDITIONS, page 3.4. Frequent starting or reversing 4. Excessive inching, jogging or plugging should be avoided since this type of operation will drastically shorten the lifeof motor and contactor. Always allow the trolley to coast to a stop before reversing its direction.23

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853INSPECTION AND MAINTENANCE CHECK LISTELECTRIC POWERED OVERHEAD CHAIN HOISTType of Hoist ___________________________________________________________Location _______________________________________________________________Manufacturer___________________________________________________________Capacity (Tons)________________________________________________________Original Installation Date ______________________________________________Manufacturer’s Serial No. ______________________________________________Item Frequency of Inspection Possible Deficiencies OK ActionRequiredFrequent PeriodicDaily Monthly 1-12 Mo.Operating Controls * * * Any deficiency causing improper operationLimit Switches * * * 1. Any deficiency causing improper operation2. Switch sticks or does not open circuit when tripped.Motor Brake * * * 1. Slippage or excessive drift2. Glazing, contamination or excessive wearHooks* * * Excessive throat opening 15% bent or twisted more than 10degrees, damaged hook latch, wear, chemical damage,worn hook bearing. Cracks (use dye penetrant, magnetic orother suitable detection method)* * * Cracks, excessive wear or other damage which may impairSuspension Lugthe strength of the lug. Cracks (use dye penetrant,magnetic particle or other suitable detection method)Chain * * * Inadequate lubrication, excessive wear or stretch, cracked,damaged or twisted links, corrosion or foreign substanceHook and SuspensionLug Connections* Cracks, bending, stripped threadsPins, Bearings, BushingsShafts, Couplings, Chain Guides* Excessive wear, corrosion, cracks, distortionNuts, Bolts, Screws * Looseness, stripped and damaged threads, corrosionLoad SheavesHousings, Load Block* Distortion, cracks, and excessive wear.Build-up of foreign substances* Cracks, distortion. Excessive wear, internal build-up offoreign substancesWiring and Terminals * Fraying, defective insulationContact Block, ReversingContactors, other Electrical * Loose connections, burned or pitted contactsApparatus & TerminalsSupporting Structure and TrolleyDamage or wear which restricts ability to support* imposed loadsNameplates, Decals,Warning Labels* Missing, damaged or illegibleGear Oil * Low level or needs changingNOTE: Refer to Maintenance and Inspection Sections of the Hoist-Maintenance Manual for further details.FREQUENCY OF INSPECTIONFrequent — Indicates items requiring inspection daily to monthly. Daily inspections may be performed by the operator if properly designated.Periodic — Indicates items requiring inspection monthly to yearly. Inspections to be performed by or under the direction of a properly designated period. Theexact period of inspection will depend on frequency and type of usage. Determination of this period will be based on the user’s experience. It isrecommended that the user begin with a monthly inspection and extend the periods to quarterly, semi-annually or annually based on user’s monthlyexperience.Figure 13A — Recommended Inspection and Maintenance Check ListNOTE: This inspection and maintenance check list is in accordance with our interpretation of the requirements of the SafetyStandard for Overhead Hoists ASME B30.16. It is, however, the ultimate responsibility of the employer/user to interpret andadhere to the applicable requirements of this safety standard.24

Country Club RoadP.O. Box 779Wadesboro, NC 28170 USATEL: (800) 477-5003FAX: (800) 374-6853ITEMINSPECTOR’S REPORTREMARKS (LIST DEFICIENCIES AND RECOMMENDED ACTION)Inspector’sDateSignature Inspected Approved by DateFigure 13B — Recommended Inspector’s ReportRECOMMENDED LUBRICATION SCHEDULE*COFFING ELECTRIC POWERED CHAIN HOISTPAGE AND COMPONENT TYPE OF LUBRICANT TYPE OF SERVICE ANDREFERENCE NO.FREQUENCY OF LUBRICATIONPages 40 & 41Ref. No. 18HEAVY NORMAL INFREQUENTLoad Chain SAE 90 gear oil Daily Weekly MonthlyPage 38 & 39 Gearing SAE 90 Extreme Pressure (EP) At periodic inspection (see Figure 13A)gear oilPage 36 & 37Ref. No. 9 & 7Limit Switch Shaft multi-purpose oil orgeneral purpose sprayMonthly Yearly YearlyPages 40 & 41Ref. No. 38, 50Load Hook Bearing SAE 30 gear oil Weekly Monthly YearlyPages 40 & 41Ref. No. 44Idler Sheave Bearing(Bushing) AssemblyAlternate — multipurpose lithium At periodic inspection (see Figure 13A)base bearing greaseNOTE: All bearings except hook and idler sheave bearings are prelubricated and sealed.(*) This lubrication schedule is based on a hoist operating in normal environment conditions. Hoists operating in adverse atmospherescontaining excessive heat, corrosive fumes or vapors, abrasive dust, etc., should be lubricated more frequently.Figure 14 — Recommended Lubrication Schedule25

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 15 - Basic Hoist1312111234561578 1410Parts List for Basic Hoist9Ref Part Ref PartNo. Description No. Qty No. Description No. Qty1 Motor — 1 12 Suspension Lug Assembly 50KG84 1(See Figures 16 & 17)13 Hook Hole Cover JF277-1 12 Sheave Housing Screw H2978P 4 14 Coffing Decal JL677 23 Sheave Housing15 Capacity Decal1/2 Ton & Under JL33 1250 lbs JL675-1 11 & 2 Ton JL39 11/4 Ton JL675-2 14 Gear Housing1/2 Ton JL675-3 11/2 Ton & Under JL35 11 Ton JL675-4 11 & 2 Ton JL44 12 Ton JL675-5 15 Gear Case Gasket JL560 1 ▲ Nylon Cover, Optional6 Gearbox Cover JL34 1(Includes capacity decal)7 Electrical Cover Gasket JL563 11/8 Ton 08770W 11/4 Ton 08771W 18 Electrical Cover JF36-6 11/2 Ton 08772W 19 1/4" Spring Lockwasher H4062P 11 Ton 08773W 110 1/4-20UNC X 3/4" Screw H1106P 12 Ton 08774W 111 10-24UNC X 1/2" Screw H2970 2(▲ ) Not Shown26

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 16 - Hoist Motor, 1-Speed, 1-Phase1121347 511362†9† Refer to the motor nameplate for part number, voltage,full load amperage, horsepower, and other motorinformation.8141014Parts List for Hoist Motor, 1-Speed, 1-PhaseRef Part Ref PartNo. Description No. Qty No. Description No. Qty1 Hoist Motor9 SINPAC ® Starting Switch 839J2 11/4 hp, 115/230V-1Ph 861JL11 11/2 hp, 115/230V-1Ph 861JL12 11 hp, 115/230V-1Ph 861JL14 12 Stator Assembly * 13 Rotor Assembly * 14 End Shield JL021209-20 15 Rear Bearing 500K3 16 Front Bearing 732012C 17 Shim Washer JL4301-01 18 Capacitor1/4 & 1/2 hp JL810-7 11 hp JL810-4 110 Capacitor/Start Switch Cover JL3108-03 211 Gasket JL564 112 Thru Bolt1/4 & 1/2 hp JL003801-41 41 hp JL003801-19 413 #10 Spring Lockwasher H4082P 414 8-32UNC X 5/16" Screw H2751 3* Not available as an individual part.27

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 17 - Hoist Motor, 3-Phase18947536† Refer to the motor nameplate for part number, voltage,full load amperage, horsepower, and other motorinformation.†2Parts List for Hoist Motor, 3-PhaseRef Part Ref PartNo. Description No. Qty No. Description No. Qty1 Hoist Motor (1-Speed)1/4 hp, 230/460V-3Ph-60Hz 863JL1 11/2 hp, 230/460V-3Ph-60Hz 863JL2 11 hp, 230/460V-3Ph-60Hz 863JL4 11/4 hp, 575V-3Ph-60Hz 863JL5 11/2 hp, 575V-3Ph-60Hz 863JL6 11 hp, 575V-3Ph-60Hz 863JL8 11/4 hp, 208V-3Ph-60Hz 863JL9 11/2 hp, 208V-3Ph-60Hz 863JL10 11 hp, 208V-3Ph-60Hz 863JL12 11/4 hp, 380V-3Ph-50Hz 863JL1 11/2 hp, 380V-3Ph-50Hz 863JL2 11 hp, 380V-3Ph-50Hz 863JL4 1Hoist Motor (2-Speed)1/4 hp, 230V-3Ph-60Hz 873JL1 11/2 hp, 230V-3Ph-60Hz 873JL2 11 hp, 230V-3Ph-60Hz 873JL4 11/4 hp, 460V-3Ph-60Hz 873JL5 11/2 hp, 460V-3Ph-60Hz 873JL6 11 hp, 460V-3Ph-60Hz 873JL8 11/4 hp, 575V-3Ph-60Hz 873JL9 11/2 hp, 575V-3Ph-60Hz 873JL10 1* Not available as an individual part.1 hp, 575V-3Ph-60Hz 873JL12 11/4 hp, 208V-3Ph-60Hz 873JL13 11/2 hp, 208V-3Ph-60Hz 873JL14 11 hp, 208V-3Ph-60Hz 873JL16 11/4 hp, 380V-3Ph-50Hz 873JL5 11/2 hp, 380V-3Ph-50Hz 873JL6 11 hp, 380V-3Ph-50Hz 873JL8 12 Stator Assembly * 13 Rotor Assembly * 14 End Shield JL021209-20 15 Rear Bearing 500K3 16 Front Bearing 732012C 17 Shim Washer JL4301-01 18 Thru Bolt (1-Speed)1/4 & 1/2 hp JL003801-62 41 hp JL003801-35 4Thru Bolt (2-Speed)1/4 hp JL003801-19 41/2 hp JL003801-17 41 hp JL003801-16 49 #10 Spring Lockwasher H4082P 428

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 18 - Brake & Solenoid Parts21512131113343 4153 56121514 810NOTE: Refer to wiring diagram insideelectrical cover of hoist or Figures12A - 12F, when connecting any wires.169710Parts List for Brake & Solenoid PartsRef Part Ref PartNo. Description No. Qty No. Description No. Qty1 Disc Brake Assembly*1/4 hp, 115V 854JL1 11/2 hp, 115V 854JL2 11 hp, 115V 854JL3 11/4 hp, 230V 854JL4 11/2 hp, 230V 854JL5 11 hp, 230V 854JL6 11/4 hp, 460V 854JL7 11/2 hp, 460V 854JL8 11 hp, 460V 854JL9 11/4 hp, 575V 854JL10 11/2 hp, 575V 854JL11 11 hp, 575V 854JL12 11/4 hp, 208V 854JL13 11/2 hp, 208V 854JL14 11 hp, 208V 854JL15 11/4 hp, 380V 854JL16 11/2 hp, 380V 854JL17 11 hp, 380V 854JL18 12 Plate & Stud Assembly JF859A 13 Brake Disc1/4 hp 581J1A 11/2 hp 581J1A 21 hp 581J1A 34 Brake Plate for 1/4 hp JF291 1Brake Plate for 1/2 hp & 1 hp JF291 25 Plate & Armature Assembly JF858 16 Spring 344J6 37 Retainer JF710 18 Plate & Frame Assembly JF857 19 Brake Coil*115V (white leads) 853JL1 1230V (orange leads) 853JL2 1460V (black/red leads) 853JL3 1575V (gray leads) 853JL4 1208V (red leads) 853JL5 1380V (violet leads) 853JL6 1415V (brown leads) 853JL7 110 Locknut H3978 311 Adapter JL142 112 Screw H2976P 213 Retaining Ring H5501 214 Shading Coil 860J1 2Shading Coil Adhesive H7812 115 Spacer for 1/4 hp JL141 3Spacer for 1/2 hp 141J2 3* Dual-voltage 115/230V models use 115V Brake Assembly and Coil.Dual-voltage 230/460V models use 230V Brake Assembly and Coil.29

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 19 - Electrical Parts1-Speed Hoist with 1-Speed Trolley Models1121915 16512151641017181314219131439116987NOTE: It is of great importance that the hoistreversing contactors are replaced according tothe horsepower and voltage of the hoist. Notethat for 1/2 & 1/4 hp hoists, the hoist contactoris the same as the trolley contactor.Parts List for Electrical Parts, 1-Speed, 1-SpeedRef Part Ref PartNo. Description No. Qty No. Description No. Qty1 Gear Box Cover JL34 12 Panel Plate 257JL200 13 Hoist Reversing Contactor*1/2 hp & 1/4 hp:24V Coil 28860 1115V Coil 24799 11 hp, 115/230V-1 Phase:24V Coil 24791 1115V Coil 28905 11 hp, 3-Phase:24V Coil 25943 1115V Coil 24729 14 Trolley Reversing Contactor*24V Coil 28860 1115V Coil 24799 15 Transformer*Pri.: 115/230V, Sec.: 24V 821J412 1Pri.: 115/230V, Sec.: 115V 821J411 1Pri.: 230/460V, Sec.: 24V 821J432 1Pri.: 230/460V, Sec.: 115V 821J431 1Pri.: 575V, Sec.: 24V 821J452 1Pri.: 575V, Sec.: 115V 821J451 1Pri.: 208V, Sec.: 24V 821J472 1Pri.: 208V, Sec.: 115V 821J471 1Pri.: 380V, Sec.: 24V 821J482 1Pri.: 380V, Sec.: 115V 821J481 16 Terminal Block115/230V 909J14 3230/460V 909J10 37 Marking Strip 909J11 18 End Plate115/230V 909J15 1230/460V 909J12 19 End Clamp 909J13 210 Tie Cable Assembly115/230V-1Ph 955JG43-1 13-Phase 955JG43 111 PB & Cable Assembly — 1(See Figures 22 - 24)12 Panel Standoff 110JL1 213 1/4" Internal-tooth Lockwasher H4134 214 1/4-20UNC X 4" Screw H1110P 215 8-32UNC X 5/16" Screw H2751 216 #8 External-tooth Lockwasher H4158 217 1/4” Flatwasher H4002P 118 10-24UNC X 1/2” Screw H2970 219 Grommet H9086 2* Coil voltage of the contactor and the secondaryvoltage of the transformer must be the same.This is referred to as the control voltage.Standard units are supplied with 24V Control.30

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 20 - Electrical Parts2-Speed Combinations - Hoist Controls18NOTE: Units with 2-speed hoists and/or 2-speedtrolleys have trolley controls located in a controlbox. See Figure 21.16910811 12523141311 129161015761542-Speed HoistOnlyNOTE: Ensure that hoist reversing contactor andspeed control relay are replaced according to thehorsepower of the hoist. Note that for 1/2 & 1/4 hphoists, the hoist contactor is the same as thetrolley contactor.Parts List for Electrical Parts, 2-Speed Combinations - Hoist ControlsRef Part Ref PartNo. Description No. Qty No. Description No. Qty1 Gear Box Cover JL34 12 Panel Plate 257JL200 13 Hoist Reversing Contactor*1/2 hp & 1/4 hp, 24V Coil 28860 11/2 hp & 1/4 hp, 115V Coil 24799 11 hp, 24V Coil 25943 11 hp, 115V Coil 24729 14 Hoist Speed Control Relay*1/2 hp & under, 24V Coil 28878 11/2 hp & under, 115V Coil 28870 11 hp, 24V Coil 28885 11 hp, 115V Coil 28879 15 Transformer*Pri.: 230/460V, Sec.: 24V 821J432 1Pri.: 230/460V, Sec.: 115V 821J431 1Pri.: 575V, Sec.: 24V 821J452 1Pri.: 575V, Sec.: 115V 821J451 1Pri.: 208V, Sec.: 24V 821J472 1Pri.: 208V, Sec.: 115V 821J471 16 Interconnection Cable — 1(See Figure 21)7 PB & Cable Assembly — 1(See Figures 22 - 24)8 Panel Standoff 110JL1 29 1/4" Internal-tooth Lockwasher H4134 210 1/4-20UNC X 4" Screw H1110P 211 8-32UNC X 5/16" Screw H2751 212 #8 External-tooth Lockwasher H4158 213 1/4" Flatwasher H4002P 114 10-24UNC X 1/2" Screw H2970 115 End Clamp 909J13 216 Grommet H9086 2* Coil voltage of the contactor and the secondaryvoltage of the transformer must be the same.This is referred to as the control voltage.Standard units are supplied with 24V Control.31

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 21 - Electrical Parts2-Speed Combinations - Trolley Controls1NOTE: Units supplied with a 2-speed hoist and/or trolleyhave trolley controls located in a control box.An interconnection cable runs from the hoist to thecontrol box. A tie cable connects the trolley motor tothe controls in the box.237674Parts List for Electrical Parts, 2-Speed Combinations - Trolley ControlsRef Part Ref PartNo. Description No. Qty No. Description No. Qty1 Control Box 260K100-1 1 6 End Clamp 909J13 2652-Speed Only2 Panel Plate 257K640 17 10-32NF X 1/2" Screw H2881 23 Din Rail 258J2000H .66 Ft4 Reversing Contactor*24V Coil 28860 1115V Coil 24799 15 Speed Control Relay (2-Speed Only)*24V Coil 28878 1115V Coil 28870 1▲▲Interconnection Cable (Hoist to Control Box)3-Phase 954KG25 11-Phase 954KG25-1 1Tie Cable (Control Box to Trolley Motor)1-Speed Trolley 955KG12 12-Speed Trolley 955KG12-1 1* Coil voltage of the contactor and the secondary voltage of the transformer are the same. This is referred to as thecontrol voltage. Standard units are supplied with 24V Control.▲ Not Shown.32

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 22 - Pushbutton Station 1-Speed Hoist, 1-Speed Trolley2319185342214 272621211324916 2015122062510171178Parts List for Pushbutton Station 1-Speed Hoist, 1-Speed TrolleyRef Part Ref PartNo. Description No. Qty No. Description No. Qty1 Pushbutton Station and Cable Assembly6' Cable Length PB300-6A 111' Cable Length PB300-11A 116' Cable Length PB300-16A 118' Cable Length PB300-18A 121' Cable Length PB300-21A 131' Cable Length PB300-31A 1Special (Specify Length) PBS300-#A 12 Pushbutton Assembly 534K98 13 Pushbutton Cable Assembly6' Cable Length PB300-6 111' Cable Length PB300-11 116' Cable Length PB300-16 118' Cable Length PB300-18 121' Cable Length PB300-21 131' Cable Length PB300-31 1Special (Specify Length) PBS300-# 14 Rubber Grommet JF761 15 Enclosure PB282-4 16 Cover PB283 17 Hoist Pushbutton PB284-2 28 Trolley Pushbutton PB284-1 29 Interlock (1-speed, Red) PB285 210 Boot PB286 411 Compression Spring PB287 412 Conical Spring PB288 413 Contact Plate PB289 414 Common Contact Plate PB290 215 Contact Washer PB291 416 Screw PB301 417 Boot Washer PB293 418 Grommet PB294-2 119 Cap PB295 120 O-ring X6477-1 321 Rubber Seal H7851 2 ft22 Screw H2991 323 Screw H2992 424 Screw H2993 825 Warning Label PB296 126 Lockwasher H4160 827 Jumper Wire JF940-42 1(#) Equal to cable length in feet.33

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 23 - Pushbutton Station, 2-Speed Hoist,1-Speed Trolley or 1-Speed Hoist, 2-Speed Trolley52315 27251422219 323221251017 2132271431 2924201930331622462631NOTE: Pushbutton shown is the 534JG5 with2-speed hoist buttons and 1-speed trolley buttons.216292812117Parts List for Pushbutton Station 2-Speed, 1-Speed or 1-Speed, 2-Speed8Ref Part Ref PartNo. Description No. Qty No. Description No. Qty1 Pushbutton Station and Cable Assembly2-Speed Hoist, 1-Speed Trolley 534JG5-# 11-Speed Hoist, 2-Speed Trolley 534JG6-# 12 Pushbutton Assembly2-Speed Hoist, 1-Speed Trolley 534JG5 11-Speed Hoist, 2-Speed Trolley 534JG63 Pushbutton Cable AssemblyStandard PB Drop PB309-# 1Special PB Drop PBS309-# 14 Rubber Grommet JF761 15 Enclosure PB282-4 16 Cover PB283 17 Hoist Pushbutton PB284-22 28 Trolley Pushbutton PB284-21 29 Interlock (2-speed, Black) PB285-1 210 Interlock (1-speed, Red) PB285 111 Boot PB286 412 Compression Spring PB287 413 Conical Spring PB288 214 Common Contact Plate PB289 415 Contact Plate PB290 416 Contact Washer PB291 41817 Screw H1852P 418 Boot Washer PB293 419 Grommet PB294-2 120 Cap PB295 121 O-ring X6477-1 322 Rubber Seal H7851 4 ft23 Screw H2925 324 Screw H2992 425 Screw H2993 1226 Warning Label PB296 127 Lockwasher H4160 1228 Spacer 755J2 229 Lower Spring 344J5 430 Insulating Bushing 755J1 231 Lower Contact 201J1 232 Spacer 200J16 333 2-Speed Adapter PB308 1(#) Equal to cable length in feet.Standard Lengths are 6', 11', 16', 18', 21' and 31'.When ordering specify length, ie., 534JG5-16 forpushbutton with 16' cable length.34

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 24 - Pushbutton Station 2-Speed Hoist, 2-Speed Trolley5221326251422920 3120 3124271423191830 28293242139162031156251226111071217Parts List for Pushbutton Station 2-Speed Hoist, 2-Speed Trolley8Ref Part Ref PartNo. Description No. Qty No. Description No. Qty1 Pushbutton Station andCable Assembly 534JG7-# 12 Pushbutton Assembly 534JG7 13 Pushbutton Cable AssemblyStandard PB Drop PB309-# 1Special PB Drop PBS309-# 14 Rubber Grommet JF761 15 Enclosure PB282-4 16 Cover PB283 17 Hoist Pushbutton PB284-22 28 Trolley Pushbutton PB284-21 29 Interlock (2-speed, Black) PB285-1 210 Boot PB286 411 Compression Spring PB287 412 Conical Spring PB288 413 Contact Plate PB289 414 Common Contact Plate PB290 615 Contact Washer PB291 416 Screw H1852P 417 Boot Washer PB293 418 Grommet PB294-2 119 Cap PB295 120 O-ring X6477-1 321 Rubber Seal H7851 122 Screw H2925 323 Screw H2992 424 Screw H2993 1625 Warning Label PB296 126 Lockwasher H4160 1627 Jumper (2-Speed Common) JF940-42 228 Lower Spring 344J5 429 Insulating Bushing 755J1 430 Lower Contact 201J1 431 Spacer 200J16 332 2-Speed Adapter PB308 1(#) Equal to cable length in feet.Standard Lengths are 6', 11', 16', 18', 21' and 31'.When ordering specify length, ie., 534JG5-16 forpushbutton with 16' cable length.35

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 25 - Standard Limit Switch Assembly1656344815165131417910111272Parts List for Standard Limit Switch AssemblyRef Part Ref PartNo. Description No. Qty No. Description No. Qty1 Gear Box Cover JL34 18 Bushing JF531-4 12 Limit Switch Assembly 918JG4 1(Includes items 4-12)3 Limit Switch Bracket Assembly 918JG3 1(Includes items 4-8)4 Switch 815J1 25 6-32UNC X 1" Screw H1402P 46 6-32UNC Elastic Locknut H3944 47 Limit Switch Bracket JF900-3 1(Includes Item 8)9 Limit Switch Shaft JF117-3S 110 Limit Switch Nut (silver) SK6000-63Z 111 Limit Switch Nut (gold) SK6000-63W 112 Retaining Ring H5520 113 Insulator JF754 114 Limit Switch Stub Shaft JL140 115 E-Ring H5563 116 Spring JF343-3 117 10-24UNC X 1/2" Screw H2970 236

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 26 - Long Lift Limit Switch Assembly14222316141315101113148937125624176 1520216521218519Parts List for Long Lift Limit Switch AssemblyRef Part Ref PartNo. Description No. Qty No. Description No. Qty1 Gear Box Cover JL34 114 6-32UNC X 1" Screw H1402P 42 Limit Switch Assembly 944JG6 13 Post 110J14 14 8-32UNC X 1/2" Screw H1210 15 #8 External-tooth Lockwasher H4158 36 8-32UNC X 1/4" Screw 854823 37 Limit Switch Shaft & Gear 117JG2 18 Limit Switch Nut (gold) SK6000-63W 19 Limit Switch Nut (silver) SK6000-63Z 110 Thrust Washer 255K16 111 Spring PB287 115 6-32UNC Elastic Locknut H3944 416 Mounting Plate 129J1 117 Frame and Guide Assembly 258JG7 118 End Plate 258J8 119 8-32UNC X 3/8" Screw H2741P 220 Drive Pinion 427J1 121 Retaining Ring H5520 122 Limit Switch Stub Shaft JL140 123 E-Ring H5563 124 10-24UNC X 3/8" Screw H2981P 212 Bushing JF531-4 213 Switch 815J1 237

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 27 - Gearbox1415161617415623*20*18*21*221518191824252*202623789272873111213293027311310(*) NOTE: This stage of gearing is not required on 32FPM models.(**) NOTE: Orient output gear (32) with long bosstowards gear housing (2) on 1/2 ton &under models and towards gear box cover(3) on 1 & 2 ton models.**322638

Please have the hoist model number, serial number, andpart number with description available for reference.Parts List for GearboxRef.PartNo. Description No. Qty1 Sheave Housing1/2 Ton & Under JL33 11 & 2 Ton JL39 12 Gear Housing (Includes oil seals)1/2 Ton & Under JL35 11 & 2 Ton JL44 13 Gear Box Cover JL34 1(Includes oil seals)4 Spring Washer 360J1 15 O-Ring H5605 16 Pressure Relief Fitting SK1912-21W 17 Dowel Pin H5382 28 Gear Case Gasket JL560 19 Oil Fill Plug S25-4 110 Oil Drain Plug H6268 111 Oil Level Check Plug S25-13 112 Oil Seal JL561 113 Screw H2978P 414 Motor Coupling JL107 115 Oil Seal 561K2 216 Bearing 500K33 217 Input Pinion8 & 16 fpm JL400B 132 fpm JL400-1 118 Retaining Ring H5501 319 Brake Adapter JL142 120 Bearing for 8 & 16 fpm 500K34 221 High Speed Gear for 8 & 16 fpm JL426 122 Intermediate Pinion1/2 Ton & Under, 16 fpm JL402A 11 & 2 Ton JL403A 123 Bearing 500K36 224 Output Pinion JL401 125 Overload Clutch Assembly1/8 Ton, 32 fpm 591JG22 11/4 Ton, 16 fpm 591JG25 11/4 Ton, 32 fpm 591JG22 11/2 Ton, 16 fpm 591JG16 11/2 Ton, 32 fpm 591JG21 11 & 2 Ton 591JG17 126 Retaining Ring H5503 227 Bearing JF504-2 228 Load Sheave Shaft Assembly __ 1(See Figure 28)29 Load Sheave __ 1(See Figure 28)30 Spacer __ 1(See Figure 28)31 Oil Seal 561K20 132 Output Gear1/2 Ton & Under JL420 11 & 2 Ton JL421 1* Gear Oil H7642 1½pt* Not Shown39

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 28 - Chaining Parts1161517181412112-TonModels25242322211920291227891356413710113240411/2-Ton & UnderModels4526463835433736312844 32 333431833238 3736331435392-Ton Models495042301-Ton Models484740

Please have the hoist model number, serial number, andpart number with description available for reference.Parts List for Chaining PartsRef Part Ref PartNo. Description No. Qty No. Description No. Qty1 Sheave Housing1/2 Ton & Under JL33 11 & 2 Ton JL39 12 Gear Housing1/2 Ton & Under JL35 11 & 2 Ton JL44 13 Dowel Pin H5382 24 Load Sheave1/2 Ton & Under JF16-4 11 & 2 Ton JF16-3 15 Load Sheave Shaft JL132 16 Roll Pin H5240 17 Spacer, 1 & 2 Ton JF285 18 Chain Guide1/2 Ton & Under JF250-3 21 & 2 Ton JF254-3 29 Chain Guide Screw H2976P 210 Washer, 1/2 Ton & Under H4134 211 Chain Guide Plate1/2 Ton & Under JF272 21 & 2 Ton JF273 212 Chain Guide Plate Screw H2692P 213 Chain Guide Plate Spacer JF127 214 Bearing JF504-2 215 Dead End Screw S49-77 116 1/4" Flatwasher H4002P 817 Dead End Screw Nut H3845P 118 Load Chain1/2 Ton & Under JL19B •1 & 2 Ton JL19-1 •19 Chain Stop Kit1/2 Ton & Under 75JG7K 11 & 2 Ton 75JG6K 1(Kits include halves,sleeve, and retaining ring)20 Chain Support JF109 121 Chain Support Pin JL18 122 Cotter Pin H5025P 123 Lockwasher H4083P 124 1/2-20UNF Hex Jam Nut H3621P 125 Chain Support Screw JF703 126 Bottom Block Assembly1/2 Ton & Under 913JG4AS 127 Load Block Frame JF20-2 128 Load Block Frame (threaded) JF20-3 129 Load Block Screw JF700 130 Bottom Block Assembly, 1 Ton 913JG3AS 131 Load Block Frame 30J14 232 1/4-20UNC x 1¼"Socket Head Cap Screw S49-77 233 1/4" Internal-Tooth Lockwasher H4134 234 Load Block Pin 18J8 135 Bottom Hook AssemblyW/Latch, 1/2 Ton & Under 3JG20S 136 Latch Kit 4X1304 137 Slotted Hex Nut H3986P 138 Bearing JF510 139 Bottom Block Assembly, 2 Ton JF914-6 140 Load Block Frame JF30-1 241 Load Block Screw H2403P 242 3/8-24 Hex Locknut H3964P 243 Sheave Shaft Assembly JF917-1 144 Sheave & Bearing Assembly JF916 145 Sheave Shaft JF122-1 146 Roll Pin H5234 247 Bottom Hook Assemblywith Latch, 2 Ton 3KG1W 148 Latch Kit 4X1305 149 Slotted Hex Nut H3991P 150 Bearing JF511 1* Replacement chain is sold by the foot. For single-chained models, add 2 ft to the lift for the total amount of feet.For double-chained models, double the lift and add 3 ft.41

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 29 - Standard Trolley General Assembly11111212344112131412556721211149832111 1220181719715169101412141311Parts List for Standard Trolley General AssemblyRef Part Ref PartNo. Description No. Qty No. Description No. Qty1 Trolley Transmission Assembly - 1(See Figures 30 & 31)2 Motor - 1(See Figure 32 & 33)3 Side PlateUp to 7" Flange Width 5K101 27" to 9" Flange Width 5K102 24 Plain Wheel AssemblyAmerican Standard I-Beam (ASI)(tapered flange) 45KG1 2Wide Flange Beam 45KG11 2(flat flange)Patented Track 45KG5 22" Patented Track 45KG35 25 Geared Wheel Assembly* (35, 75, 100 & 150 fpm)ASI Beam 45KG2 2Wide Flange Beam 45KG12 2Patented Track 45KG6 22" Patented Track 45KG36 26 Output Pinion35, 75, 100 & 150 fpm 420K1 124 & 50 fpm 420K7 118 fpm 420K5 17 Gear35, 75, 100 & 150 fpm 420K2 224 & 50 fpm 420K8 218 fpm 420K6 28 Retaining Ring H5501 29 Load Pin3.33 to 6" 103K1 26 to 9" 103K13W 210 Suspension Lug Assembly 50KG84 111 3/4-16UNF Elastic Stop Nut H3945 812 3/4" Flatwasher (.125" thick) H4211 1613 3/4" Flatwasher (.075" thick) H4210 2014 3/4" Flatwasher (.135" thick) H4209 8015 WheelASI Beam 45K1 1Wide Flange Beam 45K6 1Patented Track 45K4 12" Patented Track 45K36 116 Wheel AxleASI or Wide Flange Beams 102K1 1Patented Track Beams 102K3 117 Bearing 500K4 118 Retaining Ring H5520 119 1/4-20UNC x 3/4" Screw H2165 220 3/16 x 3/4" Spring Pin H5331 221 Spacer 200K1 1* For assemblies not listed, consult factory.42

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 30 - Trolley Transmission13142Standard Transmissions:930JG1L, 35, 24 & 18 fpm930JG2L, 75 & 50 FPM930JG3L, 100 FPM930JG4L, 150 FPM14341192021161718159225678791011412Parts List for Trolley TransmissionRef Part Ref PartNo. Description No. Qty No. Description No. Qty1 Gear Housing 39K22 12 Housing Adapter 38K60A 13 Bearing 500K3 14 Gasket 560K2 25 Output Shaft 100K12 16 Woodruff Key S23-15 17 External Retaining Ring H5527 28 Worm Gear35, 24 & 18 FPM 487K4 175 & 50 FPM 487K3 1100 FPM 487K2 1150 FPM 487K1 19 Bearing 500K7 210 Shim Washer 202K1 111 O-ring H5609 112 End Cap 32K3 113 1/4-20UNC x 3/4" SocketHead Screw H2215 614 1/4" Spring Lockwasher H4084P 315 Worm35, 24 & 18 FPM 485K21 175 & 50 FPM 485K22 1100 FPM 485K23 1150 FPM 485K24 116 Bearing JF504-2 117 External Retaining Ring H5549 118 Internal Retaining Ring SK2658-6W 119 Plug S25-13 120 Gasket 560K3 221 Splice Plate 295K1 222 #10-24NC x 3/8" SlottedHead Screw H1009P 81343

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 31 - Trolley Transmission with Optional Brake13141416171823191594123202125262556343029 3172687910113327 28 304123235342434Transmissions with Brake:930JG1BRL - 35, 24 & 18 FPM930JG2BRL - 75 & 50 FPM930JG3BRL - 100 FPM930JG4BRL - 150FPM1 Gear Housing 39K23 12 Housing Adapter 38K60A 13 Bearing 500K3 14 Gasket 560K2 25 Output Shaft 100K12 16 Woodruff Key S23-15 17 External Retaining Ring H5527 28 Worm Gear35, 24 & 18 FPM 487K4 175 & 50 FPM 487K3 1100 FPM 487K2 1150 FPM 487K1 19 Bearing 500K7 210 Shim Washer 202K1 111 O-ring H5609 112 End Cap 32K3 113 1/4-20UNC x 3/4" SocketHead Screw H2215 614 1/4" Spring Lockwasher H4084P 315 Worm35, 24 & 18 FPM 485K25 175 & 50 FPM 485K26 1100 FPM 485K27 1150 FPM 485K28 116 Bearing JF504-2 117 External Retaining Ring H5549 12222Parts List for Trolley Transmission with Optional BrakeRef Part Ref PartNo. Description No. Qty No. Description No. Qty18 Internal Retaining Ring SK2658-6W 119 Oil Seal 561K2 120 Gasket 560K3 221 Splice Plate 295K1 222 #10-24NC x 3/8" SlottedHead Screw H1009P 823 Brake Housing 37J11 124 Brake Cover 36J10 125 Socket Head Screw S49-12 426 Stud 141J12 327 Brake Adapter JL142 128 Retaining Ring H5501 129 Brake Disc 581J1A 130 Spring 344J6 331 Plate & Armature JF858 132 Plate & “E” Frame JF857 133 Brake Coil115V JF853-1 1230V JF853-2 1460V JF853-3 1575V JF853-4 1208V JF853-5 1380V JF853-6 134 Nut H3978 335 Retainer JF710 11344

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 32 - Trolley Motor, 1-Phase1111246 51032†8† Refer to the motor nameplate for part number, voltage,full load amperage, horsepower, and other motorinformation.713913Parts List for Trolley Motor, 1-PhaseRef Part Ref PartNo. Description No. Qty No. Description No. Qty1 Trolley Motor8 SINPAC ® Starting Switch 839J2 11/4 hp, 115/230V-1Ph JL861-11M 11/2 hp, 115/230V-1Ph JL861-12 12 Stator Assembly * 13 Rotor Assembly * 14 End Shield JL021209-20 15 Rear Bearing 500K3 16 Shim Washer JL4301-01 19 Capacitor/Start Switch Cover JL3108-03 210 Junta JL564 111 Thru Bolt JL003801-41 412 #10 Spring Lockwasher H4082P 413 8-32UNC X 5/16" Screw H2751 3NOTE: 1/2 hp motors are typically used on 2 tonmodels with speeds over 75 fpm.7 Capacitor1/4 hp JL810-6 11/2 hp JL810-7 1* Not available as an individual part.45

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 33 - Trolley Motor, 3-Phase1784653† Refer to the motor nameplate for part number, voltage,full load amperage, horsepower, and other motorinformation.†2Parts List for Trolley Motor, 3-PhaseRef Part Ref PartNo. Description No. Qty No. Description No. Qty1 Trolley Motor (1-Speed)1/4 hp, 380V-3Ph-50Hz JL873-5M 11/4 hp, 208-230/460V-3Ph-60Hz JL863-1M 11/2 hp, 208-230/460V-3Ph-60Hz JL863-2 11/4 hp, 575V-3Ph-60Hz JL863-5M 11/2 hp, 575V-3Ph-60Hz JL863-6 11/4 hp, 380V-3Ph-50Hz JL863-1M 11/2 hp, 380V-3Ph-50Hz JL863-2 1Trolley Motor (2-Speed)1/4 hp, 208-230V-3Ph-60Hz JL873-1M 11/2 hp, 208-230V-3Ph-60Hz JL873-2M 11/4 hp, 460V-3Ph-60Hz JL873-5M 11/2 hp, 460V-3Ph-60Hz JL873-6M 11/4 hp, 575V-3Ph-60Hz JL873-9M 11/2 hp, 575V-3Ph-60Hz JL873-10M 11/2 hp, 380V-3Ph-50Hz JL873-6M 12 Stator Assembly * 13 Rotor Assembly * 14 End Shield JL021209-20 15 Rear Bearing 500K3 16 Shim Washer JL4301-01 17 Thru Bolt (1-Speed) JL003801-62 4Thru Bolt (2-Speed)1/4 hp JL003801-19 41/2 hp JL003801-17 48 #10 Spring Lockwasher H4082P 4NOTE: 1/2 hp motors are typically used on 2 tonmodels with speeds over 75 fpm.* Not available as an individual part.46

Please have the hoist model number, serial number, andpart number with description available for reference.Figure 34 - Optional Mounting ArmMOUNTING OPTIONSArm UpArm DownOptional 804K1 Current Collector14 375624Parts List for Optional Mounting Arm78Ref.PartNo. Description No. Qty1 Mounting Arm 803KG8 182 Mounting Plate 802K1 13 Brace Plate 802K12 14 Shackle 806K1 25 1/4-20UNC Nut H3561P 46 1/4" Lockwasher H4062P 47 3/4" Flatwasher H4211 48 3/4-16UNF Elastic Stop Nut H3945 2Note: Arm may be used for mounting current collectors or as a festooning tow arm or similar applications.47

®WARRANTYEvery hoist is thoroughly inspected andperformance tested prior to shipment from thefactory. If any properly installed, maintained andoperated hoist as outlined in the applicableaccompanying Coffing Hoists manual develops aperformance problem due to defective materials orworkmanship as verified by Coffing Hoists, repairor replacement of the hoist will be made to theoriginal purchaser without charge and the hoistwill be returned, transportation prepaid. Thiswarranty does not apply where deterioration iscaused by normal wear, abuse, improper orinadequate power supply, improper or inadequatemaintenance, eccentric or side loading,overloading, chemical orabrasive actions, excessiveheat, unauthorized modificationsor repairs, or use of non-Coffingrepair parts. EXCEPT AS STATED HEREIN,COFFING HOISTS MAKES NO OTHERWARRANTIES, EXPRESS OR IMPLIED,INCLUDING WARRANTIES OFMERCHANTABILITY AND FITNESS FOR APARTICULAR PURPOSE.Coffing Hoists • Country Club Road • P.O. Box 779 •Wadesboro, North Carolina 28170 USATel: 800.477.5003 • Fax: 800.374.6853 • 704.694.6829www.coffinghoists.com© 2003 Coffing ® Hoists Printed in USA