AirStar - Gaffey Overhead Cranes
Contents
1. 3 4 and 1 ton double reeved models has not been capsized AWARNING Never operate hoist with defective chain anchor pins brake or hooks e Lubricate chain per paragraph 4 4 3 3 OPERATING HOIST With hoist installed and air pressure turned on hoist is operated in the following manner a Pull Cord Control 1 Pull top handle marked with arrow pointing up down to raise load 2 Pull bottom handle marked with arrow pointing down down to lower load 3 Release handle being used to stop either lifting or lowering 4 Speed of lifting and lowering is varied between slowest inching to full speed by the pull exerted on control handle being used Page 5 i E W TO RAISE i TO LOWER N l n a Figure 3 1 Pull Cord Control Handles b Pendant Throttle Control 1 Depress throttle valve lever marked UP to raise load See Figure 3 2 2 Depress throttle valve lever marked DOWN to lower load 3 Release lever being depressed to stop either lifting or lowering 4 Speed of lifting and lowering is varied f by the position of the throttle valve lever being depressed 4 12003 ep Figure 3 2 Pendant Throttle Control Handle 3 4 PULLING AND PIVOTING HOIST AND LOAD a On Pendant Throttle Control models the valve handle is supported by a strain cable that is suitable for pulling trolley suspended hoists when empty or lightly loaded Use a tag line or pole to pull or push loads2. 9 BAH 149 Washer Thrust Bearing 2 2 10 BAH 150 Bearing Assembly Needle 1 1 11 BAH 151 Shield Bearing 1 1 12 Nut Hook 1 1 13 BAH 152 Pin Spring Drive 1 1 14 BAH 170 Screw Hex Socket Head Cap 1 1 1 15 BAH 171 Washer Flat 1 1 1 18 BAH 172 Cover Brake Housing 1 1 1 19 BAH 113 Screw Slotted Head 2 2 2 22 BAH 153 Shaft Control 1 1 1 23 BAH 119 Bushing Oilite Control Shaft 3 3 3 t24 BAH 115 Chain Load Coil Type 11 5 Lg 1 1 BAH 116 Chain Load Coil Type 22 7 Lg 1 t25 BAH 1 17 Lever Control 1 1 1 Continued On Next Page Page 18 Figure 8 1 Frame and External Parts Coil Chain Models Cont d Ref Part Description Quantity Required No Number 1 4 Ton 1 2 Ton 1 Ton t26 BAH 154 Block Assembly Lower 1 4 Ton 1 BAH 155 Block Assembly Lower 1 2 Ton 7 1 lt t27 BAH 156 Body Lower Block 1 4 Ton 1 7 lt BAH 157 Body Lower Block 1 2 Ton 7 1 5 t28 BAH 158 Latch Kit 1 1 t29 BAH 160 Hook and Nut Assembly With Latch 30 BAH 149 Washer Thrust Bearing 31 BAH 150 Bearing Assembly Needle 32 BAH 151 Shield Bearing 33 BAH 152 Pin Spring Drive 34 Nut Hook 35 BAH 121 Pin Spring Drive t36 BAH 122 Pin Connecting Lower Block BAH 124 Cord Assembly Control Includes Ref Nos 37 thru 40 37 BAH 125 Handle Down Control 38 BAH 126 Handle Up Control 39 BAH 128 Cord Down Control 40 BAH 127 Cord Up Control BA
3. Washer 2 8 1 45 BAH 1332 Sprocket Coil Chain Lower Block 1 8 1 46 BAH 1324 Screw Socket Head 3 8 1 47 BAH 1328 _ Latch Kit Lower Hook 1 8 1 48 BAH 1327 Hook Nut and Latch Assembly Lower S 1 8 1 55 BAH 1333 Hook and Bracket Assembly Upper Includes Latch 1 8 1 56 BAH 1334 Latch Kit Upper Hook 1 8 1 59 BAH 1340 Label Rated Load 1 8 1 59 BAH 1341 Label Rated Load 1 8 3 39 BAH 1335 Sprocket Coil Chain 1 1 8 3 40 BAH 1336 Guide and Stripper Assembly Coil Chain 1 1 Paqe 26 Figure 8 7 Special Parts Table Spark Resistant Models NOTES Page 27 Recommended Spare Parts for Your CM AIRSTAR Air Hoist Certain parts of your hoist will in time require replacement under normal wear conditions It is suggested that the following parts be purchased for your hoist as spares for future use One Pair of Brake Shoes One Set of Gaskets One Set of Oil Seals and 0 Ring One Set of Motor Blades NOTE When ordering parts always furnish Model and Catalog Number of Hoist and Lift of Hoist on which the parts are to be used Parts for your hoist are available from your local recognized CM repair station For the location of your nearest repair station write or phone In USA COLUMBUS McKINNON CORPORATION INDUSTRIAL PRODUCTS DIVISION 140 JOHN JAMES AUDUBON PARKWAY AMHERST NY 14228 1197 800 888 0985 In CANADA COLUMBUS McKINNON LTD PO BOX 1106
4. 1 4 BAH 954 Blade Rotor 8 5 BAH 955 Rotor and Shaft Assembly 1 6 BAH 956 Pin Spring 1 7 BAH 957 Pin Spring 3 8 BAH 958 Body 1 9 BAH 959 Plate End Drive 1 10 BAH 960 Ring Retaining 1 NOTES Page 24 To enable us to expedite your parts order always give Catalog Num ber Model Number and Capacity found on hoist nameplate 12010B Figure 8 6 Control Cylinder and Pendant Throttle Control Parts Ref Part Description City No Number Req d 1 BAH 1201 Cylinder Assembly Control Pendant Includes Ref Nos 2 thru 10 and 15 2 2 BAH 1202 Ring Lock Cylinder 1 3 BAH 1203 Screw Set Hex Socket 1 4 BAH 1204 Cap End Cylinder 1 5 BAH 1205 Spring Piston Cylinder 1 6 BAH 1206 Seal U Ring Piston 1 7 BAH 1207 Piston Control Cylinder 1 8 BAH 1208 Cylinder Pendant Control 1 9 BAH 1209 Seal O Ring Piston Stem 1 10 BAH 1210 Retainer O Ring Seal 1 11 BAH 1110 Spring Throttle Valve 2 12 BAH 1 109 Guide Spring Throttle Valve 2 13 BAH 1108 Seal O Ring Throttle Valve 2 14 BAH 1 125 Valve Throttle 1 15 BAH 1111 Gasket O Ring Control Cylinder 2 Continued On Next Page Page 25 Figure 8 6 Control Cylinder and Pendant Throttle Control Parts Cont d Ref Part Description Qty No Number Req d 16 Hose and Strain Cable Assembly Pendant Throttle BAH 1211 For 10 Lift 1 BAH 1212 For 12 Lift 1 BAH 1213
5. On pendant throttle control models control hoses must be attached to cylinders on throttle valve housing as follows Facing air inlet end of hoist the hose to DOWN lever side of pendant handle should be connected to cylinder on right hand side of housing hose to UP lever side should be connected to cylinder on left hand side of housing The third hose connects to tapped hole in bottom left side of control head and at top rear of handle 7 5 TESTING HOIST a General After completion of assembly and before placing hoist in service hoist should be tested to insure proper operation To test Suspend hoist from an overhead supporting member of sufficient strength to carry combined weight of hoist and rated load connect to air supply of correct pressure and perform the following checks and adjustments b Check Control Operation Pull down on pull cord handle or depress lever on pendant control briefly to determine that hook travels in the direction to correspond with control being operated If load hook travels in a direction opposite to control being operated the pull cords or control hoses are improperly installed With Pendant Control Hoists the control lever should attain a full throw when each lever on the handle is fully depressed If full movement of control lever is not accomplished the set screw in the corresponding control cylinder should be turned in If full movement occurs before lever is fully depressed the set screw shou
6. WHEEL BRAKE ARM ek abe 12587 BRAKE CAM Figure 7 15 Brake Adjustments Page 15 e Installation of Load Chain 1 To install roller type load chain first temporarily install connecting link on tail end of load chain Then with the air off brake cover removed and brake shoes locked in open position with wedge between control lever and hoist body turn brake wheel in hoist direction and feed chain in through lever control into chain sprocket Once chain is over sprocket brake cover can be replaced hoist connected to air and the chain run through hoist under power until sufficient chain has been run through to allow tail end to be attached to boss on side of frame with chain anchor On single reeved hoist attach lower block to load end of chain On double reeved hoist run lower block assembly onto chain and attach load end of chain to lug suspension bracket 2 When installing coil chain on the hoist make sure the weld on the second link faces out or away from the sprocket See Figures 7 16 and 7 17 Now with the air off brake cover removed and brake shoes locked in open position with wedge between control lever and hoist body turn brake wheel in hoist direction and feed chain in through lever control into chain sprocket Continue to feed the chain through until approximately 15 to 16 hangs through the tail chain side of the hoist Take the first link and swing it up do not twist see Figure 7 16 to the
7. bearing Use a feeler gage between end plate and body to make sure the bearing is not pressed onto shaft so far as to bow the end plate Align dowel pin holes in end plate with those in body and assemble pins Assemble three button head cap screws 3 Rotor blade replacement is the only field service recommended on air motors See paragraph 7 2 e For any other repairs the air motor should be returned for factory servicing 4 Lubricate motor with small amount of Air Hoist Motor Oil or good grade 10W machine oil approximate viscosity 150 SSU at 100 F Multi viscosity detergent type engine oil is not recommended c Assembly of Control Head At reassembly of control head and throttle valve observe these precautions 1 Lightly oil throttle valve and bushing with S A E 20 oil If shifter pin was removed from valve assemble valve with threaded hole facing slot at bottom of bushing in housing Figure 7 13 Shifter pin should be assembled with LOCTITE Extreme care must be taken not to get any LOCTITE on valve outside diameter since this will lock up valve and scrap the complete head assembly NOTE Apply lubricating oil to 0 rings and U seals before installing and take care during installation so as not to cut pinch or otherwise damage them 2 Use new 0 ring seals at each end of valve Install spring guides and valve springs in bores on each side of housing and secure with spring retainer pull cord models or control cyli
8. bearings brake cam and valve shifter Clean control cylinders Adjust brake 6 4 Hoist loses power Insufficient air pressure Clogged air intake screen Clogged muffler screen Worn or broken rotor blades Check air pressure and ad just See this Section paragraph 1 Remove throttle valve hous ing Clean screen and muf fler Replace rotor blades 6 5 Cannot regulate speed by control handles Brake improperly adjusted Speed adjustment screws improperly set Adjust brake Readjust screws Page 10 SECTION VI TROUBLE SHOOTING speed differs from rated speed at full load Trouble Probable Cause Remedy 6 6 Cannot regulate speed by 1 Brake improperly adjusted 1 Adjust brake pendant handle 2 Control cylinders improp 2 Adjust control cylinder set erly adjusted screws 6 7 Hoist lifting or lowering 1 Valve shifter or control 1 Repair or install new parts shaft bent or damaged 2 Incorrect air pressure or 2 Check pressure near hoist inadequate air supply when hoist is operating 3 Speed adjustment screws 3 Readjust screws See Figure improperly set 2 4 4 Loss of power 4 See paragraph 6 4 and lubricate SECTION VII DISASSEMBLY AND REASSEMBLY 7 1 GENERAL a The following disassembly and reassembly instructions apply to all models of CM AIRSTAR Air Hoists Where needed variations to instructions are provided to co
9. include with order the exact Catalog Number and Model Number from hoist nameplate 8 2 PARTS LIST The parts lists consist of four columns The first column Ref No is the index number of the parts on the exploded view illustrations The second column Part Number lists the number of the part for ordering purposes The third column names and gives a brief description to help identify the part The last column s list the total number of times the item is used in the assembly of which it is a part NOTICE Information herein is subject to change without notice Parts must be order from a recognized CM Repair Station or from a CM Hoist Distributor NOTES Page 17 To enable us to expedite your parts order always give Catalog Num ber Model Number and Capacity found on hoist nameplate Nameplate BAH 163 Drive Screw BAH 164 Warning Label BAH 166 12005B ANSI B30 16 Figure 8 1 Frame and External Parts Coil Chain Models Ref Part Quantity Required No Number Description 1 4 Ton 1 2 Ton 1 Ton 1 BAH 105 Bolt Suspension Bracket 2 2 2 2 BAH 108 Lockwasher Shakeproof External 2 2 2 3 BAH 107 Nut Hex Cadmium Plated 2 2 2 t4 BAH 106 Hook and Bracket Assembly Suspension 1 1 t5 BAH 145 Hook and Nut Assembly Upper Includes Ref No 6 1 1 t6 BAH 146 Latch Kit 1 1 7 BAH 147 Bushing Machinery 1 1 8 BAH 148 Bracket Suspension 1 1
10. is suspended by trolley provide sufficient hose to reach from air source to farthest point of trolley travel CM Hose Trolleys are recommended to keep hose up out of the way see Figure 2 2 AIR INLET ms H SWIVEL 1 2 I D PRESSURE HOSE 3 8 NPTF MALE PIPE THREAD Shee Ss 12014 HOSE TROLLEY Prec ft dD Figure 2 2 Air Hoist Supported by CM Hose Trolleys c A filter and lubricator unit Figure 2 3 must be installed between air source and air hose leading to hoist These keep air flowing to hoist free of dirt and add lubricant to air so internal parts of motor are constantly lubricated Use Air Hoist Motor Oil or good grade 10W machine oil approximately viscosity 150 SSU at 100 F Multi viscosity detergent type engine oil is not recommended Feed one drop of oil for every 50 to 75 cubic feet of air going through the air motor IN aneii F LOW Sissig OUT Figure 2 3 Air Filter and Lubricator Unit d The recommended operating air pressure for all capacities of CM AIRSTAR Air Hoists is 90 psi When line pressure exceeds 100 psi while hoist is operating it is recommended that a pressure regulator valve be provided in the air supply line to maintain proper pressure However there is a wide range of pressures within which the hoists will operate Refer to Performance Charts See Figure 2 5 2 4 HOISTING AND ADJUSTMENTS a Hoist speed is adjusted at the factory to give maximum lifting speed and i
11. replaced Chain with excessively pitted corroded nicked gouged twisted or worn links should be replaced using only factory approved chain Never weld or attempt to repair coil chain Load chain for spark resistant models is made of stainless steel Surface hardness treatment is no more than 001 deep and the core is lower in hardness than standard alloy steel load chain For these reasons the rated capacity of spark resistant models is lower than that of standard models as follows RATED LOAD LINES OF FOR STANDARD LOAD CHAIN MODEL RATED LOAD FOR SPARK RESISTANT MODEL 1 4 Ton 1 2 Ton 1 Ton LA WEAR Figure 5 1 Check Chain Wear at Bearing Surfaces Between Links Figure 5 2 Checking Coil Chain Using Vernier Caliper Page 8 ALLOWABLE CHAIN WEAR ELONGATION CHAIN SIZE NO OF PITCHES MAXIMUM WIRE DIA TO MEASURE WEAR LIMIT ACAUTION Do not assume that load chain is safe because it measures below replacement points given herein Other factors such as those mentioned in visual checks above may render chain unsafe or ready for replacement long before elongation replacement is necessary AWARNING _ When replacing coil load chain use only factory approved chain conforming to factory specifications for material hardness strength and link dimensions Chain not conforming to CM hoist specifications may be dangerous as it will not fit in the
12. to traverse heavily loaded hoists Observe caution to stay clear of loads b To pivot load push on one corner of load Lower hook will swivel through 360 to permit load to be swung to the desired position The upper hook hook suspension models is also designed to rotate so that side pulls will swing hoist to face the load thus reducing side thrust 3 5 UPPER AND LOWER LIMIT STOPS A lower block and chain operated limit stop is provided to guard against overtravel of load in either raising or lowering direction which can cause damage to hoist When highest position is reached the lower block trips the control lever Figure 3 3 When lowest position is reached the tail end of load chain trips the control lever Figure 3 4 The control lever is connected to the control shaft which actuates inlet valves controlling air pressure to air motor Limit stops are intended as safety devices and should not be used as a routine basis to stop travel of lower block or shut off hoist Page 6 LIMIT LEVEF 12011A Figure 3 3 Control Lever Being Tripped bv Lower Block TAIL END OF 12012A LOAD CHAIN Figure 3 4 Control Lever Being Tripped by Tail End of Load Chain 3 6 OPERATING PRECAUTIONS AWARNING Equipment covered herein is not designed or suitable as a power source for lifting or lowering persons Safe operation of an overhead hoist is the operator s responsibility Listed below are some basic rules that can m
13. ton disconnect end of load chain from tail end anchor boss at side of hoist frame Remove chain anchor by prying off spring clip and remove connecting link attaching chain to anchor boss on roller chain models Figure 7 1 Remove socket head cap screw holding end link to tail end anchor on coil chain models If hoist is connected to air service run chain out of hoist by operating control in lowering direction If hoist is not connected to air service the chain can be pulled out of hoist by hand while holding brake open by pulling down on control lever CONNECTING NK ROLLER CHAIN LINK DEAD END 10947A bi E Figure 7 1 Removing Connecting Link at Tail End of Load Chain Roller Chain Models 2 On models with double reeved chains 3 4 and 1 ton disconnect end of chain as in paragraph 1 above run chain out of hoist by operating it in lowering direction and disconnect opposite end of chain from anchor at side of upper suspension bracket 3 On single reeved 1 4 3 8 and 1 2 ton models separate load chain coil or roller type from lower block assembly Drive out small spring pin securing lower block pin in lower block and push out lower block pin to release chain On roller chain models an adapter is used to attach chain to lower block This adapter is removed from end of chain by first driving out small spring pin and then pushing out adapter pin 4 Lower blocks 1 4 3 8 and 1 2 ton are of a pinn
14. unit construction and generally should not be disassembled However if it is felt that the blades need replacing the dead opposite drive end end plate can be removed to inspect the blades 3 Removal of dead end plate requires a puller to remove the end plate bearing from the shaft 4 Remove 3 button head cap screws from dead end plate Attach puller to end plate with two 1 4 28 screws taking care not to turn them into end plate more than 1 4 inch thus hitting and damaging rotor Remove end plate by turning puller screw against motor shaft 5 Inspect blades for wear or breakage Inspect end plate rotor and body for damage Since the end plates and body are matched and doweled at assembly they are not serviced separately If there is significant damage replace motor f Removal of Brake Wheel Internal Load Gears and Sprocket 1 Rotate brake wheel until holes in web are aligned with four socket head cap screws Figure 7 8 Remove screws then lift brake wheel off Figure 7 9 after prying up lightly and evenly with screwdriver to free ball bearing Ball bearing and clamp plate are pressed off after removing retaining ring from wheel hub BRAKE WHEEL Figur r o Removing ag uciLvv jacuring Bearing Clamp Plate BALL BEARING GEAR PLATE RETAINING SCREW Figure 7 J Removing Brake Wheel and Ball Bearing Assembly 2 Remove four socket head screws securing gear plate to frame and lift off plate and interme
15. 10 BROOK ROAD NORTH COBOURG ONTARIO K9A 4W5 905 372 0153 WARRANT Y WARRANTY AND LIMITATION OF LIABILITY A Seller warrants that its products and parts when shipped and its work including installation construction and startup when performed will meet applicable specifications will be of good quality and will be free from defects in material and workmanship All claims for defective products or parts under this warranty must be made in writing immediately upon discovery and in any event within one 1 year from shipment of the applicable item unless Seller specifically assumes installation construction or start up responsibility All claims for defective products or parts when Seller specifically assumes installation construction or start up responsibility and all claims for defective work must be made in writing immediately upon discovery and in any event within one 1 year from completion of the applicable work by Seller provided however all claims for defective products and parts must be made in writing no later than eighteen 18 months after shipment Defective items must be held for Seller s inspection and returned to the original f o b point upon request THE FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES WHATSOEVER EXPRESS IMPLIED AND STATUTORY INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS B Upon Buyer s submission of a claim as provided above and its substa
16. 46 BAH 131 Screw Socket Head Cap 7 z 3 48 BAH 146 Latch Kit 1 49 BAH 133 Hook Bearing and Nut Assembly With Latch 7 1 50 BAH 134 Nut Hex Self Locking z 3 51 BAH 138 Pin Cotter 3 2 52 BAH 213 Pin Chain Anchor 1 53 BAH 212 Hook and Bracket Assembly With Latch 1 54 BAH 146 Latch Kit z 1 55 BAH 101 Frame Assembly Includes Ref No 20 1 1 1 56 BAH 162 Lockwasher Spring 2 2 2 57 BAH 222 Dead End Roller Chain Link 1 1 1 58 BAH 171 Washer Flat 1 1 1 59 BAH 170 Screw Hex Socket Head Cap 1 1 1 60 Label Rated Load BAH 173 1 4 Ton 1 E BAH 174 1 2 Ton BAH 175 1 Ton 1 Hook nut is drilled in place on hook shank and is not available separately Load chain lengths listed are forstandard 10 foot lifts Longer chains are available on order NOTES Page 21 To enable us to expedite your parts order always give Catalog Num ber Model Number and Capacity found on hoist nameplate Figure 8 4 Throttle Control Head Parts All Models Ref Part Description Qty No Number Req d 1 BAH 1101 Body Swivel Inlet 3 8 18 N P T 1 2 BAH 1102 Seal 0 Ring Inlet Swivel 1 3 BAH 1103 Bushing Inlet Swivel 1 4 BAH 1104 Gasket Inlet Swivel Bushing Brass 1 5 BAH 1105 Ring Retaining External 1 6 BAH 1106 Screen Inlet Swivel 1 7 BAH 1126 Housing Assembly Control Head Includes Ref No 22 amp Throttle Valve Bushing Not Show
17. D AND DESCRIBED HEREIN IS NOT DESIGNED OR SUITABLE FOR LIFTING OR LOWERING PERSONS A EAEN sh ah tec Paragraph 4 5 Lubricate Upper Hook and Lower Block Assembly 000 00e eee eeeee 7 Paragraph 4 6 Lubricate Control Shaft Brake Cam and Valve Shifter 000 000 7 Paragraph 4 7 Lubricate Trolley Wheel Bearings SECTION V MAINTENANCE Paragraph 5 1 General Paragraph 5 2 Thirty Day Inspection Paragraph 5 3 Annual Inspection SECTION VI TROUBLE SHOOTING SECTION VII DISASSEMBLY AND REASSEMBLY Paragraph 7 1 General Paragraph 7 2 Disassembly 000 0 eee ee eens Paragraph 7 3 Cleaning and Inspection Paragraph 7 4 Reassembly 00 0c eee neues Paragraph 7 5 Testing Hoist 0 00000 e eee eee Paragraph 7 6 Pendant Throttle Control Assembly SECTION VIII PARTS LIST Paragraph 8 1 Introduction Paragraph 8 2 Parts List anaana 00 0 cee eee eee Figure 8 1 Frame and External Parts Coil Chain Figure 8 2 Frame and External Parts Roller Chain Figure 8 3 Gearing Sprocket and Load Brake Parts Figure 8 4 Control Head Parts Figure 8 5 Air Motor Parts Figure 8 6 Control Cylinder and Pendant Throttle Parts Figure 8 7 Special Parts Table Spark Resistant Models NOTICE Information contained in this book is subject to change without notice Page 2 SECTION GENERAL DESCRIPTION 1 1 GENERAL CM AIRSTAR Air Hoists are precision bu
18. For 15 Lift 1 BAH 1214 For 20 Lift 1 17 BAH 1117 Pin Valve Shifter 1 18 BAH 1118 Shifter Throttle Valve 1 19 BAH 161 Pin Spring Drive 1 20 BAH 1231 Eye Bolt Strain Cable 2 21 BAH 1232 S Hook Wire Strain Cable 2 BAH 1217 Handle Assembly Pendant Throttle Control Includes Ref Nos 22 thru 32 1 22 BAH 1218 Case Control Handle 1 23 BAH 1219 Pin Lever 1 24 BAH 1220 Gasket 0 Ring Valve 2 25 BAH 1221 Gasket 0 Ring Valve Bushing 2 26 BAH 1222 Bushing Throttle Valve 2 27 BAH 1223 Valve Throttle Control 2 28 BAH 1224 Lever Throttle Control 2 29 BAH 1225 Screw Machine Round Slotted Head 4 30 BAH 1226 Guard Control Lever 1 31 BAH 1227 Gasket 2 32 BAH 1230 Spring 2 Figure Ref Part Description Quantity Required Number Number Number 3 8 Ton 3 4 Ton 8 1 4 BAH 1303 Hook and Bracket Assembly Upper 1 8 1 5 BAH 1304 Hook Nut and Latch Assembly Upper 1 8 1 6 BAH 1305 Latch Kit Upper Hook 1 8 1 24 BAH 1308 Chain Coil Type Load 11 5 Lg 1 24 BAH 1309 Chain Coil Type Load 22 7 Lg 1 8 1 25 BAH 1310 Lever Control 1 1 8 1 26 BAH 1315 Block Assembly Lower Complete 1 8 1 27 BAH 1318 Body Lower Block 1 8 1 28 BAH 1320 Latch Kit Lower Hook 1 8 1 29 BAH 1319 Hook Nut and Latch Assembly Lower 1 S 8 1 36 BAH 1312 Pin Connecting Lower Block 1 F 8 1 BAH 1322 Block Assembly Lower Coil Chain S 1 8 1 42 BAH 1326 Body Lower Block 7 1 Pair 8 1 44 BAH 1330
19. H 129 Clip Cord 1 4 Not Shown 4i BAH 161 Pin Spring Drive Control Lever t BAH 130 Block Assembly Lower 1 Ton Includes Ref Nos 42 thru 49 t42 BAH 132 Body Lower Block Pair 43 BAH 135 Bearing Assembly Needle t44 BAH 136 Washer t45 BAH 137 Sprocket Coil Chain t46 BAH 131 Screw Socket Head Cap 3 t47 BAH 146 Latch Kit Lower Hook gt t48 BAH 133 Hook Bearing and Nut Assembly With Latch 7 49 BAH 134 Nut Hex Self Locking 5 50 BAH 141 Bracket Lug Suspension Parallel Mount 1 1 51 BAH 142 Bracket Lug Suspension Parallel Mount 7 7 52 BAH 143 Bracket Lug Suspension Cross Mount 5 53 BAH 138 Pin Cotter 2 54 BAH 139 Pin Chain Anchor 3 t55 BAH 140 Hpok and Bracket Assembly With Latch 7 3 t56 BAH 146 Latch Kit ee On ee a Os NerrrNer i WRPREPWHENNBP RPP RP RP RP RRB 57 BAH 101 Frame Assembly Includes Ref No 23 1 1 58 BAH 162 Lockwasher Spring 2 2 t59 Label Rated Load BAH 173 1 4 Ton 1 BAH 174 1 2 Ton 1 BAH 175 1 Ton A 1 tSee Special Parts Table Figure 8 7 for Spark Resistant Models Hook nut is drilled in place on hook shank and is not available separately Load chain lengths listed are for standard 10 foot lifts Longer chains are available on order NOTES Page 19 To enable us to expedite your parts order always give Catalog Num ber Model Number and Capacity f
20. OCTITE on the threads and should not be removed for routine servicing If valve is to be removed use a hex key to remove pin from bottom of throttle valve See Figure 7 13 The valve can now be removed from bushing in housing The throttle valve bushing is pressed into place and honed to provide a 0001 to 0003 inch clearance with valve If bushing is scored worn or otherwise damaged the housing and bushing assembly should be replaced along with the valve 5 Remove air inlet swivel body and bushing from top of housing Retain bushing gasket for reuse Pull strainer screen from housing bore 6 Remove retaining ring from bottom of swivel body and pull off bushing Remove O ring seal from its groove in bushing 7 Disassemble control cylinder pendant throttle control models by removing cylinder lock ring Cylinder and cap will come off with lock ring Lift out spring and then remove piston and seal assembly from cylinder Piston shaft O ring seal and retainer washer will drop out as piston is removed e Removal and Disassembly of Air Motor 1 Remove air motor from hoist frame by placing entire unit on motor end and lifting frame straight up as shown DO NOT tap on end of motor shaft since this will destroy critical rotor alignment and damage motor If necessary motor may be grasped at bearing boss on the dead end plate to assist in removal E _ AIR MOTOR 11677B Figure 7 7 Removing Motor from Frame 2 Motor is a
21. OPERATION SERVICE amp PARTS MANUAL CM AIRSTAR AIR HOISTS Rated Loads 1 4 thru 1 ton 225 thru 900 kg Follow all instructions and warnings for inspecting maintaining and operating this hoist The use of any hoist presents some risk of personal injury or property damage That risk is greatly increased if proper instructions and warnings are not followed Before using this hoist each operator should become thoroughly familiar with all warnings instructions and recommendations in this manual Retain this manual for future reference and use Forward this manual to the operator Failure to operate this equipment as directed in this manual may cause injury Before installing hoist fill in the information below Refer to the Hoist and Motor data plates Model No Serial No 11999C Purchase Date Air Pressure Rated Load COLUMBUS McKINNON CORPORATION INDUSTRIAL PRODUCTS DIVISION 140 JOHN JAMES AUDUBON PARKWAY AMHERST NEW YORK 14228 1197 U S A PRINTED IN U S A MAY 1996 COPYRIGHT 1996 COLUMBUS McKINNON CORPORATION PART NO 117209 1 FOREWORD This book contains important information to help you install operate and maintain your new CM AIRSTAR Air Hoist We recommend that you study its contents thoroughly before putting your hoist to use Through proper installation application of correct operating procedures and by practicing the recommended maintenance suggestions you will be assured maximum service fro
22. ain hoists Replace damaged parts 5 Check connection of chain to lower block on 1 4 3 8 and 1 2 ton hoists Replace parts showing evidence of damage twisting or elongation 6 Check connection of chain to anchor on side of suspension bracket on double reeved 3 4 and 1 ton hoists Replace parts showing evidence of damage twisting or elongation 7 Lubricate load chain if required See paragraph 4 4 Section IV b Inspect Lower Block 1 Check for bent or distorted hook If hook is opened beyond the dimension given in Figure 5 3 it must be replaced Also check to see that hook swivels and is free to pivot on roller chain models Lubricate these points if necessary 2 On 3 4 and 1 ton hoists check sprocket and bearings in lower block for freedom of movement and signs of damage Lubricate if necessary Replace damaged parts MEASURE OPENING HOIST RATED LOAD TONS NORMAL REPLACE HOOK IF OPENING OPENING IS GREATER THAN Figure 5 3 Upper and Lower Hook Openings Shown with latch removed for clarity 3 Check hook latches Replace damaged or bent latches or AWARNING Hooks upper or lower damaged from chemicals deformation or cracks or having more than 15 percent in excess of normal throat opening or more than 10 degrees twist from the plane of the unbent hook or opened allowing the hook latch to bypass hook tip must be replaced Any hook that is twisted or has excessive thr
23. ake an operator aware of dangerous practices to avoid and precautions to take for his own safety and the safety of others Observance of these rules in addition to frequent examinations and periodic inspection of the equipment may save injury to personnel and damage to equipment a Operate hoist cautiously to become familiar with its performance b Do not load hoist beyond rated load c Take up chain slack carefully to avoid jerking load d Never use hoist load chain as a sling e Always be sure there is no twist in coil load chain On 3 4 and 1 ton hoists check to see that lower block is not capsized between strands of chain f Check both upper and lower limit stop operation by raising or lowering empty hook to limit of travel Hoist must shut off g When lifting load make certain it is free to move and will clear all obstructions h Stand clear of all loads and never lift or travel loads over people j Avoid operating hoist when hook is not centered under hoist Be sure that hoist trolley or other support mechanism is correctly positioned for handling the load before lifting k Guide load so as to have it under control at all times l Do not operate hoist with twisted kinked or damaged chain m Do not operate damaged or malfunctioning hoist n Conduct periodic visual inspection for signs of damage or wear o Observe inspection and maintenance procedures described in this manual p Never lift or transport a load un
24. amp Bearing 1 10 BAH 312 Gear Internal 1 11 BAH 313 Nut Spindle 1 12 BAH 314 Shaft Intermediate Gear 2 13 BAH 315 Bearing Assembly Needle 4 14 BAH 316 Gear Intermediate 2 15 BAH 350 Thrust Plate 1 16 BAH 355 Spring Brake Shoe 1 17 BAH 351 Plate Gear 1 18 BAH 352 Screw 1 19 BAH 318 Screw Socket Head Self Locking 2 20 BAH 325 Ring Retaining External 1 21 BAH 326 Bearing Assembly Ball Brake Wheel 1 22 BAH 327 Plate Clamp Brake Wheel Bearing 1 23 BAH 311 Lockwasher Shakeproof Internal 6 24 BAH 360 Screw Socket Head 4 25 BAH 328 Wheel Load Brake 1 26 BAH 345 Screw Socket Head Self Locking 4 28 BAH 353 Cam Brake Actuator 1 30 BAH 338 Pin Spring Drive Brake Cam 1 34 BAH 354 Shoe Assembly Brake 2 35 BAH 321 Ball Steel Brake Fulcrum 2 38 BAH 347 Screw Socket Head 6 t39 BAH 339 Sprocket Chain Coil Type Only 1 t40 BAH 340 Guide and Stripper Assembly Chain Coil Type Only 1 t See Special Parts Table Figure 8 7 for Spark Resistant Models Quantities shown are for roller chain models Coil chain models require four 4 each Pane 22 To enable us to expedite your parts order always give Catalog Num ber Model Number and Capacity found on hoist nameplate Figure 8 5 Motor Parts All Models Ref Part Description Oty No Number Req d BAH 950 Motor Assembly Air 1 1 BAH 951 Screw Hex Socket Button Head 6 2 BAH 952 Bearing Ball 2 3 BAH 953 Plate End Dead
25. ber 1 4 Ton 1 2 Ton 1 Ton 23 BAH 215 Adapter Roller Load Chain 1 1 BAH 216 Block Assembly Lower Complete Includes Ref Nos 23 24 33 34 35 amp 36 1 gt z BAH 217 Block Assembly Lower Complete Includes Ref Nos 23 24 33 34 35 amp 36 1 24 BAH 154 Block Assembly Lower Includes Ref Nos 25 thru 32 1 BAH 155 Block Assembly Lower Includes Ref Nos 25 thru 32 1 25 BAH 156 Body Lower Block 1 4 Ton 1 BAH 157 Body Lower Block 1 2 Ton 1 26 Nut Hook 1 1 27 BAH 152 Pin Spring Drive 1 1 28 BAH 151 Shield Bearing 1 1 29 BAH 149 Washer Thrust Bearing 2 2 i 30 BAH 150 Bearing Assembly Needle 1 1 E 31 BAH 160 Hook and Nut Assembly With Latch 1 1 32 BAH 158 Latch Kit 1 1 33 BAH 121 Pin Spring Drive 1 1 34 BAH 122 Pin Connecting Lower Block 1 1 35 BAH 218 Pin Spring Drive 1 1 E 36 BAH 219 Pin Connecting Roller Chain Adapter 1 1 7 BAH 124 Cord Assembly Control Includes Ref Nos 37 thru 40 1 1 1 37 BAH 125 Handle Down Control 1 1 1 38 BAH 126 Handle Up Control 1 1 1 39 BAH 128 Cord Down Control 1 1 1 40 BAH 127 Cord Up Control 1 1 1 BAH 129 Clip Cord 1 4 Not Shown 1 1 1 41 BAH 161 Pin Spring Drive Control Lever 1 1 1 BAH 207 Block Assembly Lower 1 Ton Includes Ref Nos 42 thru 50 s 1 42 BAH 220 Body Lower Block Pair 7 1 43 BAH 135 Bearing Assembly Needle 2 44 BAH 136 Washer E 2 45 BAH 211 Sprocket Roller Chain 1
26. bly steps as noted b Inspect Brake Remove brake housing cover and brake shoes as outlined in paragraph 7 2 c Check brake shoe linings and brake wheel for wear and scoring Replace badly worn or scored parts Check condition of brake cam and spring Replace any damaged parts c Inspect Internal Load Gears Remove gear plate and intermediate gears as outlined in paragraph 7 2 f Check condition of gear teeth on internal gear intermediate gears and motor shaft pinion Replace worn or damaged parts d Inspect Chain Sprocket and Bearings Remove sprocket and internal gear as a unit paragraph 7 2 f Check condition of teeth or pockets on chain sprocket and inspect ball bearing assemblies Replace worn or damaged parts e Inspect Throttle Valve Shifter Remove valve shifter and control shaft paragraph 7 2 c and shifter pin paragraph 7 2 d Check condition of shifter pin and shaft bearings Replace worn or damaged parts f Inspect Throttle Valve Housing Remove throttle housing assembly paragraph 7 2 d and disassemble it as outlined Check condition of throttle valve valve bushing in housing and 0 rings on valves Replace worn or damaged parts g Inspect Air Motor Remove air motor assembly from hoist paragraph 7 2 e Check motor for condition of bearings possible rotor rubbing on body or end plates blade freedom in rotor slots shaft and gear If motor appears to be in good condition do not service other than lubricat
27. diate gears as a unit Figure 7 10 Do not remove the two socket head screws from flange around brake wheel bearing hole Figure 7 9 unless it is necessary to replace intermediate gears INTERMEDIATE GEARS INTERNAL mae B GEAR PLATE GEAR x Figure 7 10 Removing Gear Plate and Intermediate Gears Page 13 3 On roller chain models remove two fillister head screws attaching chain stripper to frame and lift out stripper Chain stripper on coil chain models is integral with chain guide 4 On coil chain models remove four fillister head screws attaching chain guide and stripper assembly to hoist frame This will free guide to allow sprocket to be pulled through it as it is removed in step 5 Refer to Figure 7 11 5 Rotate internal gear Figure 7 10 until holes in web align with six socket head screws securing bearing clamp plate to frame Remove internal gear chain sprocket and ball bearings as a unit Figures 7 11 and 7 12 It may be necessary to tap sprocket to free ball bearings from bores in frame INTERNAL GEAR SPROCKET AND BEARING ASS Y CHAIN STRIPPER ROLLER CHAIN ae O Fo 10957A Figure 7 11 Removing Internal Gear Chain Sprocket and Ball Bearing Assembly Roller Chain Model 6 To disassemble intermediate gear sprocket and ball bearing assembly remove retaining ring and pull outer ball bearing from sprocket Remove spindle nut from other end of sprocket and pull internal gear free o
28. e of regular motor oil 4 5 LUBRICATE UPPER HOOK AND LOWER BLOCK ASSEMBLY a On 3 4 and 1 ton hoists apply a few drops of S A E 60 oil on shank of upper hook where it enters suspension bracket b On single line hoists 1 4 3 8 and 1 2 ton disassemble upper and lower hooks as described in 7 2 b 4 and grease thrust bearings with a good grade of bearing grease c On double line hoists 3 4 and 1 ton lower blocks disassemble as described in 7 2 b 5 and grease needle bearings for sprocket shaft and hook with a good grade of bearing grease 4 6 LUBRICATE CONTROL SHAFT BRAKE CAM AND VALVE SHIFTER a Apply a few drops of S A E 60 oil on control shaft at bearing points b Apply graphite grease on valve shifter and on brake cam 4 7 LUBRICATE TROLLEY WHEEL BEARINGS If hoist is mounted on a trolley apply light grease to wheel bearings as recommended by trolley literature AWARNING Before performing any internal work on hoist remove load and be certain air is shut off SECTION V MAINTENANCE 5 1 GENERAL Preventive maintenance services required on CM AIRSTAR Air Hoists are for the most part simple periodic inspection procedures to determine condition of hoist components Below are suggested inspection procedures based on daily average hoist usage Hoist subjected to severe service or to adverse environments should be examined weekly or as conditions warrant 5 2 THIRTY DAY INSPECTION Hoist may be left su
29. ed construction permitting individual replacement of body thrust bearing or hook To disassemble drive spring pin from hook nut With pin removed hold hook nut from turning with drift punch and rotate hook to unscrew it from nut Separate hook bearing shield needle bearing and two thrust washers from body Hook and nut are drilled at assembly and are replaced only as an assembly Page 11 5 On 3 4 and 1 ton double reeved models the lower block assembly is disassembled by removing socket head screws and nuts holding body halves together Cc Removal of Brake Cover Control Lever and Load Brake 1 On pendant throttle control models for convenience disconnect control hoses from air cylinders open strain cable S hook at eye bolt on throttle housing and remove pendant throttle control assembly from hoist Refer to paragraph 7 6 for disassembly and reassembly of pendant throttle control 2 Remove two screws securing brake housing cover to frame and lift off cover 3 To remove control lever and shaft drive spring pins from control lever Figure 7 2 and valve shifter at end of shaft using a drift punch Lightly tap valve shifter end of shaft and withdraw shaft by pulling on brake cam end Figure 7 3 As shaft is withd i control lever will fall free _ 4 CONTROL 4 gt LEVER ay F i SPRING DRIVE PIN VALVE SHIFTER 12015 Figure 7 2 Driving Spring Pin from Control Lever and Shaft Fi
30. f sprocket shaft Remove clamp plate and pull off remaining ball bearing INTERNAL GEAR SPROCKET AND BEARING ASS Y CHAIN GUIDE AND STRIPPER ASSEMBLY COIL CHAIN 10958A Figure 7 12 Removing Internal Gear Chain Sprocket and Ball Bearing Assembly Coil Chain Model Page 14 7 3 CLEANING AND INSPECTION Before reassembly all parts should be thoroughly cleaned and inspected to determine their serviceability Replace all parts that are excessively worn or damaged Minor nicks and scratches should be filed to remove raised edges NOTE Bearings that are sealed are lubricated at the factory for normal life of the bearing and must not be washed If they are exposed to wash or infiltration with foreign matter they must be replaced 7 4 REASSEMBLY a General The procedure to be followed to reassemble hoist is in reverse order of the disassembly steps outlined in paragraph 7 2 Listed below are special assembly precautions which should be observed to assure proper assembly b Assembly of Motor When reassembling motor observe the following precautions 1 If any blade replacement is required the full set of blades should be replaced Blades must be installed so that the edges with chamfered corners face down into the slots 2 Reassemble end plate and bearing as follows Remove dowel pins locating end plate to body Support shaft and press bearing onto shaft using a drift that contacts both inner and outer race of
31. frame boss and fasten in place The rest of the chain cab be pulled through and then the lower block fastened in place on single reeved hoist On double reeved hoist allow approximately 17 to 18 of chain to hang on the lifting direction side Figure 7 17 Run the lower block assembly onto chain and swing do not twist the remainder of the chain up and attach to lug on suspension bracket Remove wedge from between lever and frame and replace covers NOTE Chain must not be twisted and link welds must be positioned as shown in Figure 7 17 POSITION OF 1ST LINK WELDS FACING OUT AXIS OF LOWER BLOCK PIN MUST BE PARALLEL TO AXIS OF SPROCKET SHAFT AS SHOWN REMOVE ONE LINK IF LAST LINK IS 90 OUT OF POSITION 11697B FIGURE 7 16 Installing Single Reeved Load Chain 1 4 3 8 and 1 2 Ton Models Page 16 y Coe Ai a a id a3 POSITION OF s 1ST LINK l IF LAST LINK IS 90 FROM POSITION JA SHOWN REMOVE ONE LINK E WELDS 20 SX FACING RL Sy OUT 116988 Xe we Figure 7 17 Installing Double Reeved Load Chain 3 4 and 1 Ton Models f Assembly of Control Cords On pull cord models control cords must be attached to control lever as follows Facing air inlet end of hoist the cord to top handle arrow pointing up should be attached to right end of lever cord to bottom handle arrow pointing down attached to left end of lever g Assembly of Pendant Throttle Control
32. gure 7 3 Removing Control Shaft 4 Remove brake spring by carefully prying it up evenly with a screwdriver until spring is about half way off Using brake spring spreader Part No 306989 Figure 7 4 remove spring from brake arms Figure 7 5 Page 12 BRAKE SPRING SPREADER PART NO 306989 8524 Figure 7 4 Special Tool for Removing Brake Spring BRAKE SPRING 10950A Figure 7 5 Removing Brake Spring Using Special Tool AWARNING Do not pry spring all the way off with screwdriver since spring is apt to fly in most any direction with considerable force 5 Remove brake shoes Be sure not to lose steel fulcrum balls 6 Remove steel balls from recesses in sides of upper brake boss d Removal and Disassembly of Control Head Assembly 1 Remove control head assembly by taking out six socket head screws and lifting assembly from frame Figure 7 6 Figure 7 6 Removing Control Head Assembly 2 Lift muffler and screen from recess in control head housing 3 On pendant throttle control models remove control cylinder assemblies from each side of control head housing Figure 7 14 On pull cord control models remove throttle valve spring retainer caps from each side of housing Figure 7 13 Valve springs spring guides and O ring seals can now be removed from valve bore at each side of housing 4 The throttle valve is retained in the control head by the valve shifter pin The pin is assembled with L
33. ilt chain type hoists which are built in three rated loads 1 4 1 2 and 1 ton Each size is available in pull cord control and pendantthrottle control models In addition there are model variations with coil type or roller type load chains and hook or lug type suspensions Coil chain hoists are also provided in spark resistant models Note Spark resistant models have rated loads of 3 8 and 3 4 ton 1 2 BASIC CONSTRUCTION All sizes and models are of the same basic design having many common and interchangeable parts They consist primarily of an aluminum alloy frame which houses a vane type air motor chain sprocket wheel and gearing A shoe type brake is mounted on one end of frame and is encased in an aluminum alloy end cover A control head assembly with built in muffler and air inlet swivel connection is mounted on opposite end of frame An upper suspension hook or lug bracket is attached to the top of the frame Either a special nickel steel roller type load chain or an alloy steel coil type load chain with spring latch type lower block assembly is employed to raise and lower loads A block and chain operated limit stop lever is mounted at bottom of frame and is pinned to throttle valve control shaft Hoist operation is controlled by either pull cords or a pendant throttle control assembly 1 3 DIFFERENCES BETWEEN MODELS AND SIZES The main differences between hoist models are in the type of control type load chain and type suspension e
34. ing well with light oil h Reassemble and Test Hoist Reassemble hoist as outlined in Section VII paragraph 7 4 After reassembly test hoist in accordance with paragraph 7 5 Page 9 SECTION VI TROUBLE SHOOTING Trouble Probable Cause Remedy 6 1 Hoist does not operate Insufficient air pressure at Check air pressure and ad source just Brake improperly adjusted Clogged air intake screen Excessive overload Clogged valve Valve shifter not function ing Motor failure Adjust brake Shut off air disconnect air hose clean inlet swivel screen Reduce load Remove valve caps remove any obstructions clean and lubricate valve Check for proper installa tion of drive pin in valve shifter and control lever and also that shifter pin is assembled solidly to throttle valve Disassemble motor and check rotor blades Replace defective parts 6 2 Hoist will not hold load in suspension Brake out of adjustment Brake lining oily glazed or badly worn Excessive overload Adjust brake Remove brake arms and replace with new Reduce load 6 3 Control lever does not re turn to horizontal posi tion Control shaft bent Foreign material rust or corrosion causing it to bind Foreign material rust or corrosion in control cyl inders or pendant throttle control Brake improperly adjusted Remove shaft and straighten or replace Remove shaft and clean Lubricate
35. ld be turned out The screw should not extend beyond end of cylinder c Check Hoist Under Rated Load Attach rated load to lower hook and check hoist operation 1 Operate hoist to raise load When control is released hoist should stop and hold load at that level 2 Operate hoist to lower load a short distance then release control Hoist should stop and hold load at that level 3 Operate hoist to lower load and observe rate of speed at which load descends Adjust lowering and hoisting speeds to the desired rate of speed as outlined in paragraph 2 4 AWARNING Do not lift more than rated load except for test purposes Overloading hoist can result in chain breakage hook deformation and other failures which can cause serious injury and damage A test at greater than rated load should be a properly supervised official test only not an operator test If any load sustaining parts have been altered replaced or repaired hoist should be load tested at 125 of rated load by a designated qualified person with a written report recording test load as recommended in ANSI B30 16 Safety Standards 7 6 PENDANT THROTTLE CONTROL ASSEMBLY a General After long periods of use the pendant throttle control assembly will require some maintenance attention To service the control handle assembly shut off air supply bleed air from hoist and control and disconnect hoses and strain cable at control handle Disassemble and reassemble co
36. load sprocket and chain guide correctly causing damage to hoist and it will wear prematurely deform and eventually break 3 Roller Type Load Chain Visually check for possible twists broken links wear or elongation Check roller chains for elongation from wear by pulling chain taut and measuring as follows On RC 625 or H 5 size chain 5 8 pitch measure distance over a length of 20 pitches center to center distance between 21 rivets it must not exceed 12 3 4 inches If chain exceeds this limit replace damaged section or install new load chain assembly Check chain for twist If twist in any 5 extension exceeds 15 replace chain Check chain for camber If any section has side bow exceeding 1 4 in five feet replace chain Use only factory approved chain If chain is to be spliced to replace damaged section it is recommended that this be done by a recognized CM Repair Station since splicing link must have a spun head requiring special tools Spring link must not be used except to secure the tail chain to the hoist frame See Figure 7 1 ACAUTION It must not be assumed that load chain is safe because it measures below replacement points given herein Other factors such as those mentioned in visual checks above may render chain unsafe or ready for replacement long before elongation replacement is necessary 4 Check anchor end of chain at side of hoist frame for damage to last link also connecting link on roller ch
37. m of hoist that actuates the throttle control valve Pendant Throttle Control models have a convenient lever type control valve handle Figure 3 2 suspended from the control cylinders on sides of control head housing AWARNING Do not lift more than rated load except for test purposes Overloading hoist can result in chain breakage hook deformation and other failures which can cause serious injury and damage A test at greater than rated load should be a properly supervised official test only not an operator test If any load sustaining parts have been altered replaced or repaired hoist should be load tested at 125 of rated load by a designated qualified person with a written report recording test load as recommended in ANSI B30 16 Safety Standards 3 2 PRE OPERATIONAL CHECKS Check the following before operating hoist with load a Inspect chain anchor connections at side of hoist frame and at upper hook or lug mounting bracket on 3 4 and 1 ton double reeved models Anchor screw or pin should be secure and not bent or broken Chain should be solidly anchored b Check hoist brake for proper adjustment and operation Refer to Section V paragraph 5 2 d c Check hooks They should not be bent or distorted and should not be opened beyond the correct opening sizes given in Figure 5 3 Hook latches should not be bent or damaged and springs not broken d Check chain to make sure it is not twisted or kinked Be sure lower block
38. m your hoist Complete inspection maintenance and overhaul service is available for CM AIRSTAR Air Hoists at recognized CM Repair Stations Refer to your telephone directory yellow pages under HOISTS They are staffed by quali JECTION GENERAL DESCRIPTION Paragraph 1 1 General Paragraph 1 2 Basic Construction Paragraph 1 3 Differences Between Models and Sizes Paragraph 1 4 Hoist Data SECTION II INSTALLATION Paragraph 2 1 General Paragraph 2 2 Suspending Hoist 0 005 Paragraph 2 3 Connecting Hoist to Air Service Paragraph 2 4 Hoisting and Lowering Speed Adjustments SECTION III OPERATION Paragraph 3 1 General Paragraph 3 2 Pre Operational Checks Paragraph 3 3 Operating Hoist 20 0 eee Paragraph 3 4 Pulling and Pivoting Hoist and Load Paragraph 3 5 Upper and Lower Limit Stops Paragraph 3 6 Operating Precautions JECTION IV LUBRICATION Paragraph 4 1 General Paragraph 4 2 Service Air Line Lubricator Paragraph 4 3 Gearcase 000 c eee Paragraph 4 4 Lubricate Load Chain fied factory trained service men and stock approved CM replacement parts Replacement parts information is also included in this book for your convenience Since it will likely be a long time before parts information is needed we suggest that after you have become familiar with operation and preventive maintenance procedures this book be carefully filed for future reference EQUIPMENT ILLUSTRATE
39. mployed These are described in paragraphs a through c below Differences between sizes are in reeving of the load chain On 1 4 and 1 2 ton hoists the load chain is single reeved one part of chain on 1 ton hoists the chain is double 12018C 12019C 12020C 1201F reeved two parts of chain Standard lift is 10 though increased lifts may be ordered a Control differences are in methods employed for operating hoist There are two types pull cord control and pendant throttle control These are further described in Section I paragraphs 3 1 and 3 3 b Two types of load chains are used as the lifting medium roller chain and coil chain The roller type chain is a special precision manufactured nickel steel chain The coil type chain is full flexing electric welded link chain carburized alloy steel on standard models and surface hardened chrome nickel stainless steel on spark resistant models Both types are especially designed for use in hoisting c Suspension differences include a conventional hook type mounting and a lug type mounting Hook suspension allows portability permitting hoist to be easily moved from job to job Lug suspension allows rigid trolley mounting of hoist on an overhead l beam to permit traversing hoist and load Rigid mounting of trolley on hoist affords maximum headroom advantage saving up to 3 3 16 compared to a hoist hook suspended on a trolley 1 4 HOIST DATA Rated Loads 1 4 1 2 and 1
40. n 1 8 BAH 1108 Seal O Ring Throttle Valve 2 9IBAH 1109 Guide Spring Throttle Valve 2 10 BAH 1 110 Spring Throttle Valve 2 11 BAH 1111 Gasket 0 Ring Valve Spring Retainer 2 12 BAH 1 112 Retainer Spring Throttle Valve 2 13 BAH 1113 Screen Muffler 1 14 BAH 1114 Muffler Exhaust 1 15 BAH 812 Gasket Air Seal Motor End Plate 1 16 BAH 813 Gasket Control Head to Frame 1 17 BAH 1115 Bearing Assembly Needle Control Shaft 1 18 BAH 1116 Plug Pipe 1 8 N P T 1 19 BAH 1117 Pin Valve Shifter 1 20 BAH 1118 Shifter Throttle Valve 1 21 BAH 161 Pin Spring Drive 1 22 BAH 1125 Valve Throttle 1 23 BAH 1120 Gasket O Ring Adjusting Screw 2 24 BAH 1 121 Screw Adjusting Speed 2 25 BAH 1122 Screw Hex Socket Cap 6 26 BAH 1 123 Lockwasher Spring 6 Page 23 To enable us to expedite your parts order always give Catalog Num ber Model Number and Capacity found on hoist nameplate 12007B Figure 8 3 Gearing Sprocket and Load Brake Parts All Models Ref Part Description Qty No Number Req d 1 BAH 301 Ring Retaining External 1 2 BAH 302 Bearing Assembly Ball Sprocket 1 3 BAH 303 Guide Assembly Chain Roller Type Only 1 4 BAH 304 Stripper Chain Roller Type Only 1 5 BAH 305 Screw Button Head 6 6 BAH 306 Lockwasher Shakeproof Internal 6 7 BAH 307 Sprocket Chain Roller Type Only 1 8 BAH 308 Bearing Assembly Ball Sprocket 1 9 BAH 309 Plate Cl
41. nders pendant throttle control models Use new 0 ring gaskets 3 At reassembly of control cylinders pendant throttle control models use new U type seals on piston heads and 0 ring seals on piston stems Be sure U type seals face direction illustrated in Figure 7 14 4 Use new 0 ring gaskets on adjusting screws When installing screws in control head housing turn them in until heads are flush or slightly below face of housing Adjustment is accomplished during testing of hoist paragraph 2 4 5 At reassembly of screen and air inlet swivel install a new 0 ring seal inside swivel bushing 6 In mounting control head housing on hoist use a new motor to head air seal gasket and a new head to frame gasket Cross Section Of Control Head Throttle Valving O RING VALVE pouty BUSHING VALVE SPRING SPRING ED 240 RETAINER Ke 07 RING P C MODEL SPRING SHIFTER GUIDE PIN VALVE contro ROTILE 12001 SHIFTER SHAFT Figure 7 13 Section View Showing Assembly of Throttle Valve Springs and Valve Shifter in Control Head CONTROL CYLINDER O RING ASSEMBLY SET SCREW LOCK RING O RINGS U TYPE PISTON SEAL Cup side must face in direction shown 12002A Figure 7 14 Section View Showing Assembly of Control Cylinder on Control Head Pendant Throttle Control Models d Assembly of Brake If the brake linings show excessive wear re
42. ntiation Seller shall at its option either i repair or replace its product part or work at either the original f o b point of delivery or at Seller s authorized service station nearest Buyer or Il refund an equitable portion of the purchase price C This warranty is contingent upon Buyer s proper maintenance and care of Seller s products and does not extend to fair wear and tear Seller reserves the right to void warranty in event of Buyer s use of inappropriate materials in the course of repair or maintenance or if Seller s products have been dismantled prior to submission to Seller for warranty inspection D The foregoing is Seller s only obligation and Buyer s exclusive remedy for breach of warranty and is Buyer s exclusive remedy hereunder by way of breach of contract tort strict liability or otherwise In no event shall Buyer be entitled to or Seller liable for incidental or consequential damages Any action for breach of this agreement must be commenced within one 1 year after the cause of action has accrued C Columbus McKinnon Corporation Industrial Products Division 140 John James Audubon Parkway Amherst New York 14228 1197 1 800 888 0985 Fax 716 689 5644
43. ntrol handle as outlined in paragraphs b and c below b Disassembly 1 Remove four screws and lift control lever guard from handle 2 Drive lever pin from handle housing and separate two control levers from housing 3 Using a suitable spanner tool unscrew bushings and valves from handle housing Remove air seal gaskets from bushing seats in the handle assembly Remove 0 ring seals from ends of valves and pull valves and valve springs from bushings Remove 0 ring gaskets from bushings c Reassembly 1 Clean all parts in cleaning solvent and carefully inspect for wear or damage before reassembly 2 Install new air seal gaskets on bushing seats in the handle housing 3 Install new 0 ring gaskets on valve bushings Insert springs and valves in bushings and install new 0 ring seals on ends of valves Valves and bushings can now be reinstalled in handle housing using spanner tool 0 rings should be lubricated before reassembly 4 Position control levers on housing align holes and install lever pin 5 Place guard over levers and secure to housing with four machine screws 6 Reinstall control handle assembly on hoist Attach control hoses to handle housing as outlined in paragraph 7 4 g SECTION VIII PARTS LIST 8 1 INTRODUCTION Parts illustrations and parts lists covering CM AIRSTAR Air Hoists bearing model number given on front cover will be found on following pages When ordering replacement parts
44. oat opening indicates abuse or overloading of the hoist Other load bearing components of the hoist should be inspected for damage See Section V paragraph 5 3 below c Inspect Upper Suspension 1 On hook suspended models check for bent or distorted hook If hook is opened beyond the dimension given in Figure 5 3 it must be replaced Also check to see that hook swivels Lubricate if necessary 2 On push trolley suspended models check condition of trolley parts and lug bracket Replace bracket or any trolley parts which are damaged or cracked 3 Check hook latch Replace damaged or bent latch or broken spring d Check Brake Operation 1 With air turned on and with rated load attached to lower hook operate hoist to raise load applying pressure to pull cord handle or throttle control lever If load drifts down before the motor starts to actuate the brake is out of adjustment 2 To adjust brake insert hex key through hole in brake cover Turn screw counterclockwise to tighten brake or clockwise to loosen brake see Figure 7 15 5 3 ANNUAL INSPECTION Hoist must be disconnected from air service and removed from overhead suspension Hoists subjected to severe service or to adverse environments should be examined weekly or as conditions warrant a Hoist should be partially disassembled as necessary to inspect hoist parts noted in paragraphs b through h below Refer to Section VII for disassembly and reassem
45. ound on hoist nameplate PARTS NOT SHOWN Nameplate BAH 163 Drive Screw BAH 164 Warning Sticker BAH 165 120068 Warning Label BAH 166 ANSI B30 16 Figure 8 2 Frame and External Parts Roller Chain Models Ref Part Description Quantity Required No Number 1 4 Ton 1 2 Ton 1 Ton 1 BAH 105 Bolt Suspension Bracket 2 2 2 2 BAH 108 Lockwasher Shakeproof External 2 2 2 3 BAH 107 Nut Hex Cadmium Plated 2 2 2 4 BAH 106 Hook and Bracket Assembly Suspension 1 1 1 5 BAH 145 Hook and Nut Assembly Upper Includes Ref No 6 1 1 1 6 BAH 146 Latch Kit 1 1 1 7 BAH 147 Bushing Machinery 1 1 8 BAH 148 Bracket Suspension 1 1 1 9 BAH 149 Washer Thrust Bearing 2 2 1 10 BAH 150 Bearing Assembly Needle 1 1 11 BAH 151 Shield Bearing 1 1 12 Nut Hook 1 1 1 13 BAH 152 Pin Spring Drive 1 1 1 14 BAH 201 Link Assembly Roller Chain For Connecting Tail End of Chain Only Must Not Be Used to Join Chain 1 1 1 15 BAH 172 Cover Brake Housing 1 1 1 16 BAH 113 Screw Slotted Head 2 2 2 19 BAH 153 Shaft Control 1 1 1 20 BAH 119 Bushing Oilite Control Shaft 3 3 3 21 BAH 203 Chain Load Roller Type 11 1 2 Lg 1 1 BAH 204 Chain Load Roller Type 22 1 Lg 1 22 BAH 1 17 Lever Control 1 1 1 Continued On Next Page Page 20 Figure 8 2 Frame and External Parts Roller Chain Models Cont d Ref Part Description Quantity Required No Num
46. ow ACAUTION The structure used to suspend hoist must be of sufficient strength to withstand reasonable forces to which hoist and support may be subjected Hoist must be aligned with load to avoid side pulls SUSPENSION LUG BOLT SIZE AND HOLE SPACING Hoist Rated Load Ton 1 4 3 8 1 2 3 4 1 Bolt Size ins 5 8 Center Distance Between Bolt Holes ins 3 1 8 Suspension Lug Widths ins 4 c On rigid mount trolley suspended hoists the trolley side plates must be properly spaced so trolley will fit beam on which hoist will operate Adjustment for various I beam sizes is accomplished by rearrangement of spacer washers on through bolts which connect trolley side plates to hoist suspension lug Refer to instruction sheet furnished with CM Rigid Mount Trolleys for complete instructions AWARNING If trolley is mounted on an open end beam end stops must be installed to prevent trolley from running off the end of the beam resulting in injury to operator and others and damages to load and other property d If chain container is to be used on hoist install it following instructions furnished with container 2 3 CONNECTING HOIST TO AIR SERVICE a Connect hoist to nearest filtered and lubricated air source using minimum 1 2 D air hose assembly see Figure 2 1 Avoid use of reducing bushing and nipple or hose assemblies of smaller diameters which may cause restrictions Page 4 b If hoist
47. place brake shoes In reassembling the brake the brake wheel assembly goes into position first and is fastened in place by the four screws referred to in paragraph 7 2 f 0 See Figures 7 8 and 7 9 Now place the steel fulcrum balls in their receiving cup using a small amount of thick grease to hold them in place The balls should retract completely into the receiving cups Now place the shoes up to the fulcrum balls and brake wheel Replace the brake spring using the spreader tool to start the spring over the shoes See Figures 7 4 and 7 5 Tap the spring into place Adjust brake shoes per instructions in Figure 7 15 Brake Adjustment at Reassembly Turn screw A in until arms pivot on fulcrum ball to make C 010 015 Checking Adjustment Without Load Without load and with air turned off open brake arms manually by operating limit lever to see if brake wheel can be turned freely by hand If wheel refuses to turn the brake may not be properly adjusted Recheck adjustment and then if the wheel does not turn freely check for possible damage such as bent brake arms improper lining brake cam slippage or other malfunctions in the unit Brake Adjustment With Load 1 With load on hook pull UP control cord or press UP lever slowly Load must not creep down before motor starts Turn adjusting screw out as required 2 Brake must stop and hold load in both directions FALCRUM BALLS SCREW A BRAKE
48. s set at average between minimum and maximum lowering speed b To adjust the hoisting or lowering speed turn appropriate regulator screw Figure 2 4 in either direction a little at a time while operating hoist under load LOWERING SPEED DOWN ADJUSTING SCREW Up ADJUSTING SCREW 12013 Figure 2 4 Hoisting and Lowering Speed Adjustment ACAUTION Maximum lowering speed with rated load is very high Adjust with care Heads of adjusting screws should not extend beyond outer surface of housing c When the screwdriver slots on ends of adjusting screws are horizontal hoist in normal suspended position the hoist speeds will be at either minimum speed or maximum speed Rotating the screws 180 in either direction will give a full adjustment between minimum and maximum speed limits NOTE Screws have arrow stamped on end to assist operator with adjustment 1 4 TON RATED LOAD HOIST Min Max Min Max Min Max Min Max Min Max Min Max PSIG 1000 LBS NOTE Hoist Speeds are shown in feet per minute f p m 1 Figure 2 5 Hoist Performance Charts SECTION III OPERATION 3 1 GENERAL Operation of CM AIRSTAR Air Hoists is controlled by either pull cords or a pendant throttle control depending upon the model Pull Cord Control models have pull type control cords Figure 3 1 suspended from a rocker type lever at botto
49. s should be washed clean using commercial fluid and repacked with NLGI EP 2 Grease 4 4 LUBRICATE LOAD CHAIN A small amount of lubricant will greatly increase load chain life therefore chain should not be allowed to run dry Chain should be cleaned and lubricated as directed in paragraphs a and b below depending upon type of chain User should set up a regular schedule for chain lubrication after observing operating conditions for a few days Use Bar and chain Oil LUBRIPLATE or equal on load chain a Coil Chain Under ordinary conditions only weekly attention will be necessary for alloy steel chain Under hot and dirty conditions it may be necessary to clean chain at least once a day and lubricate it several times between cleanings Thoroughly clean chain with an oil solvent and relubricate by coating it lightly with penetrating oil and graphite Make sure that lubricant coats wear surfaces between links Stainless steel load chain must be well lubricated at all times and must be inspected daily when in use b Roller Chain Under ordinary conditions only monthly attention will be necessary Under hot and dirty conditions weekly attention may be required Thoroughly clean chain with an oil solvent and apply a good grade of S A E 20 motor oil Wipe off excess oil When subjected to excessive moisture or corrosive atmospheres DO dripless oil lubricant from American Grease Stick Company is recommended for use on roller chain in plac
50. spended a Inspect Load Chain 1 Operate hoist under load and observe operation of chain over sprocket in both directions of chain travel Chain should feed smoothly into and away from the sprocket If chain binds jumps or is noisy first see that Page 7 it is clean and properly lubricated If trouble persists inspect chain and mating parts for wear distortion or other damage 2 Coil Type Load Chain Clean chain for inspection Examine visually for gouges nicks weld splatter corrosion or distorted links Slacken chain and check bearing surfaces between links for wear Figure 5 1 Greatest wear will often occur at sprocket at high or low point of lift particularly when hoist is subjected to repetitive lifting cycles Case hardness of chain is about 015 deep Chain must be replaced before the case is worn through Also check chain for elongation using a vernier caliper Figure 5 2 Select an unworn unstretched section of chain usually at slack or tail end and measure and record the length over the number of chain links pitches indicated in Figure 5 2 Measure and record the same length of a worn section in the load side of the chain Obtain the amount of wear by subtracting the measurement of the unworn section from the measurement of the worn section If the result amount of wear is greater than the amount specified in the ALLOWABLE CHAIN WEAR table the chain has elongated beyond the maximum allowable length and must be
51. til all personnel are clear Never lift people on hook or load q Do not divert attention from load while operating hoist Never leave a suspended load unattended r Do not use limit stop as normal operating stop This isa safety device only s Do not jog unnecessarily t Personnel not physically fit or properly qualified shall not operate hoist u Do not remove or obscure warning labels v Use common sense and best judgement whenever operating a hoist Observe American National Standard Safety Standard ANSI B30 16 latest issue SECTION IV LUBRICATION 4 1 GENERAL The lubrication services outlined in paragraphs 4 2 through 4 7 should be performed at regular intervals to maintain top hoist performance and insure long life Frequency of lubrications will depend on type of hoisting service hoist is subjected to and should coincide with preventive maintenance inspections See Section V Maintenance 4 2 SERVICE AIR LINE LUBRICATOR Servicing air line filter and lubricator unit is of primary importance since it is the only source of lubrication for control valves and air motor Fill lubricator with Air Hoist Motor Oil or good grade 10W machine oil approximate viscosity 150 SSU at 100 F Multi viscosity detergent type engine oil is not recommended 4 3 GEARCASE The gearcase is grease packed at the factory and requires no further greasing unless the gearcase is for any reason disassembled Then at reassembly the part
52. ton Air Pressure recommended 90 psi Air Consumption 48 cfm at 90 psi Net Weight basic hoist 36 pounds Suspension Hook or lug Control Pull Cord or Pendant Throttle For standard models Spark resistant models are rated at 3 8 and 3 4 ton Figure 1 1 Views of Various Air Hoist Models Page 3 SECTION II INSTALLATION 2 1 GENERAL CM AIRSTAR Air Hoists are completely lubricated and load tested before being shipped from the factory To place hoist in service attach to a suitable overhead suspension Paragraph 2 2 in area to be used connect hoist to nearest air supply paragraph 2 3 and check and adjust hoist speed paragraph 2 4 2 2 SUSPENDING HOIST a On hook suspended hoists select a suitable overhead support in area hoist is to be used one capable of holding combined weight of hoist and its rated load and hang hoist up Be certain that upper hook is firmly seated in center of hook saddle and that the spring safety latch is properly closed over hook opening In some cases it may be necessary to first remove spring latch before hook will fit over a support Reinstall latch after hook is engaged b On lug suspended hoists select a suitable overhead support in area hoist is to be used one capable of holding combined weight of hoist and its rated load Mount hoist using through bolts of appropriate size to fit mounting holes in suspension lug at top of hoist Use only suspension bolts provided by CM See table bel
53. ver differences between models suspensions controls load chain capacity sizes with applicable models specifically noted b A complete teardown procedure is given However if only certain parts require repair or replacement a partial teardown may be performed using applicable portions of the instructions c For easier handling during disassembly the following disassembly steps may where conditions permit be completed before hoist is removed from its overhead suspension or disconnected from its air supply Remove chain container if hoist is so equipped Remove lower block and load chain assembly following procedure outlined in paragraph 7 2 b d These hoists contain precision machined parts and should be handled with care at disassembly and reassembly When removing or installing parts with press fits be careful to apply pressure evenly On ball bearings apply pressure to face of inner or outer race whichever is adjacent to mating part This will avoid damage to bearing races from brinelling by pressing through bearing balls Apply a thin film of oil to parts having a tight fit when installed 7 2 DISASSEMBLY a Removal of Hoist from Overhead Suspension 1 Turn off air at source 2 Operate control to bleed air from hoist 3 Disconnect air hose at inlet swivel 4 Remove hoist from overhead suspension b Removal of Lower Block and Load Chain Assembly 1 On models with single reeved load chains 1 4 3 8 and 1 2
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